Details
The Starter Generator Test Bench by Neometrix Defence Limited is a state-of-the-art testing system meticulously engineered to evaluate the performance and reliability of starter generators used in advanced light helicopters (ALH). Built for precision, durability, and user convenience, the test bench integrates advanced testing mechanisms with a robust control interface to meet the rigorous standards of the aviation industry. Core Functionalities and Test Types 1. Generator Mode Testing - Designed to assess the performance of the generator under both load and no-load conditions. - A resistive load bank provides incremental load steps (0A, 50A, 100A, 150A, 200A) with additional high-current loads of 300A, 375A, and 450A. - Cooling systems integrated into the load bank ensure sustained performance during extended testing sessions. - Load application is controlled via a dedicated control panel equipped with user-friendly switches for precise load selection. - An ABB AC drive allows precise control of the motor speed, ensuring the generator operates within its design parameters. 2. Starter Mode Testing - Simulates starter motor functionality by powering the starter generator (S/G) in DC motor mode using a 30V, 500A DC power supply. - A Magtrol Hysteresis Dynamometer applies variable mechanical loads, enabling torque testing across a wide range. - The DSP6001 processor facilitates fine-grained control of mechanical load adjustments. - Real-time monitoring of starting voltage, current, and torque ensures accurate data collection for diagnostic analysis. 3. Vibration Measurement Testing - Detects and analyzes vibrations produced by the rotating shaft orgear assembly when the S/G operates as a DC motor. - A vibration sensor transmits signals to a vibration analyzer, enabling precise frequency and amplitude measurements. - The system includes a handheld tachometer for monitoring shaft rotation speeds up to 15,000 RPM. - Tests are powered by a 30V, 100A DC power supply, ensuring consistent and reliable operation during vibration analysis. 4. Concentricity and Bar-to-Bar Difference Measurement - High-precision measurement tools ensure accurate analysis of physical parameters like concentricity and bar-to-bar resistance. - A digital micrometer with a measurement range of +50 µm to -50µm provides detailed feedback on component uniformity and structural integrity. Key Features - High-Speed AC Motor and Gearbox System - The test bench features a 5000 RPM AC motor, rigidly coupled to a dual-output gearbox with a 1:3 ratio, enabling maximum speeds of 15,000 RPM. - Designed to accommodate starter generators up to 6kW, the motor and gearbox combination ensures smooth and vibration-free operation. - Resistive Load Bank - The load bank is tailored for high-power testing scenarios, offering fine-tuned load adjustment and efficient cooling systems to maintain stability during prolonged tests. - Current loads are easily selectable from the control panel, ensuring precision and adaptability for various testing needs. - Advanced Monitoring and Data Acquisition - Speed range: 0-15,000 RPM with real-time feedback via a digital tachometer. - Torque measurement: 0-45 Nm (generator mode) and 0-20 Nm (starter mode). - Current monitoring: 0-500A for generator load testing; 0-100A for no-load testing. - Voltage monitoring: 0-30VDC (starter mode) and 0-50VDC (generator mode). - Temperature sensors monitor input/output air (up to 100°C) and generator frame (up to 200°C). - Sophisticated Control Panel - An intuitive mimic panel allows operators to manage load, speed, and other testing parameters effortlessly. - Integrated meters and displays provide real-time readings of all key parameters, including voltage, current, torque, and RPM. - Fully equipped with safety interlocks and alarms to protect both operators and the equipment. Technical Specifications - Input Power: 3-phase, 415V, 50 Hz. - Drive Power: 90 kW. - Torque: 40 Nm constant. - Speed Range: 0-15,000 RPM. - Resistive Load Bank Ratings: - 25A (2 units), 50A (4 units), 100A (2 units), and combined high-current loads up to 450A. - DC Power Supplies: - 0-30VDC, 500A (starter testing). - 0-30VDC, 100A (vibration testing). - Resistance Measurement Range: 0-2 Ohms. - Vibration Frequency Analysis: 1-10,000 Hz. - Digital Tachometer: 1-25,000 RPM. Advantages of the Test Bench 1. Reliability and Precision - Engineered to handle rigorous testing scenarios with minimal downtime. - Advanced sensors and control systems provide high-accuracy measurements. 2. User-Friendly Interface - Intuitive control panel simplifies the testing process, reducing operator training requirements. 3. Modular and Scalable Design - Flexible architecture allows integration of additional features or customization to meet specific client needs. 4. Robust Cooling Systems - Essential for managing heat dissipation during high-current and prolonged tests, ensuring consistent performance. 5. Wide Range of Applications - Suitable for starter generators used in advanced light helicopters, as well as other aviation and industrial systems requiring high-speed, high-torque testing. Applications This test bench is an indispensable tool for: - Aviation Industry: Ensuring the reliability of starter generators for helicopters and other aircraft. - Research and Development: Developing and optimizing new starter generator designs. - Maintenance and Repair Organizations (MROs): Providing diagnostics and performance validation for repaired components.
