Aerospace Generator Altitude Test Bench

The aerospace starter-generator altitude climate simulation test bench provides a simulated altitude environment for the test piece to conduct performance and reliability tests. The dynamometer is installed outside the altitude chamber and connected to the starter-generator inside the chamber via a high-speed sealed shaft to supply driving power or load. Depending on the test piece, an air-cooling system or an oil-cooling system can be provided to lubricate and cool the test piece within the altitude chamber.

The inlet and outlet air ducts of the air-cooling system are connected to the altitude chamber, forming an internal circulation system. The temperature of the cooling air can be controlled in the pipeline, enabling the supply of cooling circulating air to the test piece under conditions consistent with the simulated high-altitude environment, so as to test the thermal load characteristics of the test piece.

Key parameters:

• Rated power range: 1kW to 3MW

• Maximum speed range: 1000rpm to 100krpm

• Rated torque range: 1N.m to 10000N.m

• Torque measurement accuracy：0.05%FS

• Torque control accuracy：±0.2~±0.5%FS

• Speed measurement accuracy：±1rpm

• Altitude range: sea level to 20,000m

• Temperature range: -55℃~200℃

Main test contents:

• Efficiency MAP test

• External characteristic test

• Torque test

• Speed test

• Temperature rise test

• Over-load test

• Steady-state test

• Maximum speed test

• Durability with high altitude climate test

• User-defined cycle condition test

• Electrical inertia simulation test

Basic configurations:

Dynamometer & Mechanical System: A high-dynamic asynchronous or synchronous motor is selected as the dynamometer, equipped with a high-speed drive shaft system and precision, reliable mechanical components.

Frequency Converter: A four-quadrant frequency converter is adopted for dynamic or steady-state control of the dynamometer. It enables control of rotational speed, torque, allowing the dynamometer to operate in either motoring or generating mode.

DC/AC Power Supply: Supply power to the starter to simulate the start condition, generally, the current is large. According to the parameters of tested aerospace starter, the power parameters as follows:

Rated power range: 5kW to 2MW

Current range: 0 to ±2000A

DC voltage range: 12VDC to 1200VDC

AC voltage range:115VAC to 400VAC

Electric load: Absorbs the electrical energy from the generator and simulates the characteristics of the power-consuming equipment. JKT provides resistive load, inductive load, capacitive load, as well as regenerative electronic load.

Power Analyzer & Mobile Cart: A high-precision power analyzer is used to measure parameters such as current, voltage, efficiency and harmonics of the motor and controller. It can also receive torque and speed signals synchronously for calculating the motor’s mechanical efficiency.

MCU Power Supply: Provides an adjustable low-voltage power supply for the motor controller.

Test Object Cooling System: According to different tested objects, there are air-cooling system and hydraulic system. The air-cooling system provides adjustable flow rate air for the tested object. The hydraulic system provides the lubricating and cooling oil for the tested object.

Generally, the maximum temperature of the oil is very high, up to 200℃, the hydraulic system adopts high-temperature resistant hydraulic components such as pumps and valves, and is equipped with temperature and pressure compensation. It can generally operate at 180℃~200℃, while enabling precise pressure or flow control. 

The air inlet and outlet of the air-cooling system are connected to the altitude chamber, forming an internal circulation system. The temperature of the cooling air can be adjusted by the temperature control system which installed after outlet of the circulating fan, which supplies cooling circulating air to the test piece under the same conditions as the simulated high-altitude environment, so as to test the thermal load state of the test piece.

Altitude Climate Chamber: Provides a simulated altitude environment for the test piece, allowing for the adjustment of temperature, air pressure, and humidity inside the chamber.

• Pressure range: atmospheric pressure 4.4 kPa, it can continuously work under 4.4 kPa

• Relative humidity range: 10...98  % RH @ 8...95 °C

• Temperature range: -70…+150 °C

• Stability at one point in time : ± 0,5°C

• Resolution for display: 0, 1°C

• Space homogeneity: ± 2°C

• Proper interfaces for connecting electrical lines, oil piping and ventilation air

Automated Measurement & Control System: Conducts overall control and condition monitoring of the entire motor test bench.

400kW 30000rpm Altitude Climate Simulation Test bench for aero-generators

200kW 20000rpm Altitude Climate Simulation Test bench for aero-generators