Aircraft generator test bench, IGB TGB test


No matter in aerospace, defense and civil aviation markets, the prime aircraft and aviation component companies in the world focus on developing the core technologies of high efficiency and high reliability traditional or electric propulsion systems using in high-performance aircraft, flight vehicles, advanced unmanned systems and aerospace vehicles. Below is aircraft generator test bench, IGB TGB test and some examples of aircraft related test benches.

Aircraft generator test bench


Aircraft generator test bench is used by a major aircraft component manufacturer to simulate the power and quick acceleration generated by commercial airline starter‐generators. The aircraft generator test bench have been running 24 hours in 7 days since they were commissioned, only being turned off for scheduled maintenance. This aircraft generator test bench showcases the tandem motor configuration design, where two motors are coupled together to allow for double the torque at a given speed.


What is the aircraft generator?


Aircraft generator helps provide electrical power in an aircraft. Similar to aircraft alternator, aircraft generator does provide some advantages over aircraft alternators. For one, they are not as sensitive to errant electrical spikes or reversed polarity, and aircraft generator is also able to produce electrical power even when the battery is dead. Aircraft generator begins as a motor to start an airplane’s engine. After the engine is started, it turns into a generator.


About aircraft engine starting


Many variations of aircraft engine starting have been used since the Wright brothers made their first powered flight in 1903. The methods used have been designed for weight saving, simplicity of operation and reliability. Early piston engines were started by hand, with geared hand starting, electrical and cartridge-operated systems for larger engines being developed between the wars.

Gas turbine aircraft engines such as turbojets, turboshafts and turbofans often use air or pneumatic starting, with the use of bleed air from built-in auxiliary power units (APUs) or external air compressors now seen as a common starting method. Often only one engine needs be started using the APU (or remote compressor). After the first engine is started using APU bleed air, cross-bleed air from the running engine can be used to start the remaining engine(s).

Aircraft generator test – Fuel supply system in aero engine


Semi-physical simulation, also known as physical-mathematical simulation or hardware-in-loop simulation, refers to the simulation research content. A part of the simulated object system is introduced into the simulation loop in real (or physical model). The rest of the simulated object system is described in a mathematical model and transformed into a simulation model. With the help of physical effect model, the joint simulation of real-time mathematical simulation and physical simulation can be carried out.



Aiming at the fuel supply system in the aero engine, a semi-physical digital simulation test bench was constructed. The driving force and the load of the six motor drive systems were used to simulate the high and low temperature state of the fuel. Motor gear simulation system, using high-precision gear synchronous control system, controls 6 motors in accordance with a certain gear ratio for synchronous acceleration, deceleration and uniform motion.

One of the motor simulates drive system. One motor simulates the load. Other motors simulate each gear output shaft of transmission system. The maximum speed can reach 30000rpm. The simulation response and control time of motor simulation system is less than 20ms. Each motor will simulate the parameters of the aeroengine digital simulation control system, which synchronously accepts the parameters of the temperature simulation system for performing internal mathematical simulation calculations.

The control parameters are sent dynamically in real-time to each motor control and temperature control system. Through the motor simulation drive system, the structure of the transmission system is not limited and can be more flexible.


Aircraft generator test – Aero engine high speed IGB TGB test


Fatigue test is taken for high-speed bevel gears such as internal gearbox (IGB) and transfer gearbox (TGB). The S-N curves of IGB TGB test can be obtained to examine the vibration characteristics of the gears at each speed point, gear tooth root stress, transmission efficiency at different oil temperatures, meshing marks in loading state, transmission error etc.

The electrical closed loop IGB TGB test bench adopts the electric closed loop structure, the maximum test speed is 25,000rpm. The rated test torque is 400N.m. The driving end can apply 3,000N positive pressure to the bevel gear for simulating the actual working condition. The axial load of IGB TGB test bench uses compressed air and loading plate to form the loading mechanism. It can achieve axial loading in any speed. By adjusting the air pressure of IGB TGB test bench, the adjustment of the loading force can be achieved.

The state of the gear and bearing can be monitored in real-time under test for early fault warning and fault diagnosis.


Aircraft generator test – Helicopter gearbox


The helicopter gearbox test bench, just as well as engines and rotors, require highly sophisticated and technically advanced transmission test systems to develop a technology base for future rotorcraft advances. The contract to design, build and install dynamometer motors at the helicopter test center. The motors still run flawlessly today, two of dynamometers which are simulating engine inputs into the gearbox and the third dynamometer is absorbing the output loads sent to the tail rotor on the helicopter gearbox.


Background of helicopter gearbox test bench


The helicopter has evolved into a highly valuable air mobile vehicle for both military and civilian needs. The helicopter transmission, just as well as engines and rotors, require highly sophisticated and technically advanced transmission test systems to develop a technology base for future rotorcraft advances. Research studies continuously aim to increase the life, reliability, and maintainability, reduce the weight, noise, and vibration, and maintain the relatively high mechanical efficiency of the gear train.

In helicopter transmissions while also identify advanced materials and lubrication schemes, as well as advanced design concepts for both transmission components and total transmission systems. DynoEquip delivers the the highly specialized testing solutions demanded for this application. The experienced team is experts at creating custom solutions to fit specific testing.

Transmission and high-speed gearbox testing applications have long been a speciality and area of technical expertise for the team of testing and applications engineers. Regardless of the unique challenges of your application, DynoEquip has an complete systems solution to meet your helicopter transmission testing needs.

Aircraft generator test – Aviation bearing


This aviation or aerospace bearing test bench incorporates a high speed AC dynamometer with internally water cooled motor and a gearbox to be able to deliver 60,000rpm up to 120,000rpm along with high power. Aerospace bearing test bench data acquisition panel is used to monitor the temperature and vibration of both the AC motor and the gearbox. The AC motor is cooled by recirculating system. The aerospace bearing test stand is used to test bearings for aviation or aerospace applications.


About aerospace bearing


Aerospace bearings are the bearings installed in aircraft and aerospace systems including commercial, private, military, or space applications. When designing aerospace bearings, it is important to take a few things into account, including material standard, design, lubrication type, surface coatings and treatments, non-destructive testing and traceability.

In order to assure bearing performance it is necessary for the bearing steel to be of high quality. Jet engine bearings are typically manufactured from metals manufactured using a vacuum arc remelt to enable material requirements to be met. Jet engine shaft bearings and accessory drive shaft bearings normally use single piece or two piece machined retainers. The pressed steel or moulded retainers found on mass-produced bearings are not used.

Temperature and moisture resistant oils, greases and lubricants are normally specified. If the lubricant is not correct the performance of the bearing will be compromised.

Aircraft generator test – Gas turbine simulation


This gas turbine simulation dynamometer is used to precisely simulate a gas turbine. This aircraft test bench embodies the highest performance available in the world. The gas turbine simulation dynamometer system is comprised of a high speed internally fluid cooled motor, multiple variable frequency drives, multiple fluid recirculating systems, a custom cast base, a spindle to transfer the load to the test article.


What is gas turbine?


A gas turbine, also called a combustion turbine, is a type of internal combustion engine. It has an upstream rotating compressor coupled to a downstream turbine, and a combustion chamber or area, called a combustor, in between. The basic operation of the gas turbine is similar to that of the steam power plant except that the working fluid is air instead of water. Fresh atmospheric air flows through a compressor that brings it to higher pressure. Energy is then added by spraying fuel into the air and igniting it so the combustion generates a high-temperature flow.

This high-temperature high-pressure gas enters a turbine, where it expands down to the exhaust pressure, producing a shaft work output in the process. The turbine shaft work is used to drive the compressor and other devices such as an electric generator that may be coupled to the shaft. The energy that is not used for shaft work comes out in the exhaust gases, so these have either a high temperature or a high velocity. The purpose of the gas turbine determines the design so that the most desirable energy form is maximized.

Gas turbines are used to power aircraft, trains, ships, electrical generators, pumps, gas compressors and tanks.

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