The present invention relates to a test system developed for testing alternators and control units.

Alternators are devices that convert mechanical energy into alternating current. It is necessary to perform ground tests for alternators, especially used in the aviation industry, under controlled conditions before flight tests. A motor that provides mechanical input to the alternator is used to perform alternator tests. By using the electric motor for tests, mechanical input can be provided to the alternator at a desired revolution level. The electrical load required for the alternator to operate under load is provided by a load bank. Load banks apply electrical loads predetermined for the test to the alternator, allowing different conditions to be simulated during the test so that the alternators are tested. After the tests are carried out, alternator outputs are usually saved and analysed by a technician.

United States patent document no. US5949247, which is included in the known-state of the art, discloses a device which automatically tests generators according to predetermined test criteria and also automatically analyses test results according to predetermined analysis criteria. In addition, a load bank connected with the generator and applying an electrical load to the generator depending on the control signal, and an automatic test device transmitting a control signal to the load bank are disclosed.

With a test control system developed with the present invention, malfunctions and errors that may occur during alternator tests are detected. In this way, a malfunction or an error occurring in a sub-unit of the test system is prevented from damaging the entire system and the user.

Another object of the present invention is to prevent user-induced errors by automatically performing the alternator tests and to reduce the need for qualified personnel to perform the test. A further object of the present invention is to form the alternator characteristics in desired intervals by testing the alternator under desired conditions.

The test control system realized to achieve the object of the invention and defined in the first claim and the claims dependent thereon comprises at least one alternator that converts mechanical energy into electrical energy; at least one electric motor which provides mechanical energy input to the alternator at different revolutions during the test; a load bank which provides electrical load to the alternator at predetermined intervals by the user in order to perform alternator operation tests, thus simulating the loads that the alternator will be exposed in use; a main control computer which automatically controls the load applied by the load bank to the electric motor by transmitting commands to the load bank over a communication line; at least one sensor located in the load bank, alternator and/or electric motor and reading ambient data and/or operational data.

The test control system of the invention comprises a main control computer which performs health monitoring of the test control system by comparing the sensor data received with the values set by the user, and stops the electrical energy input to the system in case an error or a malfunction is detected by the health monitoring.

In an embodiment of the invention, the test control system comprises an auxiliary control unit which performs health monitoring by receiving current and/or temperature and/or humidity data from the alternator, the electric motor and/or the load bank via sensors.

In an embodiment of the invention, the test control system comprises at least one auxiliary control unit which reads the sensor data and performs health monitoring of the unit in which it is located, and transmits the sensor data to the main control computer.

In an embodiment of the invention, the test control system comprises an auxiliary control unit which transmits sensor data to the main control computer in case an error or a malfunction is detected as a result of the health monitoring, and stops the alternator test without waiting for the health monitoring output of the main control computer to be sent to the auxiliary control unit. In an embodiment of the invention, the test control system comprises a main control computer which stops the test when the auxiliary control unit fails to stop the test system in case an error or a malfunction is detected.

In an embodiment of the invention, the test control system comprises a main control computer which generates the operating characteristics of the alternator by saving the operational ambient data of the alternator and the alternator outputs.

In an embodiment of the invention, the test control system comprises a main control computer which compares the sensor data and the operating characteristics of the alternator, and performs health monitoring of the system according to the difference between the comparison data as a result of the comparison.

In an embodiment of the invention, the test control system comprises a resistive load bank.

In an embodiment of the invention, the test control system comprises a load bank which enables the alternator to be tested at intermediate values and at full load.

In an embodiment of the invention, the test control system comprises an alternator which is used to convert mechanical energy into alternating current in air vehicles.

In an embodiment of the invention, the test control system comprises a control computer which tests multiple alternators simultaneously.

In an embodiment of the invention, the test control system comprises a load bank to which additional loads can be added.

In an embodiment of the invention, the test control system comprises a main control computer which creates different test ambient conditions by adjusting the temperature and/or humidity of the ambient where the test is carried out.

The test control system realized to achieve the object of the present invention is illustrated in the attached drawings, in which: Figure 1 is a block diagram of a test system.

Figure 2 is a block diagram of a test system, an auxiliary control unit and a sensor.

All the parts illustrated in figures are individually assigned a reference numeral and the corresponding terms of these numbers are listed below:

1. Test control system

2. Alternator

3. Electric Motor

4. Load Bank

5. Main Control Computer

6. Sensor

7. Communication Line

8. Auxiliary Control Unit

The test control system (1) comprises at least one alternator (2) that converts mechanical energy input into alternating current; at least one electric motor (3) which provides mechanical energy input to the alternator (2); a load bank (4) which operates the alternator (2) under different conditions by applying variable electrical loads predetermined by the user to the alternator (2), thus allowing alternator (2) tests to be carried out; a main control computer (5) which allows automatic control of the electrical load applied by the load bank (4) to the alternator (2) by transmitting control signals to the load bank (4); at least one sensor (6) located on the load bank (4), alternator (2) and/or electric motor (3) and reading ambient data and/or operational data; at least one communication line (7) which allows the data received from the sensors (6) to be transmitted (Figure 1).

The test control system (1) of the invention comprises a main control computer (5) which performs health monitoring of the alternator (2), electric motor (3) and/or load bank (4) by comparing the data received from the sensors (6) via the communication line (7) with the limit values predetermined by the user, and stops the alternator (2) test in case an improper operation or a malfunction is detected by the health monitoring (Figure 2). At least one electric motor (3) is used, which allows control of the mechanical energy applied to the alternator (2). There is a main control computer (5) which provides control of the load bank (4) allowing revolution of the electric motor (3) to be adjusted and the energy generated in the alternator (2) to operate under load. The electrical loads applied to the alternator (2) are automatically controlled by the main control computer (5) so that the alternator (2) is operated at minimum and maximum loads. Thus, alternator (2) tests are carried out automatically. The inputs and outputs of the test control system (1) are read by the sensors (6) and saved by the main control computer (5).

The system comprises a main control computer (5) which performs health monitoring of the system by comparing the data such as current, voltage, frequency, temperature, humidity etc. received from the alternator (2), electric motor (3) and/or load bank (4) via the sensors (6) with limit values predetermined by the user for the alternator (2) test. Thus, in case of a malfunctioning in the system, the test is stopped immediately. In addition, alternator (2) tests are completely automated by means of the main control computer (5). Therefore, the necessity of performing the alternator (2) tests by expert technicians is eliminated.

In an embodiment of the invention, the test control system (1) comprises at least one auxiliary control unit (8) which is located in the alternator (2), electric motor (3) and/or load bank (4), performs health monitoring by reading the data from the sensor (6), and transmits the sensor (6) data to the main control computer (5) in case an error or a malfunction is detected. The sensor (6) data are read separately in the auxiliary control unit (8) and the main control computer (5) such that health monitoring of the alternator (2), electric motor (3) and/or load bank (4) are performed at the main control computer (5) and the control unit (8) separately. Thus, the accuracy of the health monitoring procedures is checked and the test is stopped quickly when necessary. Thus, the accuracy of the health monitoring process is checked and the test is stopped quickly when necessary.

In an embodiment of the invention, the test control system (1) comprises an auxiliary control unit (8) which transmits the sensor (6) data to the main control computer (5) in case an error or a malfunction is detected as a result of the health monitoring, and stops the test without waiting for the feedback of the main control computer (5). After the auxiliary control unit (8) transmits the sensor (6) data, it intervenes in the system without waiting for the operational results of the main control computer (5), thus preventing possible malfunctions and errors from damaging the system.

In an embodiment of the invention, the test control system (1) comprises a main control computer (5) which stops the test if the auxiliary control unit (8) does not stop the test. In the event of a software or hardware failure at the auxiliary control unit (8), the main control computer (5) is activated to stop the test.

In an embodiment of the invention, the test control system (1) comprises a main control computer (5) which outputs operational characteristics of the alternator (2) by the alternator (2) input and output information by saving the temperature, humidity input received through the sensors (6) or the revolution inputs applied by the electric motor (3) to the alternator (2) together with the alternating current outputs of the alternator (2). The alternator (2) characteristics are formed by determining the output current, voltage frequency and electrical load outputs of the alternator (2) against the revolution applied to the alternator (2). By performing the alternator (2) tests at varying ambient temperatures and humidity, the alternator (2) characteristics under different conditions are also identified.

In an embodiment of the invention, the test control system (1) comprises a main control computer (5) which performs health monitoring of the system by comparing the sensor (6) data with the operational characteristics of the alternator (2). The sensor (6) data received from the alternator (2) tested are compared with the alternator (2) characteristics so that a health monitoring is performed according to the difference between the data.

In an embodiment of the invention, the test control system (1) comprises a load bank (4) containing resistive load.

In an embodiment of the invention, the test control system (1) comprises a load bank (4) which enables the alternator (2) to be tested at intermediate values determined by the user and at full load. Thus, material life tests can be performed such that working loads, duration and maintenance intervals of the alternator (2) can be determined. In an embodiment of the invention, the test control system (1) comprises an alternator (2) used in air vehicles.

In an embodiment of the invention, the test control system (1) comprises a control computer (5) which tests multiple alternators (2) at the same time.

In an embodiment of the invention, the test control system (1) comprises a load bank (4) to which additional resistors can be added. By adding additional resistors, the electric load applied to the alternator (2) can be adjusted.

In an embodiment of the invention, the test control system (1) comprises a load bank (4) which enables the alternator (2) to be tested at intermediate values determined by the user and at full load. In an embodiment of the invention, the test control system (1) comprises a main control computer (5) which controls the test ambient conditions by adjusting temperature and/or humidity of the ambient where the test is performed. Thus, controlled tests are carried out by adjusting external factors affecting the test.