Project context and objectives

Transcription

1 1 Publishable summary Prject cntext and bjectives The All-Electric Aircraft is a majr target fr the next generatin f aircrafts and helicpters t lwer cnsumptin f nn-prpulsive pwer and thus fuel burn. The aim f ACTUATION2015 is t develp and validate standardised, mdular and pled EMA fr the first time fr all airframe systems (flight cntrl, high lift, main landing gear, nse wheel steering, dr lcks, thrust reversers) and all types f airframes (business, reginal and large aircraft and helicpters). The ACTUATION2015 detailed bjectives are t: - Reduce the verall Life Cycle Cst (LCC) (develpment, acquisitin, certificatin, maintenance, peratin) by: Prviding standardised families f EMA mdules usable in different types f applicatins and, when feasible, sharable between different applicatins Designing and prducing EMAs frm ff-the-shelf standardised mdules using standardised design and validatin methds and tls Addressing all types f aircraft systems and aircraft applicatins frm helicpters t large aircraft Standardising and reducing number f qualificatin and re-qualificatin tests - Reduce weight and imprve the reliability by Intrducing new materials, (e.g. SiC fr electrnics, magnetised cmpsites fr mtrs, etc.) Intrducing new architectures (e.g. Hybrid Pwer Device HPD used in a significant manner and applied n pwer drive reducing the number f cmpnents) Enabling the full electric architecture at aircraft level Resurces sharing and ptimising actuatin architectures (e.g. pwer generatin shared between transient actuatrs) - Increase safety margins by Develping health mnitring techniques t predict failures Implementing fault tlerant systems and architecture t guaranteeing safety, thus reducing cmplex, bulky, expensive and heavy slutins such as jam free actuatrs, - Mature the technlgy (passing frm TRL3 t TRL5 in the prject) fr industrial applicatin decisin in 2016/17 and deplyment fr the next generatin f shrt/medium range single aisle aircraft by 2020 As a result, ACTUATION2015 will cntribute t Eurpean leadership in electric actuatin standardisatin. Page 1

2 Figure 1: Overall ACTUATION2015 structure 1.1. SP1: Specificatins fr mdular EMA The first step f SP1 was addressing with airframers the standard template definitin t capture the electrical Actuatrs sizing requirements fr the cmplete system s family PFCS, HLS, LGS, TR/CD. The template has been iterated and cmpleted all alng the actuatin sizing perid with partners during the secnd year f the prject. The final template with the assciate requirements definitin is nw frzen. The secnd step was t define with partners a standard template t capture the Cmpnents requirements fr the targeted mdules: Pwer Drive Electrnics (Pwer Cre Mdule, Cntrl and Mnitring Mdule), Mtrs, Mechanics (Screw, Reducer, Gearbx, Sensrs). The template has been as well iterated and cmpleted all alng the cmpnents sizing perid with partners. The final template with the assciate requirements definitin fr cmpnents is nw frzen. Actuatin requirements are captured by Airframers fr the full aircraft range and cmpiled n the standard template. The actuatrs requirements have been revised and ptimized fllwing actuatr design phase with partners. Electrical actuatr sizing sensitivity t airframer requirements has been identified with each supplier. This has allwed airframer requirements ptimisatin / adaptatin fr keeping the EMA design as simple as pssible. The develpment f imprved EMA mdelling tls and design rules develped by partners has supprted this iterative prcess fr requirements and design ptimisatin (Actuatr and System). The requirements are nw frzen. Actuatrs mdular tplgies traded and dwn-selected t prvide the apprpriate slutin at aircraft level have been detailed and cnfirmed during the secnd year. All the actuatr tplgies are frzen. Pwer Drive Electrnics standardizatin is a majr enabler fr the full electrical aircraft cmpetitiveness in terms f Cst and Reliability. This is the mst cmplex equipment f the electrical actuatin. The PDE mdular architecture has been studied in detail and ptimized with partners all alng the secnd year. The fllwing mdularity and standardized interfaces is nw frzen: Standard Pwer Drive Electrnics mdular architecture (PDE) Standard Pwer Cre Mdule (PCM) Standard Cntrl & Mnitring Mdule (CMM) Page 2

3 Standard Internal Standardized Supply Interface (ISSI) Standard Sensrs interfaces Standard Slenid cmmand Standard Prtcl fr Inverter Cntrl Over LVDS Standard Basic Sftware (Operatin System) t supprt Airframer & Supplier sftware applicatins Mtr mdule with standardized interfaces has been detailed and ptimized with partners all alng the secnd year. The mechanical and electrical interfaces f the standard mtrs are detailed in the assciated mdule specificatin. Mechanical mdules studies have addressed bth the Linear and Rtary actuatrs. Standardized parameters have been cnslidated alng the secnd year. A typical leverage targeted fr the screw standardizatin is t cver a large range f applicatins with the same screw diameter, lead, nut and rllers. The mechanical part f electrical actuatin is the mst adherent t each applicatin and the standardizatin is mre limited as cmpared with Electrnics and Mtr. Gearbx standard sensrs and standard interface with the mtr have been defined and frzen in the specificatins. Actuatr standard sensrs have been traded and cnslidated with partners all alng the secnd year. The sensrs type and characteristics fr Mtr, Mechanics, Pwer Drive Electrnics and Applicatin are nw frzen. The Actuatr pre-sizing phase has required apprpriate mdelling tls and design rules t be created. The EMA technlgy is new and there was n cmplete prcess and tls available ff the shelf when starting the prject. This was a majr challenge regarding SP1 bjectives and schedule. These mdels and tls have been cmpleted and/r built by partners fr the EMA sizing. Design iteratins have been perfrmed alng the secnd year t reach the required level f cnfidence n cmpnents sizing. The Mdule families have been defined as a pririty fr the middle range applicatins (shrt range and reginal aircraft) t specify accurately the mdules where hardware is develped within the prject. Pwer cre ranges, cntrl and mnitring avinics capacities, mtr characteristics, screw, gearbx fr middle range applicatins have been defined. The end parts f the A/C families (e.g. Large aircraft, Business) will be clsed as sn as the detailed design phase is clsed fr the demnstratrs. Mdules specificatins cnslidatins and mdules preliminary design have been perfrmed during this secnd year based n every ther week iteratin with SP2 partners fr bth requirements and design validatin. The number f bi-lateral reviews increases in cmbinatrial fashin due t same reviews t be perfrmed with each supplier fr each prduct at cmpnent and actuatr level. The fllwing mdules Specificatins are nw frzen with the assciated mdules preliminary design (iterative prcess): Mdules specificatins SP1 Mdules preliminary designs SP1 PCM [Pwer Cre Mdule] Safran, GAS CMM [Cntrl & Mnitring Mdule] Safran, GAS Flight cntrl PDE [Pwer Drive Electrnics] Safran, GAS Braking PDE [Pwer Drive Electrnics] MBD OS [Operating System] Safran, GAS Mtr [Ailern, Spiler] GAS, SAGEM Screw [Ailern, Rudder, Elevatr] GAS / Rllvis & SKF Gearbx [Spiler] Liebherr, SAGEM Mdular actuatrs specificatins refinement and validatin fr actuatr demnstratrs have been perfrmed thrugh actuatr preliminary design pre-validatin reviews during this secnd year. Prcess based n every ther week iteratin with SP1/SP5 partners. The fllwing actuatrs Specificatins are nw frzen with the assciated actuatrs preliminary design (iterative prcess): Actuatr specificatins SP1 (demnstratrs) Actuatr preliminary designs SP1 Ailern linear actuatr GAS-F Spiler rtary actuatr SAGEM High lift epcu GAS-UK Page 3

4 Braking MBD Rtr linear actuatr SENER SP1 secnd year results and status can be summarized as fllws: Cmplete prcess cnvergence. Majr prgress n EMA key areas by airframers and partners. Amunt f studies and results beynd the DW. Numerus players Airframers and Partners. SP1 crdinatin wrklad cmpletely underestimated. Cmpetitin but all partners in cnstructive psitin. Cmplex challenging prcess turned in 24 mnths under pressure withut time lss. The utcme is dense, innvative and prmising fr the electrical aircraft. Players fully invlved fr PDR phase. Activity in line with the prpsed revised schedule The next steps will be t clse all the PDR, t finalise the Operating System standardisatin, t fllw the mdules and actuatrs detailed design, t perfrm the CDR, t finalise the definitin f mdules families fr Large aircraft and business, t fllw the Lubricatin standardizatin wrkshps, t perfrm actuatrs virtual integratin within aircraft, t supprt the mdules standardizatin prcess with WP7 in cnsistency with the mdules specificatins SP2: Technlgy mdules SP2 will develp the required technlgy t meet the cst, reliability and weight prject key targets. SP2 addresses technlgy wrks related t hardware EMA (electr-mechanical actuatr) mdules including: mechanics, mtr architecture, cmpsite materials, mechatrnics, new sensrs, pwer electrnics, while applying the standardisatin prcess. Furthermre, SP2 will design and manufacture three types f mdules (mtr, pwer electrnics, and mechanics) t be used fr integratin in SP5 (Mdules Integratin) and testing in SP6 (Validatin). The inter linkages f SP2 with ther SPs and its WPs are presented in Figure 2 belw: Page 4

5 Figure 2: SP2 diagram 1.3. SP3: Methd and tls A key step in the preliminary design prcess f electrmechanical actuatrs is the develpment f suitable design methds and tls that allw fr early design phase ptimizatin in terms f safety, perfrmance, weight and maintenance csts amng thers. In the scpe f SP3 the mst relevant preliminary design issues are addressed with fcus n the harmnizatin and ptimizatin f existing methds and tls with standardised interfaces. The partners are cntributing t enhance the capabilities f Eurpe s aerspace research field and industry with imprved methds, standard cmpnent libraries, standards fr interface-mdelling, categries fr evaluatin f critical cmpnents as well as an effective chain f tls fr qualificatin. The preliminary design apprach being cnsidered in ACTUATION2015 and thus SP3 incrprates dedicated tls fr mdelling systems f multiple physical dmains with fcus n electrmechanical actuatrs. Mdelling activities include mechanical, electrical and cntrl schemes, as well as thermal aspects. Of equal imprtance is the cnceptin f apprpriate tls t perfrm detailed safety and reliability analyses. This cnstitutes a fundamental part in the mdel-based tl chain f the preliminary design prcess. The safety and reliability tls are t cver the develpment f new cncepts fr degradatin analyses thrugh the cmpilatin f knwledge abut the behaviur f EMAs. System identificatin techniques that take int accunt the variability f inputs, parameters and cnfidence levels shall help t characterize the lack f reliability infrmatin r inexact bservatins. T cmplement this apprach, a reliability uncertainty methd is being develped which shuld deliver cnfidence levels fr calculated system and subsystem failure rates. T clse the lp f the preliminary design prcess, a virtual integratin platfrm at system and aircraft level is being develped by the partners f SP3. When finished, it shuld allw evaluating cmpnent mdels with respect t dynamic requirements, lcal recnfiguratin and interfaces t the pwer distributin system. Additinally it will prvide an envirnment t analyse system t system interactins. As a result the ntin f cnducting virtual qualificatin tests shuld be at reach. Thereupn, much wrk is being dedicated t pave the way fr virtual qualificatin and certificatin thrugh the definitin f a mdular prcess as an alternative t subsystem qualificatin in rder t ease the integratin f virtual testing int the prcess. Page 5

6 1.4. SP4: Cntrl and Mnitring SP4 is made up f three separate wrk packages: WP41 Prgnstics and Health and Usage Mnitring WP42 Advanced Cntrl and Mnitring and WP43 Regenerated Pwer Management. WPs 41 and 42 were bth kicked ff at the beginning f Year 1 but the start f WP43 was delayed t the start f Year 2. The wrk in WP41 has prgressed steadily thrughut Year 2 albeit prgress has been smewhat slwer than hped fr. During the year three physical meetings and a number f WebEx meetings have been held t review prgress and t plan the future activities. A number f reprts were written and apprved during this perid. Sme f these were deliverables and these addressed: the sftware sizing estimate fr the PHM functins, standardised methds fr EMA Usage Mnitring and standardised methds fr EMA Anmaly Detectin. A number f ther reprts were als generated during the year; these reprts were internal t the WP and captured the results f wrk carried ut by individual partners. WP42 is cncerned with lking at advanced cntrl and mnitring techniques that can be applied t the ACTUATION2015 EMAs. The cmpanies that participate in this WP are a sub-set f thse wh participate in WP41 fr this reasn the WP42 meetings have been held jintly with the WP41 meetings t minimise the travel and rganisatinal effrt required. The partners within WP42 have lked at a variety f different cntrl and mnitring ideas, techniques and slutins that can be used t enhance the perfrmance, imprve the reliability and/r aid failure identificatin. The candidate slutins that have been identified have been evaluated using a mdel f a linear ailern EMA actuatr that was develped by GAS-F and/r mdels develped by the individual partners. WP43 is cncerned with the management f pwer that can be regenerated by an EMA as part f its nrmal peratin. EMAs have fur quadrants f peratin and will cnsume pwer when perated in tw f these quadrants and will generate pwer when perated in the ther tw. The pwer that is generated by an EMA can be managed lcal t each EMA r it can be placed nt the EMAs pwer supply. Managing regenerated pwer lcal t each EMA has the disadvantage f adding functinality and thereby vlume and cst. Fr ACTUATION 2105 a decisin was made at the start f the prgramme t allw the EMAs t place any regenerated back n the supply buses; this is easy d because the EMAs are pwered frm a DC (±270V) bus. Allwing the re-generated energy t be placed nt the pwer supply is nt in itself a slutin. The regenerated energy will cause the bus vltage t rise, pssibly utside f allwable limits. Hence a means f managing the vltage levels n these buses is still needed SP5: Mdules integratin Based n SP1 requirements, SP5 will make actuatr level integratin f the different standard mdules develped in SP2, using Methds & Tls prvided by SP3, and Health Mnitring Algrithms develped in SP4. Ultimately SP5 will feed back results f analysis t SP6 fr verall assessment. SP5 will address the handling f the integratin f: Single mdule reference fr different actuatr applicatins (identify cmmn requirements t be used fr mdule design t get effective multi-actuatr integratin). Duble surce mdules n the same actuatr. A glbal crdinatin has been rganized, via peridic prgress meeting, t ensure the cherence f the wrk being perfrmed by the different partners within SP5 and make sure that the mdule specificatin is elabrated in accrdance t actuatr needs. WP52 & WP53 have nt prgressed as scheduled mainly because the prgress f the design f the demnstratrs is dependent upn the final architecture trade-ffs frm SP1 (WP16). The mdule design and specificatin in SP2 require the family f mdules t be defined as an utput f WP16 (task delayed). Nevertheless, the pre-sizing wrk perfrmed in WP16 f SP1 has develped tls and prduced results that anticipate the wrk f SP5. Fr all the EMA hardware prttypes (Ailern actuatrs, MLG retract actuatr, Helicpter Secndary Flight Cntrl actuatr & High Lift actuatr) and virtual integratin WP16 results are: Actuatr architecture clsed t be finalised, Page 6

7 CAD design and mechanical analysis has started. Fr all the applicatins, ne f the main technical difficulties encuntered in WP16 is actuatr space envelpe. A/C integratin cnstraints are strng & available spaces dedicated t actuatrs are very small SP6: Validatin SP6 will standardise test means and prcedures, validating mdular applicatin perfrmances by running standardised tests using the mdules develped in SP2 (Technlgy mdules). Besides, SP6 will assess sme f the prject end results (cst, reliability, weight, level f mdularity) and prepare certificatin. SP6 is divided int fur WPs: WP61 Mdular test bench WP62 Mdules evaluatin WP63 Mdularity technlgy WP64 Qualificatin and certifiability assessment The inter-linkages f the SP6 with ther SPs and its WPs is presented in Figure 3 belw: Figure 3: SP6 diagram Page 7

8 1.7. Expected final results and their ptential impact and use Building n POA and MOET results, ACTUATION2015 will deliver: Standards and mdular EMA prducts, tls and methds ready t use with the utput f CLEAN SKY SGO, making available the technlgy needed t develp the All-Electric Aircraft New mature actuatin technlgies (TRL 5 mdules): Imprved sensr technlgies New cntrl and pwer management techniques Standardised and enhanced Health and Usage Mnitring Mechatrnics slutins applicable t aircraft envirnmental cnditins Cmmn standards and Shp Replaceable Units (SRU) r Line Replaceable Units (LRU): Mtrs, sensrs, Pwer Drive Electrnics (PDE), pwer drive systems Cmmunality and scalability in qualificatin prcess, prviding credit fr certificatin: Qualificatin methds Data base n cmpnents technlgies and prcesses Three types f standard mdules PDE, Mtrs and Mechanics used t build several actuatr systems will be jintly specified and then develped t validate: The cncept f mdular standard cmpnent applicable t several actuatr systems (primary and secndary flight cntrl, high lift, landing gear, thrust reverser and carg drs), scalable fr applicatin t different types f systems and aircraft (frm helicpters t business and reginal aircraft up t large cmmercial aircraft) Lw cst and mature actuatin technlgy fr several actuatr systems starting with landing gear (the mst cstly system) and flight cntrl the cre f the systems aircraft architecture The verall weight, peratinal reliability, installatin and maintenance benefit at a glbal level f electrical actuatin slutin This will result in the creatin f standardised mdules hardware families, interfaces and sftware envirnment enabling the develpment and prductin f mdular EMA technlgies. Prject lg Figure 4: Prject lg Page 8

9 Prject public website: Figure 5: Website hme page Page 9