STARTGENSYS

ADAPTATION KIT DESIGN & MANUFACTURING: APU DRIVING SYSTEM

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 Obiettivo del progetto (Objective)

'The aim of this project is to design, manufacture, commissioning and validate of one complete driving system for a ground test bench intended to be used for aircraft starters/generators testing. The proposed system is complete and include one DC motor (120 kW) with associated power electronics, Human Machine Interface, Control System, Supporting Frame, High-speed Couplings, High-speed Transmission, Cooling circuit, Complete measurement System and Associtaed Software. In order to achieve a unitary test bench with low maintenance costs, we will implement innovative solutions based on the latest technologies in the fields of mechanical and electrical drives, mechanical transmissions, measurements and data processing. The proposed test bench will be able to testing EUTs (generator and/or starter/generator) in conditions similar to their use on aircraft. It will assure minimum energy consumption through energy recovery and its reintroduction in the process. The system will be environmental friendly, will use a reduced amount of oil and will have optimal mechanical regimes during service operation. Innovative aspects of the proposal are: mechanical transmission with high efficiency by using recess gear system and polygonal shafts; bidirectional and birotational speed multiplier with one output able to provide testing of EUT, both as a starter and generator, continuously and in conditions similar to their use on aircraft; use smart regenerative converters with high performance and high energy efficiency; non-contacting measuring of torques and speeds; use of specialized software for complete system configuration and management. The characteristics required by the Call for Proposal will be satisfied by those listed above.'

Introduzione (Teaser)

Along the road from conceptual design of aircraft components to fully integrated flight testing is the exploitation of dedicated test rigs for individual components. A new one to test aircraft starters and generators will support future all-electric aircraft.

Descrizione progetto (Article)

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.