Design of a Drive System for the GE Ice Testing Facility Wind Tunnel
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Date
2017-12-06
Authors
Osiowy, Blair
Friesen, Kalen
Karchut, Austen
Friehammer, Jan
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Abstract
West Canitest R&DInc., StandardAero, and General Electric Aviation are partners in the operation of the General Electric Testing, Research and Development Centre for aircraft gas turbine engine testing. At the test facility, the engine tests are conducted using a 1.2-million-pound wind tunnel. To allow for different types of tests and subject engines, the wind tunnel must be able to be moved a distance of 95 feet along 171-lb crane rail. Currently, the test facility uses forklifts to move the wind tunnel, which is unsafe for both the wind tunnel platform, the forklifts, and operators. Therefore, the test facility required a method to move the wind tunnel that is safer, more reliable, and designed for the sole purpose of moving the wind tunnel. The design team developed several concepts for a drive system that would move the wind tunnel at a required speed of 2 m/min, overcoming obstacles such as wind load and ice buildup on the rails. Concepts were developed for five initial systems: drive system orientation, drive system input, braking system, power transfer system, and control system. Ultimately, after using quantitative and qualitative selection criteria, the final design was selected for each system and combined with the other top selections to complete the final overall design. The overall design consists of two separate but identical drive systems. Each drive system attaches to one of the existing mounting plates and the existing wheel shaft. The input to the drive system contains a brushless, 3-phase, AC induction squirrel cage motor to provide the power needed for locomotion. The motor is capable of delivering30 horsepower, 144 Nm of torque, and has a built-in torque overload protection system. The motor requires a frequency inverter to control the speed. The braking system uses electromagnetic power-off brakes, so the brakes engage automatically if power is lost when the wind tunnel is in motion. These brakes are simple to maintain and operate, are reliable in extreme weather, and are able to completely immobilize the wind tunnel platform. Power is transferred from the motor to the wheel through a four-stage gearbox. The first stage of the gearbox...