Aviation Industry

Test rigs for electrical propulsion systems (EPS)

01Component and system level testing
02Realistic mechanical and electrical load simulation
03Grid fault tests

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Multi-motor propulsion systems have become an integral part of civil and military electric and hybrid aircraft. A network of electric motors not only enables take-off, but also ensures precise execution of all necessary flight maneuvers through individual and independent motor control. Operating such systems requires an integrated solution that includes inverters, batteries, power distribution, and a complex flight control system.

RENK EPS test rigs support the development and validation of the entire electric propulsion system with ground testing—a crucial step toward obtaining aircraft certification in a cost- and time-optimized manner.

01 Component and system level testing

Component or complete system

The primary focus when designing an EPU test rig is on testing the entire electric drive system at system level:

Power source (battery)
Electric motors
Power electronics/inverters
Thermal management system (cooling)
Cabling and power distribution
Sensors and subordinate control systems
Main flight control system

If individual components are not available for testing, they can be simulated by the test rig to ensure the system-level test.

However, individual components can also be tested separately for validation purposes.

02 Realistic mechanical and electrical load simulation

Dynamic load units

RENK test rigs for electric propulsion systems are also equipped with dynamic load units for the motors. This allows the entire system to operate within a HIL (Hardware-in-the-Loop) configuration capable of realistically simulating a wide variety of flight profiles.

Although it is possible to digitally emulate motor power to reduce the scope of the test rig, it is only real motors under full load that place a significant strain on the electrical system, thereby providing a comprehensive insight into the performance of the entire system.

03 Grid Fault tests

Controlled and reproducible grid fault tests

The RDDS test rig automation system not only allows critical fault conditions to be triggered, but also enables them to be precisely controlled and reproduced at any time. This is made possible by special fault injection boxes developed by RENK Magnet-Motors.

By simulating these extreme scenarios, safety mechanisms, control strategies, and redundancy concepts can be specifically developed and validated under realistic conditions.