Building the test bed for electric flight

Building the test bed for electric flight

As the Advanced Air Mobility (AAM) market takes flight, our engineers who are designing and developing new electric aircraft technologies face a host of unknown challenges.

Whilst much can be learnt from the electrification of the automotive industry, the risks associated to this technology in aerospace applications must be fully understood. Safety is our top priority and the use of novel systems in aerospace propulsion systems and the speed of their failure effects, need to be evaluated to ensure implementation of safe designs.

Within Rolls-Royce Electrical, we’ve developed extensive testing capabilities to fully investigate and understand all our power and propulsion systems for AAM, enabling us to embed and ensure safety along every stage of the journey from conception to take-off.

Helping Urban Air Mobility take off safely

For decades, aerospace engineers have been designing, developing and testing complex technical and mechanical aircraft systems to withstand the most extreme conditions. To enable a more sustainable future for flight, we must ensure that electrical propulsion systems can meet these requirements while working to understand any uncertainties.

As part of our global network of test capabilities, our facilities in Bavaria, Germany allow us to develop electric propulsion technologies for Urban Air Mobility (UAM) and Regional Air Mobility (RAM), to learn more about their behaviours to enable us to mature our technologies and advance our product development.

Over the last few years, electric machines have undergone thorough test programmes in Munich, including the 200 kW motor that powered the CityAirbus Alpha eVTOL demonstrator. The test benches have been upgraded to test our new generation of air-cooled electric motors for AAM. A new test hall expanding our electrical machine test capability will be commissioned in 2024. The test capability covers all power ranges required for AAM up to 800 kW.

Our smaller test bench for electric machines can perform specific tests on specially adapted motors on a smaller scale and with lower output. These tests provide valuable learnings for future designs in higher power classes and enable us to adapt technologies based on our test results, integrating even greater safety and noise reduction into our first prototypes.

Our engineers can also test the responsiveness and robustness of power electronics for AAM by simulating a variety of environmental loads in our state-of-the-art laboratory. These tests push our converters to the limits of their planned operational range, enabling us to ensure the highest possible levels of safety in further development and deliver an advanced product through verification and validation.

Developing the power to take us further

At our test facilities in Trondheim, Norway and Dahlewitz, Germany, our Electrical teams are also working to deliver a step change in hybrid-electric flight.

Modifications have been made to our Power Gearbox facility in Dahlewitz to enable the testing of a newly developed small gas turbine with sustainable aviation fuel (SAF). This engine will power our turbogenerator technology and enable it to recharge batteries or provide energy to electrical propulsion units directly during flight, allowing aircraft to switch between power sources. This increased efficiency provides the potential to significantly extend the routes that electric flight can support, giving passengers a faster and more sustainable way to travel.

In Trondheim, our teams delivered the back-to-back generator test programme of the most powerful hybrid-electric power and propulsion system for electric flight, before the combined generator, engine and related power electronics were executed on the 2.5 MW Power Generation System 1 (PGS1) demonstrator test at Bristol Test Bed 108. This test program helping to unlock the capabilities for larger hybrid-electric aircraft in the future. The Trondheim team are currently provisioning their test facilities to support testing of a new generator for the Turbogenerator programme. The test facility with advance test benches is capable of testing electrical machines with power ranges up to 3.5 MW.

Learning through collaboration

But the challenge of testing and developing sustainable technologies for our skies can’t be done alone. By working with our established network of research and university technology centres, we can accelerate innovative research that will help us lead the AAM market.

We’re working in collaboration with the Brandenburg Technical University (BTU) and other partners to support testing of electrical propulsion systems for the UAM market. The Centre for Hybrid Electric Systems Cottbus (CHESCO) at the BTU Cottbus-Senftenberg will help to launch the Lusatia region as a research hub for low-emissions technologies and provide test capabilities for supporting developments of hybrid electric power systems for aerospace applications. An RRE multi (8-off)axis electric propulsion system test rig will be fully commissioned in 2024 and located at an interim CHESCO facility to support the development of our AAM programmes.

In Hungary, our Electrical teams work with state-of-the-art digital simulation and test software to bring our developments from concept to prototype at pace. For over a decade, they’ve also been working alongside the Budapest University of Technology at Economics FIEK Modular Hybrid Electric Drivetrain Lab, deriving the actual data to power digital twins, optimise products and achieve the safety requirements of the aviation industry.

Our electrical team in Singapore, have leading edge lab facilities for developing power electronics capabilities and Energy storage system capabilities. The teams work with the Nanyang Technological University to drive advancement of technologies to enable development of electrical machines and electrical propulsion systems.

Ready for take-off – with increased peace of mind

Our global test capabilities help us to not only optimise the design of a fail-safe portfolio for AAM but also ensure that our electrical power and propulsion technologies undergo rigorous testing prior to ground and flight tests. Alongside this, the data we gather can help us build a digital twin to enhance development and improve product performance throughout the entire lifecycle. All of this enables us to reduce operational risk and facilitate timely certification for our customers, as we make completely new ways to fly a reality together.

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