Spin Testing Improves Electrified Propulsion Rotor Design for Production and Certification



2023 AeroTech
Authors Abstract
There is a demonstrated need for effective design verification testing to support certification strategies for nascent electric motors and electric propulsion systems. Design efforts pursue efficiency pushing electrified propulsion rotors to be lighter and incorporate greater power density; however, there is no clear path established for supporting structural integrity and durability test requirements as required by global certification agencies.
Application of new materials, unique rotor design characteristics, and modified certification requirements drive unusual requirements for rotor modeling substantiated by component test data that addresses complex stress distribution characteristics.
Our paper addresses testing electrified propulsion rotors using spin test protocols adapted to support integrity and durability test goals. We further incorporate key concerns for planning and executing component spin tests of rotating structures necessary to support global engine certification efforts. Results from component tests are effective for mitigating risks associated with the preservation of certification test schedules and potential end product safety issues.
This paper presents data measurement techniques that are incorporated with specific spin tests to enhance the value of acquired data. Adapted test protocols include Overspeed and Low cycle fatigue (LCF) tests, which are more relevant types of spin tests for certification purposes.
Innovative measurement techniques for capturing the rotor growth behavior for both mappings the speed-dependent growth trends and the circumferential profile of deforming rotor under centrifugal load generate useful data to evaluate materials and structural behavior affecting performance up to failure.
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Endo, H., Hartnagel, M., Buschbeck, A., and Schonfeld, M., "Spin Testing Improves Electrified Propulsion Rotor Design for Production and Certification," SAE Technical Paper 2023-01-1021, 2023, https://doi.org/10.4271/2023-01-1021.
Additional Details
Mar 7, 2023
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Content Type
Technical Paper