The aim of this project was to design, manufacture, commission and validate four complete and identical driving systems for a ground test bench intended to be used for aircraft starters/generators testing.
The four driving systems were integrated in one single product and functioned simultaneously or not, independently and/or interdependently. Each system drove one single generator or starter/generator and was able to simulate electrical start of the aircraft engine, as well as electrical generation. Any two of the four drive systems had the possibility to be synchronised in speed and position. The four drives were locally or remote controlled and were integrated with ancillaries available at the place of use. A complete measurement channel deserved the entire test bench.
In order to achieve a unitary test bench with low maintenance costs, we implemented innovative solutions based on the latest technologies in the fields of mechanical and electrical drives, mechanical transmissions, measurements. The proposed systems were complete and included four DC motors (with maxim power of 160 kW each) with associated electronics. This completely fulfilled the imposed condition of identical systems.
Innovative aspects of the proposal were: mechanical transmissions with high efficiency by using recess gear system and polygonal shafts; bidirectional and birotational speed multiplier; non-contacting measuring of torques and speeds; use of specialized software for complete system configuration and management. The systems was environmental friendly, had low noise emission and used a reduced amount of oil. The main characteristics and capabilities required by the CfP were satisfied.
The general objective of the Clean Sky Eco-Design ITD was to make a significant step towards the concept of the all-electric vehicle systems aircraft. Thus, the feasibility of such an aircraft had to be investigated through the study of innovative energy management architectures while reducing ground and flight tests with innovative concepts and technologies.
To develop, validate and finally demonstrate these energy management architectures in the frame of Clean Sky programme, a modular test rig had been developed, based on Hispano-Suiza's COPPER Bird® bench (Characterization & Optimization of Power Plant and Equipment Rig).
The ELTESTSYS project had been started in August 2011 in order to design, manufacture, commission and validate of four complete and identical driving systems intended to be used for aircraft starters/generators testing inside the modular test rig above mentioned. The project, funded by the European Community's Seventh Framework Program (Clean Sky / Eco-Design) under the grant agreement n° 270584, involved two Romanian organisations: Institute for Theoretical & Experimental Analysis of Aeronautical Structures STRAERO S.A & National Research and Development Institute for Gas Turbines COMOTI. The ELTESTSYS consortium was coordinated by STRAERO and the specific project requirements were provided by Hispano Suiza as Topic Manager and end user of the ELTESTSYS Test Bench. The main project final result is the ELTESTSYS Test Bench, which is actually installed and used at Hispano-Suiza's COPPER Bird® bench in Colombes, France. The project was successfully completed in November 2013.
The ELTESTSYS Test Bench consisted in four identical Driving Systems, associated control and power cabinets and a control and storage computer. Each system drives one single generator or starter/generator and is able to simulate electrical start of the aircraft engine, as well as electrical generation. Any two of the four drive systems have the possibility to be synchronized in speed and position. The four drives function simultaneously or not, independently and/or interdependently, can be locally or remote controlled and are integrated with ancillaries and central control system available at Hispano-Suiza's COPPER Bird® bench. A complete measurement channel deserves the entire test bench. Innovative aspects of the ELTESTSYS Test Bench are: mechanical transmissions with high efficiency by using recess gear system; bidirectional and birotational speed multiplier (23000 RPM); non-contacting measuring of torques and speeds; custom software for complete system configuration and management.
The ELTESTSYS Test Bench was used at Hispano-Suiza's COPPER Bird® bench in Colombes, France, in the frame of Clean Sky programme, for testing generators and/or starter-generators in order to validate the integration of electrical systems and equipment, the quality of the energy produced, as well as demonstrating the maturity of technologies and systems for more electric aircraft.