Aircraft starter generator testing

 

Starter generator testing is an essential process that involves the evaluation of aviation starter generators, which play a critical role in aircraft systems. These generators serve a dual function: they initiate the aircraft engine’s start-up and simultaneously generate electrical power during flight operations.

The starter generator testing bench is a sophisticated setup specifically designed to assess the performance, reliability, and functionality of these vital components. By creating conditions that closely mimic real-world operational scenarios, the testing bench enables thorough evaluations of starter generators under various loads and configurations.

One of the primary functions of the testing bench is to generate power through multiple parallel outputs from the starter generators. This capability allows engineers to rigorously test different configurations and loads, ensuring that each generator can meet the demands of aircraft systems during both start-up and in-flight conditions. The ability to simulate diverse operational situations is crucial for validating the performance of starter generators, as it helps ensure their reliability in critical moments during flight.

Starter generator testing solution enables performance validation through independent test rigs and power analysis.

The core components of the starter generator testing system consist of several integral subsystems that work together to facilitate comprehensive testing. The load machine set inverter system is a key element responsible for converting the electrical power generated by the starter generator into usable energy. This system enables the application of varying load conditions during the testing process, allowing engineers to assess how well the generator performs under different electrical demands.

In addition to the inverter system, the mechanical system supports the physical assembly of the test rig, ensuring stability and safety during operation. A well-designed mechanical structure is essential to prevent vibrations and movements that could affect testing accuracy. This stability is crucial when testing starter generators, as even minor shifts can lead to erroneous data.

The measurement and control system is another vital component of the testing setup. This system is responsible for monitoring key performance parameters such as voltage, current, and frequency in real time. By providing immediate feedback on these metrics, engineers can analyze the generator’s performance and make necessary adjustments during testing.

This capability enhances the accuracy of the evaluations and helps identify any potential issues before the starter generator is installed in an aircraft.

Furthermore, the power analysis system plays a critical role in assessing the quality and efficiency of the generated power. By analyzing the electrical output, this system helps identify discrepancies or performance issues that may arise during operation. Detecting such issues early on is essential for ensuring that the starter generator can meet the rigorous demands of aviation standards and regulations.

What is the aircraft generator?

The aircraft generator is typically driven by the aircraft’s engine through a mechanical connection, such as a driveshaft or gearbox. The primary function of an aircraft generator is to convert mechanical energy from the engine into electrical energy to power various onboard systems and equipment. This includes supplying electricity to the aircraft’s avionics, lighting, communication systems, hydraulic pumps, and other electrical components.

 

What is the aircraft starter generator?

The aircraft starter generator combines the roles of a traditional starter motor and a generator into one unit. Initially, it is used to provide the necessary mechanical force to start the engine by rotating the crankshaft. Once the engine is running, the starter generator switches to generator mode, producing electrical power to operate the aircraft’s systems and recharge the onboard batteries.

 

Starter generator testing system components

 

  • Load machines and their inverter systems

    The starter generator testing system can dynamically perform four-quadrant switching control.

     

  • Power analysis system

     

  • Load system

    The load is a programmable DC load.

     

  • Subject Cooling System

    The starter generator testing system is capable of providing forced ventilation cooling for the subject.

     

  • DC power supply

    DC power supply to the product power supply.

     

  • Measurement and control system

    Multiple starter generator testing can operate independently, or any combination of multiple operation control. A set of software control systems is adopted.

     

  • Mechanical system

     

  • Engine inertia simulation

    With the engine inertia simulation function, inertia in the range of adjustable, inertia rotation direction can be adjusted in both directions.

     

  • Software system

    The software system serves as the control center of the platform.

Aircraft generator testing system offers integrated control software and measurement to validate generator and controller.

Starter generator test platform integrates dynamic loading, power analysis, cooling, and control for validation.

 

Aircraft generator and controller closed-loop testing

 

The starter generator testing system is used for aviation alternator and DC generator performance function tests and matching controller closed-loop test programs. The aircraft generator testing system is equipped with manual and automatic control and measurement functions through the control software; special test programs can be written for the products to complete the motor test project.

 

    1. Aircraft AC generator testing

      The starter generator testing system has the functions of demagnetizing operation and stabilizing operation, separate-excitation and self-excitation, short-circuit operation (single-phase-to-ground, three-phase-to-ground, between-two-phase, two-phase-to-ground, and between-three-phase short-circuit), operation of transformer fixed-phase function, short-circuiting of transformer, loading and unloading of permanent magnet machine, loading of single-phase imbalance load, and composite effect of simultaneous change of load-revving speed, and so on. The starter generator testing system can record transient curves of rotational speed, voltage, current, frequency, etc., with a waveform capture function.

       

    2. Aircraft DC generator testing

      It has the functions of separate-excitation operation and self-excitation operation, short-circuit operation (DC short-circuit), DC motor terminal voltage measurement, etc. It can record the transient curve of speed, voltage, current, frequency, etc. It has the function of waveform capture. The starter generator testing system can record transient curves of speed, voltage, current, frequency, etc., and has a waveform capture function.

 

Aircraft generator test solutions assess AC and DC models, validating functions like short-circuit and loading.

 

Aircraft generator testing system composition

 

The aircraft generator testing system consists of a dragging table, a load unit, a measuring and control unit, a cooling unit (including air-cooling equipment and oil-cooling equipment), and relevant supporting accessories. The system can be automatically controlled and manually operated by a computer to realize the control and adjustment of speed and load.

 

  1. Drag table

    Frequency conversion speed control; both axes can be output, same direction, reversible;

     

  2. Load unit

    The load has an automatic adjustment function. When a certain road load fails, the system can recognize and allocate other road loads according to the logic call to ensure that the system load is within the precision range. The temperature sensor is set in the load box, with a load over-temperature protection function.

     

  3. Measurement control unit

    The data measurement adopts an automatic method to realize automatic recording, storing, generating test reports, printing, and other functions of test data. The system is reserved for remote data access and data transmit interface, with the function of data transmit with TDM.

     

  4. Cooling unit

    The cooling unit consists of air-cooling equipment and oil-cooling equipment.

 

Aircraft generator testing solution combines drive, programmable load, and cooling to enable performance evaluation.

 

 

High-temperature and low-temperature starter generator testing

 

The starter generator testing system incorporates rigorous evaluations under both high-temperature and low-temperature conditions to ensure the reliability and performance of aviation starter generators in extreme environments. The temperature chamber is a vital component of the testbed, designed to simulate these conditions effectively. By subjecting the starter generators to high temperatures, engineers can assess how well the components withstand thermal stress and whether they maintain optimal performance levels. This testing is critical, as elevated temperatures can lead to increased resistance, potential overheating, and degradation of materials, all of which could adversely affect the generator’s efficiency and lifespan.

Conversely, low-temperature testing is equally important, as starter generators must perform reliably in cold conditions often encountered during flight operations, particularly at high altitudes. In this environment, the viscosity of lubricants can change, and electrical components may behave differently. The starter generator testing system evaluates the generator’s ability to start and generate power efficiently under these lower temperatures, ensuring that it can function correctly when needed. The liquid cooling system is also utilized during these tests to monitor how well the cooling mechanisms perform under varying thermal conditions, which is essential for maintaining the integrity and functionality of the starter generator throughout its operational range.

The high-temperature and low-temperature evaluations within the starter generator testing system provide comprehensive insights into the performance characteristics of aviation generators. By thoroughly assessing how these components react to extreme thermal conditions, engineers can identify potential weaknesses and implement necessary design improvements. This rigorous testing process not only helps ensure compliance with aviation standards but also enhances the overall reliability and safety of aircraft systems during critical phases of flight.

 

Starter generator test solution integrates load machine, power analysis, temperature chamber, and cooling systems for validation.

 

System composition

 

  • Load machines and their inverter systems allow dynamic four-quadrant switching control.
  • Mechanical systems
  • Measurement and control systems
  • Power analysis system
  • DC power supply for the UUT.
  • Air-cooling system can provide forced ventilation cooling for the UUT.
  • Liquid cooling systems are capable of providing oil cooling to the UUT.
  • Loading
  • Temperature range is adjustable in the climatic chamber.
  • Software system as the control center of the bench.


 

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