Simulation and Modelling Advances in the Field of Aero engines

Transcription

1 Simulation and Modelling Advances in the Field of Aero engines MATLAB EXPO 2013 Kevin Daffey Global Head of Electrical Power and Control Systems Trusted to deliver excellence

2 An Introduction to Rolls-Royce

3 Group profile

4 Business model and strategy

5 A consistent approach to business

6 2012 financial highlights

7 Civil aerospace

8 Engine Facts and Figures 8

9 How a Gas Turbine Works 9

10 How a Gas Turbine Works 10

11 How a Gas Turbine Works 11

12 12 Intermediate Pressure Turbine How a Gas Turbine Works

13 Testing and Trials 13

14 Fan Blade Off Certification Test 14

15 Simulation in Design 15 Rolls-Royce uses a wide variety of analysis techniques for design verification from whole engine to component Computational fluid dynamics is used to understand the aerodynamics of engines in order to maximise performance. Cost modelling is used to identify cost drivers and maximise value Finite element analysis is used for structural, vibration, lifing and thermo-mechanical analysis, both linear and non-linear at whole engine, component and subsystem level. Combined CFD and Structural analysis is used to study forced vibration on turbomachinery Multi-disciplinary Whole Engine Design Systems predict the behaviour of the integrated product Materials designed for required properties

16 Mechanical Simulation 16

17 Computational Fluid Dynamics 17

18 Materials and Manufacturing Simulation 18 Complex Metal Crystal Casting Predictable distortion & Machine System / Tooling Predictable Forming (Minimised Material Use) Filling and Solidification (Defect free castings)

19 Product Cost Engineering 19

20 Whole Engine Thermomechanical Modelling 20

21 Examples of MATLAB Usage in RR 21 System design teams use MATLAB SIMULINK to develop models, simulations and prototypes of control systems; System verification teams use MATLAB to analyse large volumes of test data; MATLAB SIMULINK is used for the development and running of state-space, or real-time, engine models (RTEM); MATLAB SIMULINK is used to create thermodynamic engine models (ARTEMIS); Post processing and visualisation of data generated from SCO3 thermal codes; MatLab Image Processor for thermal paint analysis data; Analysis of Engine Health Monitoring Data; Birdstike slice Calculations; Air flow transients in Bearings; Auto-code from SIMULINK for Development Engine Control Systems. Extracted from RR Intranet Site on MATLAB Tool Technical Limitations: None. It is infinitely capable, limited only by the users imaginations and the amount of memory in the computer! It s a bit slow though. I prefer Fortran & ES37.

22 MATLAB uses in Electrical and Controls Dynamic modelling of complex system Validation & verification Multi-system optimisation Design of complex systems Model-to-Code on development hardware platforms Electrical Systems System design, power system analysis, transient studies. Real World Components G FADEC 1 G Engine 1 PMS FADEC 2 Engine 2 Delegated autonomy 22 VMS Simulation Environment G G 270VDC Primary Distribution System Electrical Power & Load System

23 MATLAB uses in Electrical and Controls 23 Control laws design Performance optimisation Software packages integration MSL, SPAN/Simulink Multi-platform application Data processing and conditioning 2 TB30 T_hot<> T_hot<> 0.03 W30_offtake_for_cooling 4 T130 T130<> ThotIn+TcoldIn 3 W30 PCE_MF_Hot<> Product -u neg 2 DT_out DeltaThot 1 W130 <> Product1 W130 PCE_Eff 1 Hot_to_Cold_Eff DeltaCold et 1 5 exhaust_out valve_area Product2 TColdOut max area (of w130)

24 Photograph by Orsolya and Erlend Haarberg National Geographic 24

25 NASA image by Robert Simmon, using ALI data from the EO-1 team 25

26 Photo by Craig Murphy 26

27 Encountering An Ash Cloud Some centrifuging by fan Handling bleeds remove some ash Ash cloud 2012 Rolls-Royce plc

28 VA Gas Turbine Engine Damage Mechanisms Electronic control systems affected Molten ash sticks in turbine annulus, choking engine Lubrication system contamination Ash cloud Turbine cooling systems block, reducing component life Compressor erosion loss of efficiency and surge margin. Sulphidation of Ni alloys in turbine Ca sulphates can accrete in hot section months after eruption (sulphur aerosols) Ash starts to melt in and around combustor (clogging in combustor leading to flame extinction) 2012 Rolls-Royce plc

29 Engine Damage Mechanism HP NGVs HP turbine blades 2012 Rolls- Royce plc Combustor

30 Ash Hazard - Factors 30 DC-10 at Cubi Point Naval Air Station, Philippines Eyjafjallajokull Photo: Brynjar Gauti,

31 Monitoring Solution VAAC global coverage 2012 Rolls- Royce plc 31

32 Monitoring Solution VAAC Data 32 VOLCANO: EYJAFJALLAJOKULL PSN: N6338 W01937 VOLCANIC ASH CONCENTRATION: RED MODEL RUN: /0600 VALIDITY TIME: /0600 FLIGHT LEVEL: SFC/FL200 REMARKS: MODEL DATA Poly 1 N N Poly 2 Poly n E " " E " " " " " " " " " "

33 Volcanic Ash Advisory from London 33

34 Monitoring Solution Data-flow 34 Met Office data via Internet (automatically downloaded - daily) Ash cloud Coordinates of Grey, Black and Red Zones Summary flight Data via EHM SQL Database. Standard Engine data including aircraft ID, datetime, city pairs, corresponding airport location and coordinates Local Database Matlab Tool SQL Query On engine exposure 2012 Rolls-Royce plc

35 Future of Air Travel could be Electric 35

36 And finally, Voice of the Customer 36 Although MATLAB is used throughout Rolls-Royce it has to continue to earn its place.. Cost of ownership is not just licenses, but includes the time to develop new routines, deb-bug, execute, interpreting, configuration management, training and updating people. MATLAB is there to save engineering costs, if it doesn t save us money in product development we will change; People - Graduates who use MATLAB products during their studies, come into Rolls-Royce with varying levels of proficiency. It would be nice to have a future state where all students are taught a basic level of proficiency that can be built upon when in employment. Business Critical Decisions (technical and commercial) are often supported by modelling scenarios. The providence of the model must meet the level of criticality of the decision. With known levels of accuracy and limitations of the model. Integration with other modelling tools and Model Based Systems Engineering toolsets incorporating SysML is critical to helping Rolls-Royce remain competitive. We will continue to push for integration, MATLAB is not a universal tool for us, but part of a total suite of modelling and simulation tools..

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