The Challenge
An innovative electric Vertical Take Off and Landing (eVTOL) aircraft manufacturer needed to design, engineer, and build a high-resolution, four-axis dynamometer testing system to simulate flight-load conditions. This system had to be developed within a very tight timeframe to meet the company’s product testing and certification milestones, ensuring their eVTOL motors would perform safely and reliably under demanding flight conditions. With their aircraft’s market introduction looming and investor expectations high, the customer turned to ACS for a solution.
The Solution
ACS, a leader in advanced testing solutions for electric powertrains, took on the challenge by leveraging their partnership with Siemens and their Ntandem solution development program. They built a four-axis, 1,205 hp (900 kW) AC regenerative drive system using Siemens SINAMICS S120 drives and SIMOTICS M-1PH8 induction motors, which provided precise control over the eVTOL motors. This system served as a robust dynamometer testing system and also functioned as a dynamometer for electric motor testing to validate motor performance under simulated flight loads. The comprehensive design ensured that the dynamometer for electric motor testing could capture high-fidelity performance data essential for flight certification.
To de-risk the project, ACS coordinated closely with the customer’s facility builder and electrical contractor to ensure the test system would be installed, commissioned, and operational without delay.
The testing setup, known as an “iron bird” in the aerospace industry, assembled the entire propulsion system with motors, controllers, and critical components for real-world performance validation. ACS’ regenerative drive system also allowed for energy reuse, feeding power back to the grid and avoiding waste, further enhancing the system’s cost-effectiveness and sustainability.
The Outcome
ACS successfully delivered the dynamometer testing system on time, enabling the electric vertical takeoff and landing manufacturer to conduct flight-load testing crucial to obtaining FAA and EASA certification. The system met the rigorous precision requirements, allowing the customer to detect and resolve any discrepancies between the motor’s tested performance and design specifications. This successful project not only met the immediate needs of the eVTOL manufacturer but also positioned ACS as a key player in the emerging eVTOL market and the broader electrification of transportation.
By completing this project, ACS gained a valuable reference in the rapidly growing eVTOL market, demonstrating their ability to deliver cutting-edge testing solutions. Their partnership with Siemens was critical to the project’s success, and ACS is now well-positioned to capitalize on future electrification trends that will help decarbonize the world. The success of this dynamometer for electric motor testing project also set a benchmark for future eVTOL propulsion system validation programs.
Key Features
- A 1,205 hp (900 kW) AC regenerative drive system for electric vertical takeoff and landing aircraft, using four 335 hp (250 kW) eVTOL motors to test speed, torque, endurance, and response.
- Recovers energy to power other motors or feed the grid, reducing the need for load banks and lowering costs and energy use.
- Utilized Siemens SINAMICS S120 drives, SIMOTICS M-1PH8 motors, and SIMATIC S7-1500 PLC for efficient control and easy SCADA integration, shortening development time.
ACS Services
- ACS designed, engineered, and built a custom four-axis dynamometer testing system to simulate flight loads for an eVTOL aircraft.
- Provided full support for installation and commissioning, coordinating with builders and contractors to meet all requirements before the system’s arrival.
- Applied ACS’ Ntandem program, which facilitated close collaboration with the customer’s engineering and operations teams, ensuring the project was completed on time, on budget, and met all technical requirements.
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