Dynamometer and
Propeller Testing
Of a 560 kW Permanent Magnet Electric Propulsion System for Small
Commercial Aircraft
Agenda
Introduction and Review of Concepts and Terms
Why Aerospace? And Why only Now? What’s Stopping Us?
Guiding Technical Standards – applicable to EE
High Power Test Cell System Architecture
Mobile Propeller Laboratory (Mobile Iron Bird) System Architecture
First Flight
Observations and Recommendations
Next Steps
Introduction
Definition of Terms
Electric Motor Theory
Electric Motor
• Electromechanical Device that converts Electrical Energy to Mechanical Energy
Mechanical Energy
Electrical Energy
Source: magniX
2
Definition of Terms
Basic Aircraft Mechanics
Four Forces of Flight
2
Definition of Terms
Basic Aircraft Mechanics
Four Forces of Flight… Seriously
2
Why should we (EE’s) get more involved
in Aerospace?
Current State of CO2 Emissions
Why should we (EE’s) get more involved
in Aerospace?
EE’s are more capable of the design and analysis of Electromechanical Energy
Conversion Equipment and related Devices
Understanding of Electric Motors and Power Electronics (Drives)
Application: conversion of classic aircraft propulsion system into More Electric (hybrid) or
All-Electric Propulsion Systems
Understanding of Electrical Wiring Interconnection System (EWIS)
Understanding of Instrumentation and Control
Why should we (EE’s) get more involved
in Aerospace?
Business Sense
Electric Motors are easier and cheaper to repair / replace
Scalability (but only if…)
Conversion of all existing Internal Combustion Engine aircraft
Why should we (EE’s) get more involved
in Aerospace?
Business Sense
Electric Motors are easier and cheaper to repair / replace
Scalability (but only if…)
Conversion of all existing Internal Combustion Engine aircraft
Why only Now?
Permanent magnet motors recently more adapted and scaled
Disconnect between the Aerospace Industry and Electrical Industry
PEC currently does not cover anything involving aircraft electrical systems
Advent of More Electric or All Electric Aircraft (and EV’s) – PEC must adapt
Battery technology development is slow even on the global scale
What’s stopping us (at the moment)?
Lack of Research and Development
Electric drives are getting more attention, but we keep forgetting that these drives must
go hand in hand with motors as well
Funding challenges
Adaptation of Standards for Electric Motors and Drives
We have to choose: IEC or NEMA/NEC. Not Both.
Again… Batteries
Guiding Standards
IEC Standards
IEC 60034 series: Rating and Performance of Electrical Machines
IEC 60349-4: Electric traction Rotating electric machines for rail and road vehicles - Permanent
magnet synchronous electrical machines connected to an electronic converter
IEC TS 60034-30-2: Efficiency classes of variable speed AC motors (IE-code)
ASTM Standards
ASTM F3338: Standard Specification for Design of Electric Propulsion Units for General Aviation Aircraft
ASTM F3316/F3316M: Standard Specification for Electrical Systems for Aircraft with Electric or Hybrid-
Electric Propulsion
ASTM F3239: Standard Specification for Aircraft Electric Propulsion Systems
AS / ISO Standards
AS 9100D: Quality Management Systems for Aviation, Space, and Defense Organizations
ISO 9001: Quality Management Systems – General Requirements
Dynamometer Testing System Architecture
>>
Dynamometer Testing System
Source: magniX
Dynamometer Testing
What were actually being tested:
magni500 Electric Propulsion System
magni500 Motor: 560 kW, 1900 RPM, Synchronous Permanent Magnet Motor
Data Sheet: https://magnix.aero/products
magniDrive: 2 x 170 kW, 400-800 VDC Input, 3-phase AC output
Data Sheet: https://magnix.aero/products
What were used to test
Dynamometer System (the Speed controller)
600 kW Dynamometer, can ramp up to 4000 RPM
Controlled by a Variable Frequency Drive
Inverters (the Torque commander)
4 x 300 kW 400-800 V Automotive grade propulsion inverters
Dynamometer Testing
What were being measured:
Current and Voltage
DC – from power supply
AC – from inverter to motor, including waveforms
Torque, via a Torque Transducer
Speed, via an integrated resolver
Temperatures
Ambient Temperature
Winding, via embedded PT-1000 RTD’s
Rotor, via IR Sensor
Bearing, via embedded PT-1000 RTD closest to the bearing
Cooling Oil Parameters
Temperature
Pressure
Flow Rate
Vibration (Tri-axes), checked on various locations around the frame
Noise, via 1/3 Octave Band, 1 m away from the motor
Dynamometer Testing System
Source: magniX
Dynamometer Testing
System Level Validation
DC Power Supply Check
Cooling System Control Setup and Checking
Signals and CAN Communications System Calibration and Validation
Dynamometer Function and Vibration Check
Electric Propulsion System Tests Performed
Mechanical Validation and Determination of Back EMF
Inverter System Calibration and Functional Testing
Efficiency Mapping
Thermal Equilibrium
Mission Profile
Endurance
>>
Dynamometer Testing
Example of an Efficiency Map
<<
Source: https://www.ansys.com/blog/efficiency-maps-for-electric-motors-made-easy
Dynamometer Testing
Thermal Equilibrium
<<
Dynamometer Testing
Example of a Mission Profile
Source: https://www.researchgate.net/figure/Example-of-the-mission-profile-used-for-the-verification-missions-d-Evans-G-The_fig5_299644281
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Iron Bird System Architecture
>>
Iron Bird Testing
>>
Source: magniX
Iron Bird Testing
What were being measured:
Current and Voltage
DC – from power supply
AC – from Inverter
Speed, via an integrated resolver
Temperatures
Ambient Temperature
Winding, via embedded PT-1000 RTD’s
Rotor, via IR Sensor
Bearing, via embedded PT-1000 RTD closest to the bearing
Cooling Oil Parameters
Temperature
Pressure
Flow Rate
Propeller Governor Pressure
Vibration (Tri-axes), checked on various locations around the frame
Noise, via 1/3 Octave Band, 1 m away from the motor
Iron Bird Testing
System Level Validation
DC Power Supply Check
Cooling System Control Setup and Checking
Signals and CAN Communications System Validation
Propeller Control System Checking
Electric Propulsion System Tests Performed
Mechanical Validation
Inverter System Functional Testing
Snap Acceleration
Mission Profile (multiple repeats)
Endurance
Reduced Cooling System Testing
Safety of Flight Tests
First Flight
Source: magniX
Observations and Recommendations
Other potential applications of Electric Propulsion Systems
Agriculture
Land or Water Rescue Missions
eVTOL (Electric Vertical Take-Off and Landing) – public commuting system diversification
Anything that middle-mile (around 1,000 km) aircraft can reach
Observations and Recommendations
Disruption will face resistance from the status quo
Aircraft repairs and modifications businesses
Certifying bodies in the Philippines
Existing Infrastructure / Airport Operations
Potential Solutions – Case Studies:
Present with Case Studies, similar from magniX achieved
New Zealand – small population, early adapter (https://www.electricair.nz/)
And always remind these entities about climate change!
Observations and Recommendations
Collaboration is key to achievable and sustainable transition to aircraft electrification
Universities – via R&D, and inter-disciplinary approach; inter-University collaboration
Regional airline companies need to be convinced
Supply chain
Next Steps
Glenn’s next steps
Research about hybrid electric propulsion systems for regional to large commercial aircraft
(> 5 MW-class propulsion)
Learn more about Airworthiness and provide framework for the Philippines when it comes to
the adaption of Electric Propulsion Systems and related Infrastructure
Support conversion initiatives in the Philippines whenever possible
Other potential research topics
High Temperature Superconductive Tapes as stator coils
Hydrogen and other green fuel research
Battery research
Novel approaches – HV Ion Propulsion
