A new test rig for next-generation aircraft

The public-private partnership Clean Sky is the EU's most ambitious aeronautical research programme ever. Among its many accomplishments is a modular test rig for the development and testing of electrical networks and integrated propulsion systems (engine and nacelle) with an eye toward more-electric aircraft. The EU is funding the STARTGENSYS (Adaptation kit design & manufacturing: APU driving system) project to validate a test bench for aircraft starters and generators to complement Clean Sky's modular test rig.

The STARTGENSYS system consists of a control cabinet, a power electronics cabinet and the driving system. The test bench will facilitate testing under conditions similar to use in aircraft while focusing on low maintenance costs, reduced use of oil and minimised energy consumption.

During the first reporting period scientists brought the concepts from system definition to detailed design and initiated manufacturing activities. The control cabinet has a personal computer equipped with a high-speed control and data acquisition board. The power electronics cabinet contains the converter and associated electronics. It transfers power between the alternating current input and the electric motor. The driving system is the most complex subcomponent. It contains the electric motor and its cooling system, the gearbox and its lubrication and cooling systems, and low- and high-speed coupling systems.

Researchers have performed analyses of the frequency response of the rotors, of gear efficiency and of test bench vibrations, with preliminary results suggesting promising performance. The control software is currently under development.

The STARTGENSYS starter/generator test bench will support the work of Clean Sky, finding use in the testing of a variety of electrical systems and equipment and evaluation of power production. More specifically, the project supports the development of mechanical high-speed transmissions for aircraft. Both will contribute to the increased competitiveness and sustainability of the EU's aerospace industry.