Reliable helicopter electric actuators

Rotorcraft systems are becoming more electric for increased efficiency and safety. The Green Rotorcraft Consortium – a sub-programme of the Clean Sky Joint Technology Initiative (JTI) – focuses on advanced electrical systems for reducing noxious hydraulic fluids and fuel consumption. Testing is an essential stage in the development of electrical systems.

The EU-funded project TESTHEMAS (Design and implementation of a load simulator rig and ground test bench adaptation kit for a HEMAS test rig) is contributing to the development of more-electric helicopters by manufacturing and tuning an innovative and smart test bench for linear actuators. The test bench should be capable of conducting synchronised tests on three helicopter linear electromechanical actuator (EMA) assemblies, while applying different loads on them. The project is also implementing an adaptation kit that should be able to interface the EMA test rig with the ground electrical network test bench.

Within a 9 square metre area, the TESTHEMAS test rig is designed to be modular, versatile, and able to integrate a wide range of hydraulic and mechanical equipment. It is also equipped with a dedicated complete autonomous hydraulic power system for ground tests.

Force and velocity sensors are gathering valuable information about the test rig. A local control system is interfacing with the test rig sensors, the actuators and the equipment under test. This should allow end users to implement predictive maintenance operations, reducing diagnosis time and machine downtime.

Predictive maintenance combined with the ease of assembling and disassembling components of the test rig should allow reducing maintenance costs by at least 15 %.

The TESTHEMAS test rig will allow measuring with accuracy several physical parameters such as dynamic and thermal loads on helicopter EMAs. Relying on this data and numerical models, manufacturers should be able to enhance EMA performance and increase reliability.

Test benches replicating the actual loading conditions on EMAs are necessary to validate the prototype designed prior to in situ testing on flyable helicopters. Successful validation of the TESTHEMAS system should ensure reliable, safe and efficient performance.