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

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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