MIL-STD Compatible • ISO 9001:2015 • Multi-Brand

Starter Generator
Universal Aerospace Test Rig

Programmable, multi-brand test platform for aircraft starter generators — from light helicopter DC brush units to 270V HVDC systems. Full electrical loading, precision measurement, and automated test reporting in one integrated rig.

Customize Your Machine Explore the Rig

15,000

RPM Drive Speed

2,000 A

Peak Starter Current

50+

Compatible S/G Models

Standardised Test Types

Full Section View

Mechanical Drive Interface

Testing Sequence

How the Test Rig Works

Every test follows this 5-stage sequence. Each stage is automated, logged, and cross-referenced against the selected S/G recipe.

Mount & Configure

The starter generator is secured on the adjustable fixture plate using the model-matched adapter. The operator selects the S/G recipe from the HMI — all limits, ramp rates, and load steps auto-load.

Quick-change adapter kit for 12+ S/G flange types
Flexible coupling installed (backlash-free, 15,000 RPM rated)
Electrical terminations connected per wiring diagram
System self-check: safety interlocks verified before start

Drive & Speed Control

The 4-quadrant regenerative servo drive accelerates the rotor along the programmed ramp profile to the target test speed. Closed-loop encoder feedback maintains speed within ±0.5% of setpoint throughout testing.

Speed range: 0 – 15,000 RPM (60,000 RPM optional)
Precision planetary gearbox, low-backlash
Overspeed cut-off at 14,500 RPM (programmable)
Regenerative drive recovers energy back to grid

Electrical Loading

The programmable DC load bank applies stepped current loads from 0 to 600 A. For AC generators, the 3-phase AC load bank is switched in. Starter simulation applies 2,000 A peak for 5-second cranking bursts.

DC: 0 – 600 A in programmable steps (37, 75, 112, 150, 200, 300, 400 A)
AC: 115 V, 400 Hz, 3-phase, ≥15 kVA
Field excitation: 0–30 VDC, 0–10 A precision
Peak starter power: ~50 kW for 5-second burst

Measure & Log

All instrumentation channels are sampled simultaneously at high frequency. Live plots of voltage, current, speed, temperature, vibration, and commutation waveforms are displayed on the SCADA HMI with real-time limit checking.

Voltage: 0–50 VDC, armature / field / terminal
Current: 0–2,200 A via Hall-effect or shunt sensors
Temperature: RTD / K-type, 18–200°C
Vibration: accelerometers, 1–10,000 Hz
Commutator run-out: TIR ≤0.0007", bar-to-bar ≤0.0002"

Report & Classify

On test completion, the system auto-generates a timestamped report with all measured parameters, pass/fail against limits, operator ID, and calibration traceability. Reports export as PDF, CSV, or Excel.

Auto pass/fail against recipe limits with alert buzzer
PDF / CSV / Excel export with calibration certificates
Operator ID, timestamp, unit serial number logged
Optional: IoT push to cloud dashboard

Inside the Rig

Four Integrated Subsystems

Each subsystem is engineered independently and integrated on a single vibration-isolated frame — ensuring signal integrity and operator safety.

⚙️

Drive Train System

A Siemens 1PH8 servo motor with S120 regenerative 4-quadrant drive provides the mechanical spin — from slow cranking simulation to 15,000 RPM generator testing.

Motor TypeServo Motor (Siemens 1PH8 or equiv.)
Drive Controller4-Quadrant Regenerative (S120)
Power Range6 kW – 37 kW (50 HP)
Speed Range0 – 15,000 RPM
GearboxPlanetary, Low-Backlash (1:2.4–1:5)
CouplingHigh-Speed Flexible, 15,000 RPM Rated
Torque ControlClosed-Loop Encoder Feedback
MountingVibration-Isolated Rigid Stand

⚡

Electrical Subsystem

A programmable DC load bank, AC load bank, precision field excitation supply, and 2,000 A starter simulation bus — all switched and sequenced by PLC with hardware interlocks.

DC Load Bank0–30 VDC, 0–600 A Programmable
AC Load Bank115V, 400 Hz, 3-Phase, ≥15 kVA
Starter Simulation28–30 VDC, 2,000 A Peak / 400 A Cont.
Field Excitation0–30 VDC, 0–10 A Precision Linear DC
Peak Starter Power~50 kW (5-second burst)
Load Steps0, 37, 75, 112, 150, 200, 300, 400 A
Input Power3-Phase, 415V ±10%, 50 Hz

📡

Instrumentation

National Instruments DAQ or equivalent simultaneously samples all channels — voltage, current, speed, temperature, vibration, and commutation — with full traceability to calibration standards.

Voltage0–50 VDC, Armature / Field / Terminal
Current0–2,200 A (Hall-Effect or Shunt)
SpeedOptical Encoder / Servo Feedback
TemperatureRTD / K-Type, 18–200°C
VibrationAccelerometers, 1–10,000 Hz
CommutationHigh-Speed Oscilloscope + Camera
Resistance0–35 Ω, ±0.1% Precision
Comm. Run-OutTIR ≤0.0007", Bar-to-Bar ≤0.0002"

🖥️

Control & Software

A PC-based SCADA with touchscreen HMI overlays live data on the digital twin of the S/G under test. Automated sequences handle start/stop, ramp control, limit checking, and reporting without operator intervention.

DAQ SystemNational Instruments / LabVIEW / PLC
HMITouchscreen + PC-Based SCADA
AutomationStart/Stop, Ramp, Limit Checks
Data LoggingLive Plot, CSV / PDF / Excel Export
ReportsAuto: Timestamp, Operator ID, Pass/Fail
CommunicationEtherCAT, Remote IoT Monitoring
E-StopMultiple Mushroom-Type Locations
Em. BrakingServo / Pneumatic Disc Brake

12 Standardised Tests

Full Test Capability Suite

Every test is pre-programmed as a recipe. Operators select the S/G model, press Start — the rig executes the full sequence autonomously.

Test 01

Maximum Speed Regulation

Operate at 13,000 RPM, 30V, no-load. Verify field current and voltage regulation remain within specified limits under no-load conditions.

Test 02

Continuous Operating Speed

12,000 RPM at rated load until thermal stabilisation — frame temperature rise verified ≤2°F in any 5-minute window.

Test 03

Compounding Test

Verify that field current rises proportionally with increasing load steps (0 → 100 → 200 → 300 A). Confirms correct compounding winding behaviour.

Test 04

Minimum Speed Regulation

Confirm rated voltage output is maintained at minimum operating RPM (6,800–8,700 RPM depending on S/G model and recipe).

Test 05

Residual Voltage Test

Verify residual voltage ≥0.8V at operating speed with no load applied — confirms adequate residual magnetism in field poles.

Test 06

Overspeed Test

Run unit at 14,000 RPM for 5 continuous minutes. Zero mechanical failure. Vibration, temperature, and noise continuously monitored throughout.

Test 07

Commutation Inspection

Visual and oscilloscope analysis of brush sparking quality at multiple speed/load combinations. Camera captures high-speed imagery at test RPM.

Test 08

Locked Rotor / Start Torque

Apply rated voltage with rotor locked. Measure and verify torque output ≤9 ft-lbs (or per model spec). Confirms starter engagement performance.

Test 09

Equalising Voltage Test

Measure paralleling / equalising voltage across terminals D–E. Verify ≤2.6V for satisfactory paralleling behaviour in multi-generator installations.

Test 10

Commutator Run-Out

Unit rotated on its own bearings. Dial gauge measures total indicator run-out (TIR ≤0.0007") and bar-to-bar variation (≤0.0002").

Test 11

Magnetic Pickup Waveform

Oscilloscope captures magnetic pickup output at 6,000 RPM. Verifies ≥2.5V peak-to-peak signal for reliable engine tachometer operation.

Test 12

Frame Temperature Rise

Verify frame temperature does not exceed 175°F (97°C) above air inlet temperature at rated continuous load — confirms adequate thermal margin.

Technical Specifications

Full System Specifications

Every parameter is configurable at order time. Custom ranges and additional channels available on request.

Drive Train System

Motor TypeServo Motor (Siemens 1PH8 or equiv.)

Drive Controller4-Quadrant Regenerative (Siemens S120)

Power Range6 kW – 50 HP (37 kW), auto-configured

Speed Range0–15,000 RPM (expandable to 60,000)

GearboxPrecision Planetary, Low Backlash (1:2.4 – 1:5)

CouplingFlexible High-Speed, Backlash-Free, 15,000 RPM

Torque ControlFully Programmable, Closed-Loop Encoder

Mounting BaseVibration-Isolated Rigid Stand, Adjustable Fixtures

Electrical Subsystem

DC Load Bank0–30 VDC, 0–600 A, Programmable / Stepped

AC Load Bank115V, 400 Hz, 3-Phase, ≥15 kVA

Starter Simulation28–30 VDC, 2,000 A Peak / 400 A Continuous

Field Excitation0–30 VDC, 0–10 A, Precision Linear DC

Peak Starter Power~50 kW for 5-second burst

Load Steps0, 37, 75, 112, 150, 200, 300, 400 A

Input Power3-Phase, 415V ±10%, 50 Hz (380V/60 Hz export)

Instrumentation

Voltage Measurement0–50 VDC, Armature / Field / Terminal

Current Measurement0–2,200 A (Hall-Effect or Shunt Sensors)

RPM MeasurementOptical Encoder / Servo Feedback

Frequency (AC)400 Hz ±0.1 Hz Accuracy

TemperatureRTD / K-Type Thermocouples (18–200°C)

Vibration AnalysisAccelerometers, 1–10,000 Hz Range

Resistance0–35 Ω, ±0.1% Precision

Commutator Run-OutTIR ≤0.0007", Bar-to-Bar ≤0.0002"

Software & Safety

DAQ SystemNational Instruments / LabVIEW / PLC-Based

HMI InterfaceTouchscreen + PC-Based SCADA Control

Test AutomationStart/Stop Sequencing, Ramp, Limit Checks

Data LoggingLive Plotting, CSV / PDF / Excel Export

Emergency StopMushroom-Type, Multiple Locations

Overcurrent ProtectionSoftware + Hardware Interlocks

Overspeed Cut-OffRPM Feedback-Driven Software Limit

Emergency BrakingServo-Driven / Pneumatic Disc Brake

Build Your Test Rig

Configure & Request a Quote

Select your S/G models, choose the rig power tier, add optional modules, and submit — our engineers respond within 48 hours.

S/G Models

Rig Tier

Add-Ons

Review & Quote

Select the Starter Generator Models You Need to Test

Pick one or more from the library below, or add a custom model not listed. The rig tier in Step 2 will auto-recommend based on your selection.

Choose Your Rig Power Tier

Based on your selected S/G models, the highlighted tier is recommended. All tiers run the same 12-test suite.

Add Optional Modules

Toggle on any capabilities you need. Each module plugs into the base rig infrastructure — no rewiring required.

Review Your Configuration & Request a Quote

Engineering Excellence

Built for Precision. Designed for Production.

Every design decision prioritises measurement accuracy, operator safety, and long-term reliability in demanding defence and MRO environments.

🔄

4-Quadrant Regenerative Drive

Recovers kinetic energy back to the grid during deceleration. Reduces energy cost by up to 35% vs. resistive-braking drives, while enabling precise regenerative torque simulation for loaded deceleration tests.

📋

Auto-Recipe Loading

Operator selects the S/G part number from the HMI library. All test limits, ramp rates, load step sequences, and report templates auto-configure — zero manual entry, zero transcription errors.

🔌

Multi-Brand Adapter System

A quick-change adapter kit covers all major S/G flange geometries — Skurka, Safran, AMETEK, Thales, Honeywell, and more. Changeover between models takes under 15 minutes.

🛡️

Layered Safety Architecture

Hardware e-stops, software overspeed limits, overcurrent interlock, over-temperature shutdown, vibration-triggered auto-stop, and full mechanical guarding on all rotating parts — all independently monitored.

📊

Traceable Calibration

All instrumentation channels are calibrated against NABL-accredited standards. Calibration certificates and expiry dates are embedded in each report — satisfying AQMS and DGAQA audit requirements.

☁️

IoT Remote Monitoring

Optional EtherCAT-linked IoT gateway streams live test data to a web dashboard. Quality managers can monitor tests remotely, approve results, and access historical reports from any device.

Modular Upgrades

Optional Add-Ons

Extend the base rig at any time. Each module plugs into the existing DAQ and control infrastructure.

⚖️

Torque Transducer

Real-time rotary & static torque output measurement

〰️

Harmonic Analyzer

THD & waveform quality for AC generators

🌡️

Thermal Chamber

Hot/cold environmental simulation during testing

📡

Remote Monitoring

Web-based HMI with live data & IoT access

🎯

Auto Calibration Kit

Automated sensor calibration vs. traceable standards

📷

Commutation Camera

Real-time visual commutator inspection at speed

🔧

Multi-Model Adapter Kit

Quick-change adapters for different S/G brands

⚖️

Dynamic Balancer

2-plane balancing, ISO G 1.0, 2–15 kg rotors

📶

Wireless Vibration Pack

Advanced in-test diagnostics without cabling

🛑

Emergency Braking

Electromagnetic / pneumatic disc brake for rapid DUT stop

Common Questions

Frequently Asked Questions

Can one rig test both DC brush and DC brushless starter generators?

Yes. The rig's electrical subsystem includes separate load banks and excitation circuits for DC brush, DC brushless, and AC configurations. The operator selects the S/G type from the HMI — the correct test circuit is automatically activated and irrelevant circuits are safely isolated by hardware interlocks.

How long does it take to change over between two different S/G models?

Mechanical adapter changeover takes 10–15 minutes using the quick-change adapter kit. Recipe selection on the HMI is instantaneous. Total changeover including electrical re-termination and self-check is typically under 30 minutes for an experienced technician.

What is the highest power S/G the rig can test?

The standard rig is configured to 37 kW (50 HP) mechanical drive and 50 kW peak electrical. This covers all DC brush and most DC brushless units. For high-power AC generators (Collins 150 kVA, GE T700 65 kW, Honeywell 60 kVA), a heavy-duty variant with 90–200 kW drive and matching AC load bank is available — please contact us for a custom scope.

Are test reports accepted by DGAQA and IAF quality auditors?

Yes. Reports include: unit serial number, operator ID, calibration certificate references with expiry dates, measured vs. limit comparison for all parameters, date/time stamp, and digital signature. The format has been accepted by DGAQA-registered facilities. We can customise the report template to match your quality system's specific requirements.

Can the rig simulate actual in-flight load profiles rather than static stepped loads?

Yes — with the standard programmable load bank, arbitrary load waveforms can be programmed as ramp sequences. For fully dynamic load simulation (e.g., replicating an in-flight transient load cycle), the optional torque transducer and closed-loop load control mode provide real-time following of a recorded aircraft load profile.

What is the delivery and installation timeline?

Standard rig: 16–22 weeks from confirmed purchase order. Site installation, commissioning, and operator training: 3–5 working days. Factory Acceptance Testing (FAT) at our facility is included. Site Acceptance Testing (SAT) with your team is conducted after installation.

Is post-installation support and calibration available?

Yes. We offer Annual Maintenance Contracts (AMC) covering preventive maintenance, calibration, software updates, and priority response. Remote diagnostics via the IoT gateway allow our engineers to assist without a site visit in most cases. On-site support is available across India and internationally.

Starter GeneratorUniversal Aerospace Test Rig

How the Test Rig Works

Mount & Configure

Drive & Speed Control

Electrical Loading

Measure & Log

Report & Classify

Four Integrated Subsystems

Drive Train System

Electrical Subsystem

Instrumentation

Control & Software

Full Test Capability Suite

Maximum Speed Regulation

Continuous Operating Speed

Compounding Test

Minimum Speed Regulation

Residual Voltage Test

Overspeed Test

Commutation Inspection

Locked Rotor / Start Torque

Equalising Voltage Test

Commutator Run-Out

Magnetic Pickup Waveform

Frame Temperature Rise

Full System Specifications

50+ Compatible Starter Generator Models

Configure & Request a Quote

Select the Starter Generator Models You Need to Test

Choose Your Rig Power Tier

Add Optional Modules

Review Your Configuration & Request a Quote

Your Details

Add a Custom S/G Model

Built for Precision. Designed for Production.

4-Quadrant Regenerative Drive

Auto-Recipe Loading

Multi-Brand Adapter System

Layered Safety Architecture

Traceable Calibration

IoT Remote Monitoring

Optional Add-Ons

Torque Transducer

Harmonic Analyzer

Thermal Chamber

Remote Monitoring

Auto Calibration Kit

Commutation Camera

Multi-Model Adapter Kit

Dynamic Balancer

Wireless Vibration Pack

Emergency Braking

Built to the Right Standards

Frequently Asked Questions

Enquiry Received!

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Starter Generator
Universal Aerospace Test Rig