Details

The Drive and Control Automation System is a high-precision, fully automated test rig designed specifically for evaluating the Main Gear Box (MGB) of an Advanced Light Helicopter (ALH). The system plays a crucial role in ensuring that the MGB meets aerospace operational requirements, undergoing rigorous mechanical, hydraulic, and electrical performance testing. This test rig replicates real-world flight conditions, applying dynamic loads such as torque, thrust, and hydraulic pump loads while monitoring key parameters such as temperature, vibration, torque, speed, and electrical efficiency. The automation and control system ensures real-time data acquisition, remote operation, and precision load application, making it indispensable for aerospace and defense research and development (R&D) centers, helicopter transmission manufacturers, and aviation testing facilities.

2. System Architecture and Working Principle
The Drive and Control Automation System consists of multiple subsystems working in a synchronized manner to test the MGB under realistic load conditions.
The key working principle of the system involves:
 • Driving the MGB through a 250KW AC motor, which achieves rated speed through a lower adapter gearbox.
 • Applying controlled loads, including:
 • Thrust Loads – Simulating aerodynamic forces acting on the gearbox.
 • Torque Loads – Mimicking the rotational force experienced during operation.
 • Hydraulic Pump Loads – Simulating hydraulic-driven loads for accurate stress testing.
 • Utilizing a hydraulic power pack to regulate pressure levels and control actuators.
 • Monitoring system parameters via the Data Acquisition System (DAS).
 • Simulating electrical loads using an AC alternator with a resistive load bank.
 • Ensuring fail-safe operation with an emergency stop system and real-time safety monitoring.
This closed-loop system allows for automated, repeatable, and highly accurate gearbox performance testing.

3. Detailed Component Description
3.1 Drive System
The drive system consists of a 250KW AC motor that powers the MGB through an adapter gearbox, ensuring it reaches the required test speed.

Key Features:
 • 250KW 3-Phase TEFC (Totally Enclosed Fan Cooled) Squirrel Cage AC Induction Motor, compliant with IS/IEC standards.
 • Variable Frequency Drive (VFD) Controlled Operation, allowing precise speed adjustments for controlled testing conditions.
 • Direct Coupling with Lower Adapter Gearbox, ensuring optimal torque transmission.
 • High Torque Output with Smooth Acceleration & Deceleration, minimizing system shocks.
 • Blower Motor (1-Phase/3-Phase) for effective cooling of the drive motor.
 • Thermal Overload Protection Sensors integrated to prevent overheating.
The drive system ensures that the MGB operates at an accurate and controlled speed, which is critical for performance assessment and endurance testing.

3.2 Load Application System
The Load Application System is responsible for applying realistic mechanical forces on the MGB, simulating operational conditions experienced during flight.

Key Features:
 • Hydraulic Power Packs with motor-driven hydraulic pumps, providing adjustable pressure levels.
 • Electro-Hydraulic Proportional Valves, ensuring precise load regulation.
 • Hydraulic Actuators, applying different load types, including:
  o Thrust Load Simulation: Axial forces applied through hydraulic actuators to mimic aerodynamic loads on the rotor blades.
  o Torque Load Simulation: High-precision hydraulic torque loading system to evaluate rotational stress.
  o Hydraulic Pump Load Simulation: Motor-driven hydraulic circuits simulating real-time pump loads.

The load system is fully automated, with feedback sensors ensuring accurate force application and real-time adjustments.

3.3 Data Acquisition and Control System (DAS)
The Data Acquisition System (DAS) continuously monitors, records, and analyzes the gearbox’s performance parameters. It allows for real-time control and remote operation, ensuring a fully automated and data-driven testing process.

Key Features:
 • Temperature Monitoring System:
  - Integrated thermal sensors continuously track gearbox and motor temperatures.
  - Automated overheat protection alerts.
 • Vibration Monitoring System:
  - Integrated Electronic Piezoelectric (IEPE) sensors analyze vibration levels.
  - Prevents gearbox misalignment, wear detection, and premature failure.
 • Speed and Torque Measurement:
  - High-resolution encoders and tachometers ensure accurate speed tracking.
  - Torque transducers provide real-time torque transmission readings.
 • Digital and Analog Input Monitoring:
  - 24V DC Digital Input Modules for real-time process control.
  - Analog Input Modules (Voltage & Current) for electrical performance analysis.
 • Data Logging & Remote Access:
  - Historical test data storage for compliance verification.
  - Remote system monitoring and parameter adjustments.

The DAS is a critical component, enabling high-precision testing, automation, and system control.

3.4 Electrical and Safety System
To ensure safe and reliable operation, the system includes multiple electrical protection mechanisms.

Key Features:
 • Variable Frequency Drive (VFD): Regulates motor speed and torque dynamically.
 • 4-Pole 600A MCCB (Molded Case Circuit Breaker): Provides 100 kA breaking capacity to prevent electrical faults.
 • Motor Protection Circuit Breaker (MPCB): Ensures thermal and overload protection.
 • AC Line Reactors: Minimize voltage fluctuations and electrical noise.
 • Phase Indicator System: Provides real-time phase monitoring to prevent power imbalances.
 • Emergency Stop Push Button: Ensures instant shutdown in case of system failure.
These safety and control systems ensure that the Drive and Control Automation System functions within safe operational limits.

3.5 Load Bank System
To evaluate the electrical performance of the MGB, the system features a Load Bank Module.

Key Features:
 • AC Alternator Mounted on MGB Output Shaft, simulating real electrical load conditions.
 • Resistive Load Bank with Contactor Panel, providing adjustable electrical load testing.
 • Real-Time Power Monitoring, ensuring accurate load response evaluation.
This subsystem ensures the electrical efficiency and durability of the gearbox under realistic operational loads.

4. Technical Specifications
 • Main Drive Motor: 250KW, 3-Phase TEFC AC Induction Motor.
 • Variable Frequency Drive (VFD): Siemens/ABB/Parker, dynamic speed regulation.
 • Blower Motor: Single-phase/three-phase cooling motor.
 • Hydraulic Load System:
  - Electro-hydraulic actuators
  - Motorized hydraulic power packs
 • Electrical Safety System:
  - 4-Pole 600A MCCB, 100 kA breaking capacity.
  - Motor Protection Circuit Breaker (MPCB).
  - AC Line Reactors for voltage stabilization.
 • Data Acquisition System (DAS):
  - Temperature monitoring
  - Digital Input (24V DC) modules
  - Digital Output with SPDT relay board
  - Vibration monitoring (IEPE)
  - Speed & Torque measurement
 • Emergency Safety System: Instant emergency stop push button.

5. Applications
The Drive and Control Automation System is used in:
 • Helicopter Gearbox Testing and Certification
 • Aerospace Research & Development
 • Military and Commercial Aviation Facilities
 • OEM Helicopter Transmission Testing
 • Aerospace Test Laboratories
This highly advanced system ensures accurate, repeatable, and controlled testing for MGB durability and performance validation.

6. Conclusion
The Drive and Control Automation System is a cutting-edge testing platform that integrates automation, hydraulic load application, and real-time monitoring to ensure helicopter gearbox reliability.
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