Rotor Dynamics Test Facility

About

The Rotor Dynamics Test Facility (RDTF) is a cutting-edge system designed for evaluating the performance and behavior of Rotor-Bearing-Support systems under various configurations such as simply supported, overhung, and twin-rotor setups. It enables detailed analysis of critical speeds, vibrations, unbalance, misalignment, and damping, with advanced features like high-speed drive systems, precision lubrication, axial loading mechanisms, and real-time data acquisition through PLC-SCADA integration. Supporting rotors up to 90 kg and speeds up to 52,000 rpm, the facility provides robust safety measures, including protective enclosures and automated fault detection.
No Image

Image Gallery

Technical Details

  • Test Bench supporting structure
  • Two drive Systems
  • Two step up Gear Boxes with lubrication system
  • Two low speed couplings and two high speed couplings
  • Four instrumented pedestals
  • Oil system to supply/scavenging oil to/ from Test rotor Bearings
  • Measurement, control and safety system
  • Control console
  • Axial and Lateral loading system
  • Safety enclosure

To test the behaviour of Aircraft Rotor System by varrying the different test parameter like Speed variation (0 to 55000 RPM), Unbalance response to excessive unbalance, The response due to misalignment, Experimental validation of damping etc.

Key Features

  • To Test the different type of Aircraft Rotor
  • To Test the behaviour of Rotor due to Axial Loading System
  • To Test the behaviour of Rotor due to Lateral Misalignment System
  • To Test the behaviour of Rotor due to change in pressure and flow of bearing lubrications system
  • Critical speed validation of Rotor System at different operating speed

Download Gallery

×

Enquire Now

and we will get back to you.

Details


The Rotor Dynamics Test Facility (RDTF) is an advanced engineering system meticulously designed to evaluate the functional and operational characteristics of Rotor-Bearing-Support systems. Developed for AERDC, HAL Bangalore, this facility enables in-depth testing of rotor dynamics—an essential branch of mechanical engineering focused on understanding and analyzing the behavior of rotating machinery. Rotors are critical components in applications such as aircraft engines, turbines, compressors, and generators, where their performance significantly impacts efficiency, safety, and reliability.

Rotor Dynamics encompasses the study of vibrations, critical speeds, unbalance, stability, and misalignment in rotating systems. By testing these factors under controlled conditions, the RDTF provides invaluable insights into the performance, durability, and dynamic stability of rotors and their supporting systems.

This facility includes comprehensive features such as drive systems, measurement and control systems, lubrication units, and axial loading systems. It supports multiple rotor configurations, enabling users to simulate and analyze real-world operating conditions.

Key Features and Capabilities

1. Versatile Test Configurations
The facility supports a wide range of testing setups, accommodating varying rotor geometries, sizes, and operating conditions:
- Shaft Diameters: Supports rotors with diameters ranging from 15 mm to 70 mm.
- Rotor Mass: Capable of testing rotor weights up to 90 kg with polar inertia of up to 1 kgm².
- Disc Sizes: Accommodates rotors with disc diameters of up to 750 mm.
- Support Types: Adapts to both rigid and flexible support systems, with options for damping mechanisms such as squeeze film dampers and elastomeric dampers.
- Configurations: Includes simply supported, overhung (single and double sides), and twin-rotor systems with inter-shaft bearings.

2. Comprehensive Testing Infrastructure
- Test Bench Base Structure: 
  The mechanical structure is optimized to minimize vibrations and external excitations, ensuring stable operation. 
  Designed for efficient use of space, the bench incorporates advanced instrumentation for vibration monitoring.
- Drive System: 
  The facility features two variable-speed AC drive systems rated at 60 kW and 200 kW, offering:
- Speed Control: Encoder feedback for precise speed regulation within 0.1% of nominal speed.
- Dynamic Braking: Regenerative braking for enhanced safety and energy efficiency.
- High Acceleration: Maximum acceleration rate of 100 rpm/s to replicate real-world conditions.
- Step-Up Gearboxes: 
  Two step-up gearboxes increase the rotor speed to 41,000 rpm and 52,000 rpm, with 5% over-speed margins, ensuring compatibility with high-performance applications.
- Couplings: 
  The facility includes low-speed and high-speed couplings designed for seamless power transmission while minimizing misalignment and vibration.

3. Integrated Measurement and Control Systems
The facility employs advanced instrumentation for real-time monitoring and analysis:
 - Sensors and Signal Conditioning: Includes accelerometers, proximity probes, RTD temperature sensors, and high-speed tachometers for comprehensive data acquisition.
 - Vibration Analysis: Equipped with optional FFT analyzers, offering capabilities such as:
 - Frequency and order spectrum analysis.
 - Waterfall plots, Bode plots, polar plots, and orbits.
 - Shaft centerline tracking and transient capture.
 - PLC-SCADA Integration: Allows for automated and manual control of test operations, with safety interlocks, alarms, and data logging. 
   Operators can configure tests through a user-friendly interface.

4. High-Performance Oil and Axial Loading Systems
- Lubrication System: 
- Delivers up to 20 liters per minute at 15 bar pressure.
- Compatible with aerospace-grade oils such as MIL-E-23699/7808.
- Features water-cooled heat exchangers for maintaining oil temperatures within a range of 15°C to 150°C.
- Axial Loading System: 
- Applies thrust loads of up to 20 kN using a double-acting hydraulic actuator.
- Ensures precise load application through integrated load cells and remote control via the SCADA interface.

5. Safety and Ergonomics
- Protective Enclosure: 
- Industrial-grade laminated safety glass provides robust protection against debris while ensuring operator visibility.
- Designed to contain high-energy failures, ensuring personnel safety during high-speed tests.
- Control Console: 
- Includes dual operator PCs for data acquisition and test configuration.
- Emergency stop mechanisms and fault detection systems for enhanced safety.

Applications
The Rotor Dynamics Test Facility supports various critical testing scenarios, including:
1. Critical Speed Validation: Identifying resonance points to optimize rotor design.
2. Unbalance Response Testing: Analyzing the rotor's reaction to both residual and excessive unbalance as per ISO 1940 G2.5 standards.
3. Misalignment Testing: Simulating angular and offset misalignments to understand their impact on performance.
4. High-Speed Balancing: Ensures rotors can operate at speeds up to 42,000 rpm without introducing vibration-related failures.
5. Damping Analysis: Evaluates the effectiveness of dampers under dynamic conditions.

Technical Specifications

Maximum Speed :       Up to 52,000 rpm 
Rotor Diameter :      15 mm to 70 mm 
Rotor Mass :          Up to 90 kg  
Power :               200 kW (maximum) 
Oil Flow :            20 L/min at 15 bar pressure
Temperature Range :    15°C to 150°C  
Safety Standards :      EN 1063:1999 for enclosures 

Delivery and Support

- Design and Documentation: Comprehensive design reports, operating manuals, and schematics.
- Training: Operator training on system usage, safety protocols, and data analysis.
- Warranty and Maintenance: A standard 12-month warranty with options for extended support for up to 3 years.
- Commissioning: Full installation and testing of the facility at the HAL premises, ensuring operational readiness.

Conclusion

The Rotor Dynamics Test Facility sets a new benchmark in the field of rotor dynamics analysis. Its advanced capabilities, versatile configurations, and robust safety measures make it an indispensable asset for industries and research institutions involved in the design and development of high-performance rotating machinery.
🔧 English Keywords Rotor Dynamics Test Facility Rotor Vibration Test Bench High-Speed Rotor Testing System Rotor Critical Speed Test Rig Dynamic Balancing Test Facility Shaft Vibration Analysis Bench Rotating Machinery Test Stand Rotor Whirl and Stability Test Setup Turbo Rotor Dynamics Lab Rotor Imbalance and Resonance Testing Unit 🇸🇦 Arabic (العربية) منشأة اختبار ديناميكا الدوّار جهاز اختبار اهتزازات الدوّار منصة اختبار السرعة الحرجة للمحور نظام تحليل ديناميكي للدوارات وحدة توازن ديناميكي دوّار مرفق اختبار عدم التوازن والاهتزاز للدوارات 🇩🇪 German (Deutsch) Prüfanlage für Rotordynamik Rotor-Vibrationsprüfstand Hochgeschwindigkeits-Rotor-Testsystem Teststand für kritische Drehzahlen von Rotoren Dynamisches Wuchtprüfsystem Analyseplattform für rotierende Maschinen 🇫🇷 French (Français) Banc d’essai pour la dynamique des rotors Installation de test des vibrations de rotor Système de test à grande vitesse pour arbres tournants Banc de test de la vitesse critique du rotor Plateforme d’analyse dynamique des rotors 🇪🇸 Spanish (Español) Instalación de prueba de dinámica de rotores Banco de prueba de vibraciones de rotor Sistema de ensayo de velocidad crítica del rotor Plataforma de análisis dinámico de maquinaria rotativa Banco de equilibrio dinámico de ejes 🇨🇳 Chinese (Simplified 中文) 转子动力学测试设施 转子振动测试平台 高速转子试验台 临界转速测试装置 转子不平衡与共振分析系统 动态平衡测试平台 🇯🇵 Japanese (日本語) ローターダイナミクス試験施設 回転体の振動試験ベンチ 高速ローター試験システム 臨界速度テスト装置 回転機械のダイナミックバランス解析装置 🇷🇺 Russian (Русский) Испытательная установка для ротодинамики Стенд для анализа вибраций ротора Испытания на критическую скорость вращения Балансировочный стенд для вращающихся машин Система оценки устойчивости роторов 🇮🇳 Hindi (हिन्दी) रोटर डायनामिक्स परीक्षण सुविधा रोटर वाइब्रेशन टेस्ट बेंच उच्च गति रोटर परीक्षण प्रणाली क्रिटिकल स्पीड और डायनामिक बैलेंस जांच इकाई घूर्णन मशीनों के लिए कंपन विश्लेषण मंच
🔧 English Keywords Starter Generator Test Rig Starter-Generator Testing System Aerospace Starter Generator Test Bench Integrated Starter Generator (ISG) Test Rig Motor Generator Test Stand DC Starter Test Bench Alternator Starter Test Platform Dynamic Load Test Rig for Starter-Generator Electrical Drive Starter Generator Test System Starter Generator Endurance Testing Machine 🇸🇦 Arabic (العربية) منصة اختبار المولد البادئ جهاز اختبار بادئ التشغيل والمولد مرفق اختبار بادئ-مولد للطائرات جهاز اختبار نظام تشغيل كهربائي متكامل منصة اختبار مولد بدء الحركة 🇩🇪 German (Deutsch) Prüfstand für Starter-Generator Testsystem für Starter-Generatoren Prüfstand für integrierten Starter-Generator (ISG) Testeinrichtung für Anlasser und Generator Dynamischer Prüfstand für Startergenerator 🇫🇷 French (Français) Banc d’essai de démarreur-générateur Système de test pour générateurs de démarrage Banc d’essai ISG (démarreur-générateur intégré) Plateforme de test de générateurs de démarrage pour aéronautique 🇪🇸 Spanish (Español) Banco de prueba de arrancador-generador Plataforma de ensayo de generadores de arranque Sistema de prueba ISG (arrancador-generador integrado) Banco de carga dinámica para motores de arranque 🇨🇳 Chinese (Simplified 中文) 启动发电机测试台 起动发电一体机测试系统 一体式起动电机测试平台 航空起动发电系统测试装置 电动起动发电装置试验台 🇯🇵 Japanese (日本語) スタータージェネレータ試験装置 モータージェネレータ試験ベンチ 航空用スターター発電機テストリグ 統合スターター発電機 (ISG) 試験装置 🇷🇺 Russian (Русский) Испытательный стенд для стартер-генераторов Система тестирования стартер-генератора Стенд испытаний интегрированного стартер-генератора (ISG) Электродвигатель-генератор испытательная установка 🇮🇳 Hindi (हिन्दी) स्टार्टर जेनरेटर परीक्षण बेंच स्टार्टर-जेनरेटर टेस्ट रिग मोटर-जनरेटर टेस्टिंग मशीन इलेक्ट्रिक स्टार्टिंग और चार्जिंग सिस्टम टेस्ट प्लेटफ़ॉर्म एयरोस्पेस स्टार्टर जनरेटर टेस्ट यूनिट

Trending Products

Share This Page