Neometrix / Aerospace Test & Ground Support Equipment / Starter Generator Test Rig / NMX-SGTR

MIL-STD COMPATIBLE · ISO 9001:2015 · MULTI-BRAND · 50+ S/G MODELS

Starter Generator Test Rig — one rig, every aircraft starter generator.

Programmable, multi-brand starter generator test stand for aircraft starter generators — from light helicopter DC brush units to 270V HVDC systems. Full electrical loading, precision measurement, and automated test reporting in one integrated rig.

View 3D model Explore the rig

Neometrix Starter Generator Test Rig — full section view

Fig · 01 — The rig as built. Drive train, electrical loading, instrumentation and control on one vibration-isolated frame.

Drive speed

15,000RPM, expandable to 60,000

Peak starter current

2,000amps, 5-second cranking burst

Compatible S/G models

50+DC brush, DC brushless & AC

Standardised tests

12pre-programmed recipes

Indian Air Force & HAL

DRDO & Defence PSUs

Skurka · Safran · AMETEK · Honeywell Compatible

MIL-L-52366 · MIL-R-6809 Certified

Testing sequence

Every test follows the same 5-stage sequence.

Each stage is automated, logged, and cross-referenced against the selected S/G recipe.

Step 01

Mount & Configure

The starter generator is secured on the adjustable fixture plate using the model-matched adapter. The operator selects the S/G recipe from the HMI — all limits, ramp rates, and load steps auto-load.

Quick-change adapter · 12+ flange types

Step 02

Drive & Speed Control

The 4-quadrant regenerative servo drive accelerates the rotor along the programmed ramp profile to the target test speed, held within ±0.5% of setpoint.

0–15,000 RPM · overspeed cut-off 14,500

Step 03

Electrical Loading

The programmable DC load bank applies stepped current loads from 0 to 600 A. Starter simulation applies 2,000 A peak for 5-second cranking bursts.

DC / AC load banks · ~50 kW peak

Step 04

Measure & Log

All instrumentation channels are sampled simultaneously at high frequency — voltage, current, speed, temperature, vibration, and commutation waveforms live on the SCADA HMI.

Real-time limit checking

Step 05

Report & Classify

On completion, the system auto-generates a timestamped report with pass/fail against limits, operator ID, and calibration traceability.

PDF / CSV / Excel export

Inside the rig

Four integrated subsystems, one frame.

Each subsystem of this generator test equipment is engineered independently and integrated on a single vibration-isolated frame — ensuring signal integrity and operator safety.

01 · Mechanical

Drive Train System

A Siemens 1PH8 servo motor with S120 regenerative 4-quadrant drive provides the mechanical spin — from slow cranking simulation to 15,000 RPM generator testing.

Motor type Servo (Siemens 1PH8 or equiv.)
Drive controller 4-Quadrant Regenerative (S120)
Power range 6 kW – 37 kW (50 HP)
Speed range 0 – 15,000 RPM
Gearbox Planetary, low-backlash (1:2.4–1:5)
Coupling High-speed flexible, 15,000 RPM

02 · Electrical

Electrical Subsystem

A programmable DC load bank, AC load bank, precision field excitation supply, and 2,000 A starter simulation bus — all switched and sequenced by PLC with hardware interlocks.

DC load bank 0–30 VDC, 0–600 A
AC load bank 115V, 400 Hz, 3-phase, ≥15 kVA
Starter simulation 28–30 VDC, 2,000 A peak
Field excitation 0–30 VDC, 0–10 A
Peak starter power ~50 kW (5-second burst)
Input power 3-phase, 415V ±10%, 50 Hz

03 · Instrumentation

Instrumentation

National Instruments DAQ or equivalent simultaneously samples all channels — voltage, current, speed, temperature, vibration, and commutation — with full traceability to calibration standards.

Voltage 0–50 VDC, armature/field/terminal
Current 0–2,200 A (Hall-effect / shunt)
Speed Optical encoder / servo feedback
Temperature RTD / K-type, 18–200°C
Vibration Accelerometers, 1–10,000 Hz
Comm. run-out TIR ≤0.0007", bar-to-bar ≤0.0002"

04 · Software

Control & Software

A PC-based SCADA with touchscreen HMI overlays live data on the digital twin of the S/G under test. Automated sequences handle start/stop, ramp control, limit checking, and reporting without operator intervention.

DAQ system National Instruments / LabVIEW / PLC
HMI Touchscreen + PC-based SCADA
Automation Start/stop, ramp, limit checks
Reports Timestamp, operator ID, pass/fail
Communication EtherCAT, remote IoT monitoring
E-Stop Multiple mushroom-type locations

Fig · 02 — Mechanical drive interface — the quick-change adapter and coupling that connect the servo drive to the unit under test.

12 standardised tests

Full test capability suite, pre-programmed.

Every test is pre-programmed as a recipe. Operators select the S/G model, press Start — the rig executes the full sequence autonomously.

Test 01

Maximum Speed Regulation

Operate at 13,000 RPM, 30V, no-load. Verify field current and voltage regulation remain within specified limits.

Test 02

Continuous Operating Speed

12,000 RPM at rated load until thermal stabilisation — frame temperature rise verified ≤2°F in any 5-minute window.

Test 03

Compounding Test

Verify field current rises proportionally with increasing load steps (0 → 100 → 200 → 300 A).

Test 04

Minimum Speed Regulation

Confirm rated voltage output is maintained at minimum operating RPM (6,800–8,700 RPM depending on model).

Test 05

Residual Voltage Test

Verify residual voltage ≥0.8V at operating speed with no load applied.

Test 06

Overspeed Test

Run unit at 14,000 RPM for 5 continuous minutes. Vibration, temperature and noise continuously monitored.

Test 07

Commutation Inspection

Visual and oscilloscope analysis of brush sparking quality at multiple speed/load combinations.

Test 08

Locked Rotor / Start Torque

Apply rated voltage with rotor locked. Verify torque output ≤9 ft-lbs (or per model spec).

Test 09

Equalising Voltage Test

Measure paralleling voltage across terminals D–E. Verify ≤2.6V for satisfactory paralleling behaviour.

Test 10

Commutator Run-Out

Dial gauge measures total indicator run-out (TIR ≤0.0007") and bar-to-bar variation (≤0.0002").

Test 11

Magnetic Pickup Waveform

Oscilloscope captures magnetic pickup output at 6,000 RPM, verifying ≥2.5V peak-to-peak signal.

Test 12

Frame Temperature Rise

Verify frame temperature does not exceed 175°F (97°C) above air inlet temperature at rated load.

Technical specifications

Every parameter is configurable at order time.

Custom ranges and additional channels available on request.

Drive Train System

Motor Type	Servo Motor (Siemens 1PH8 or equiv.)
Drive Controller	4-Quadrant Regenerative (Siemens S120)
Power Range	6 kW – 50 HP (37 kW), auto-configured
Speed Range	0–15,000 RPM (expandable to 60,000)
Gearbox	Precision Planetary, Low Backlash (1:2.4 – 1:5)
Coupling	Flexible High-Speed, Backlash-Free, 15,000 RPM
Torque Control	Fully Programmable, Closed-Loop Encoder
Mounting Base	Vibration-Isolated Rigid Stand, Adjustable Fixtures

Electrical Subsystem

DC Load Bank	0–30 VDC, 0–600 A, Programmable / Stepped
AC Load Bank	115V, 400 Hz, 3-Phase, ≥15 kVA
Starter Simulation	28–30 VDC, 2,000 A Peak / 400 A Continuous
Field Excitation	0–30 VDC, 0–10 A, Precision Linear DC
Peak Starter Power	~50 kW for 5-second burst
Load Steps	0, 37, 75, 112, 150, 200, 300, 400 A
Input Power	3-Phase, 415V ±10%, 50 Hz (380V/60 Hz export)

Instrumentation

Voltage Measurement	0–50 VDC, Armature / Field / Terminal
Current Measurement	0–2,200 A (Hall-Effect or Shunt Sensors)
RPM Measurement	Optical Encoder / Servo Feedback
Frequency (AC)	400 Hz ±0.1 Hz Accuracy
Temperature	RTD / K-Type Thermocouples (18–200°C)
Vibration Analysis	Accelerometers, 1–10,000 Hz Range
Resistance	0–35 Ω, ±0.1% Precision
Commutator Run-Out	TIR ≤0.0007", Bar-to-Bar ≤0.0002"

Software & Safety

DAQ System	National Instruments / LabVIEW / PLC-Based
HMI Interface	Touchscreen + PC-Based SCADA Control
Test Automation	Start/Stop Sequencing, Ramp, Limit Checks
Data Logging	Live Plotting, CSV / PDF / Excel Export
Emergency Stop	Mushroom-Type, Multiple Locations
Overcurrent Protection	Software + Hardware Interlocks
Overspeed Cut-Off	RPM Feedback-Driven Software Limit
Emergency Braking	Servo-Driven / Pneumatic Disc Brake

Compatibility database

50+ compatible starter generator models.

From Skurka 150SG helicopters to Collins 250 kVA wide-body systems, this generator test stand covers one rig, every model. Click any row for full details.

Manufacturer	Series / Model	Type	Voltage	Current	Max Speed	Category

Engineering excellence

Built for precision. Designed for production.

Every design decision prioritises measurement accuracy, operator safety, and long-term reliability in demanding defence and MRO environments.

↻

4-Quadrant Regenerative Drive

Recovers kinetic energy back to the grid during deceleration. Reduces energy cost by up to 35% vs. resistive-braking drives, while enabling precise regenerative torque simulation.

☰

Auto-Recipe Loading

Operator selects the S/G part number from the HMI library. All test limits, ramp rates, load step sequences, and report templates auto-configure — zero manual entry.

🔌

Multi-Brand Adapter System

A quick-change adapter kit covers all major S/G flange geometries — Skurka, Safran, AMETEK, Thales, Honeywell, and more. Changeover under 15 minutes.

🛡

Layered Safety Architecture

Hardware e-stops, software overspeed limits, overcurrent interlock, over-temperature shutdown, vibration-triggered auto-stop, and full mechanical guarding.

📊

Traceable Calibration

All instrumentation channels are calibrated against NABL-accredited standards. Calibration certificates and expiry dates are embedded in each report.

☁

IoT Remote Monitoring

Optional EtherCAT-linked IoT gateway streams live test data to a web dashboard. Quality managers can monitor tests remotely and access historical reports.

Modular upgrades

Optional add-ons.

Extend the base rig at any time. Each module plugs into the existing DAQ and control infrastructure.

Torque Transducer

Real-time rotary & static torque output measurement

Harmonic Analyzer

THD & waveform quality for AC generators

Thermal Chamber

Hot/cold environmental simulation during testing

Remote Monitoring

Web-based HMI with live data & IoT access

Auto Calibration Kit

Automated sensor calibration vs. traceable standards

Commutation Camera

Real-time visual commutator inspection at speed

Multi-Model Adapter Kit

Quick-change adapters for different S/G brands

Dynamic Balancer

2-plane balancing, ISO G 1.0, 2–15 kg rotors

Wireless Vibration Pack

Advanced in-test diagnostics without cabling

Emergency Braking

Electromagnetic / pneumatic disc brake for rapid DUT stop

Standards & certifications

Built to the right standards.

Designed to satisfy the most demanding aerospace and defence quality requirements worldwide.

ISO 9001:2015

ISO 12100 (Machinery Safety)

IEC Standards

MIL-STD Compatible

MIL-L-52366

MIL-R-6809

DO-160 Ready

CE Certification (Optional)

DGAQA Registered

Common questions

Frequently asked questions.

Q · 01Can one rig test both DC brush and DC brushless starter generators?

Yes. The rig's electrical subsystem includes separate load banks and excitation circuits for DC brush, DC brushless, and AC configurations. The operator selects the S/G type from the HMI — the correct test circuit is automatically activated and irrelevant circuits are safely isolated by hardware interlocks.

Q · 02How long does it take to change over between two different S/G models?

Mechanical adapter changeover takes 10–15 minutes using the quick-change adapter kit. Recipe selection on the HMI is instantaneous. Total changeover including electrical re-termination and self-check is typically under 30 minutes for an experienced technician.

Q · 03What is the highest power S/G the rig can test?

The standard rig is configured to 37 kW (50 HP) mechanical drive and 50 kW peak electrical. This covers all DC brush and most DC brushless units. For high-power AC generators (Collins 150 kVA, GE T700 65 kW, Honeywell 60 kVA), a heavy-duty variant with 90–200 kW drive and matching AC load bank is available — please contact us for a custom scope.

Q · 04Are test reports accepted by DGAQA and IAF quality auditors?

Yes. Reports include: unit serial number, operator ID, calibration certificate references with expiry dates, measured vs. limit comparison for all parameters, date/time stamp, and digital signature. The format has been accepted by DGAQA-registered facilities. We can customise the report template to match your quality system's specific requirements.

Q · 05Can the rig simulate actual in-flight load profiles rather than static stepped loads?

Yes — with the standard programmable load bank, arbitrary load waveforms can be programmed as ramp sequences. For fully dynamic load simulation (e.g., replicating an in-flight transient load cycle), the optional torque transducer and closed-loop load control mode provide real-time following of a recorded aircraft load profile.

Q · 06What is the delivery and installation timeline?

Standard rig: 16–22 weeks from confirmed purchase order. Site installation, commissioning, and operator training: 3–5 working days. Factory Acceptance Testing (FAT) at our facility is included. Site Acceptance Testing (SAT) with your team is conducted after installation.

Q · 07Is post-installation support and calibration available?

Yes. We offer Annual Maintenance Contracts (AMC) covering preventive maintenance, calibration, software updates, and priority response. Remote diagnostics via the IoT gateway allow our engineers to assist without a site visit in most cases. On-site support is available across India and internationally.

Get in touch

Tell us your S/G models
and test standards required.

We'll match the rig configuration, adapter kit, and instrumentation to your fleet of starter generators and quality-system requirements before you commit.

Request proposal +91 7777 876 876

Starter Generator Test Rig — one rig, every aircraft starter generator.

Every test follows the same 5-stage sequence.

Mount & Configure

Drive & Speed Control

Electrical Loading

Measure & Log

Report & Classify

Four integrated subsystems, one frame.

Drive Train System

Electrical Subsystem

Instrumentation

Control & Software

Full test capability suite, pre-programmed.

Maximum Speed Regulation

Continuous Operating Speed

Compounding Test

Minimum Speed Regulation

Residual Voltage Test

Overspeed Test

Commutation Inspection

Locked Rotor / Start Torque

Equalising Voltage Test

Commutator Run-Out

Magnetic Pickup Waveform

Frame Temperature Rise

Every parameter is configurable at order time.

50+ compatible starter generator models.

Built for precision. Designed for production.

4-Quadrant Regenerative Drive

Auto-Recipe Loading

Multi-Brand Adapter System

Layered Safety Architecture

Traceable Calibration

IoT Remote Monitoring

Optional add-ons.

Torque Transducer

Harmonic Analyzer

Thermal Chamber

Remote Monitoring

Auto Calibration Kit

Commutation Camera

Multi-Model Adapter Kit

Dynamic Balancer

Wireless Vibration Pack

Emergency Braking

Built to the right standards.

Frequently asked questions.

Tell us your S/G modelsand test standards required.

Enquiry Received!

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