Industrial Applications of Spin-Testing and Balancing

Precision testing of high-speed, high-performance motors and rotors is of paramount importance in today’s aerospace, automotive, and defense industries. 

Spin testing is performed to validate the design, durability, balance, and structural integrity of the motor. The material and structural behavior of the rotor, which ties to the efficiency of a machine, is of major import across the many varied applications of electric motor technology, ranging from UAVs and UAMs to hybrid and electric vehicles. Industries that depend on high-speed rotating machinery rely heavily on test results to accurately predict how their technology will perform in real-world situations. 

Applications of Spin-Testing

Proof and overspeed testing are standard for manufacturers of rotating equipment and turbomachinery. Simply put, overspeed testing validates the rotor integrity against the speed of the rotor to a rate far greater than what the component will encounter  in its operation. For example, FAA certification of aircraft turbines disk mandates overspeed testing before the engines can be used in aircraft. 

There are myriad tests that may be relevant based on the specific type of rotor application. For example, rotors fabricated from a new materials or constitute a radically new designs are subjected to more rigorous testing to certify for relevant regulatory standards and operational safety requirements, as well as gather as much data as possible about the effectiveness of the new technology. In this case, Test Devices could help conducting advanced spin testing to design and implement the test, and measure the critical data to evaluate the performance of the part. 

At Test Devices, we possess a broad variety of spin testing capabilities suitable for various testing scenario, including:

• Proof spin and overspeed testing for compliance
• Rotor strength and material evaluation via burst test (with high-speed imaging)
• Rotor durability and fatigue evaluation via LCF testing
• Heated and thermal gradient test to capture the accurate material conditions
• Rotor growth and profile mapping – Capture the material behavior under CF load

Balancing

Proper balancing is an essential step to ensure the reliable operation of any type of rotor. Even a small unbalance can result in problems ranging from unexpected rotor wear to catastrophic equipment failure. 

Unbalance is inherent in any real-life rotors. Even the minute variation within the manufacturing tolerances, and uneven distribution of material properties about the axis of rotation could cause the bias in the distribution of the CF load in a rotor that results in undesirable vibration. 

In some cases, involving high-speed rotors, more complex scenario must be considered. Unexpected deformation of rotor due to the emergence of plasticity or shift in the internal structure of a rotor (e.g. winding settling in the motor armature) could result in an unintended unbalance. In such a scenario, the combination of both spin testing and balancing plays a critical role in identifying and resolving potential problems in the rotor.

As such, proper balancing is a critical step to the successful function of rotating components. An unbalanced condition can be very hazardous and may result in severe damage to machinery, threaten the safety of equipment operators, and drive up costs due to redesigns.

Spin testing and balancing plays a critical role in ensuring the safe and reliable operation of the final component, ensuring its integrity and reliability – optimizing the performance and extending the machine’s useful life. 

Advanced Spin Testing Services from Test Devices

Test Devices has more than 40 years of experience in advanced spin testing practices. Our state-of-the-art equipment and highly trained staff of engineers and technicians offer innovative solutions to the challenges facing designers and manufacturers of rotating components.

We can help you optimize your designs and accelerate your development and production process by providing you with all the relevant test data that you need.

Contact Us today for more information about our spin testing services or to discuss your design with one of our experts.