Overview of challenges in active power conversion for the More Electric Aircraft

Transcription

1 Electrical Technologies for the Aviation of the Future, Europe-Japan Symposium, March 26 th 2015, Tokyo Overview of challenges in active power conversion for the More Electric Aircraft Pascal THALIN VP Research & Technology/Technical Director THALES Avionics Electrical Systems

2 1 / Presentation Overview More Electrical Aircraft (MEA) context & challenges Active power conversion and motor control Thales portfolio for conventional & More Electric Aircraft Closing comments

3 MEA context & challenges

4 3 / Customer expectations Airframer / Airlines expectations - More efficient and cost-effective aircraft - Reduce the cost of operation and ownership - Cut fuel burn, increase availability, reliability & maintainability - Going green Reduced gas emissions & carbon footprint Reduced noise - Sustainable design & manufacturing Passenger expectations - Improvement in flight comfort - Non-stop IFE, connectivity, noise, services - Individual power source (laptop, mobile ) Fuel consumption savings = lower operating costs & air pollution Increased availability = passenger comfort & operating revenues

5 A/C Electrical Power (kw) 4 / Route to More Electrical Aircraft More Electrical Aircraft Market environment: Main expected benefits: Decrease fuel burn Decrease weight Through electrification of loads: Decrease power off-take Move from legacy hydraulic or pneumatic energy to electricity: ECS, Engine and APU start, braking, anti/de-icing Pneumatic Hydraulic Electric Current On-bord Power Power Optimized Aircraft Impact on aircraft requirements: Power on-board: + Voltage transformation and motion control: + Room for both, energy generation and usage optimization New innovative architectures More Electrical Aircraft Market track record: Airbus A First Variable Frequency Generator, Solid-State Power Control, DC power supply with no interruption Boeing 787 Dreamliner Intensive electrification: ECS, Engine and APU start, braking, anti/de-icing, Lithium-Ion Battery Innovative architecture, new technology, electrical network compatible with composite structure Airbus A350 XWB Electrical APU start, electrical network compatible with composite structure Dassault F5X Electrical Engine and APU start F16 A320 B747 A340 Year B787 A380 A350 A400M JSF Airbus Boeing Regional & Business Jets Fighters Military Transport

6 5 / MEA ELECTRICAL CHAIN BREAKDOWN Bleedless Engines & APU APU ATA49 Electric start Engine HV Power Generation Power Conversion Generation ATA24 Power Conversion ATA24 Power distribution ATA24/25 Electric start ATA 80 Wiring ATA 92 Load & Power Management Health Monitoring Power electronics Thermal, Drive Power Supply Drive Drive Drive Power supply Drive Air conditioning ATA21 Ice Protection ATA30 Flight Controls ATA27 Fuel ATA28 Hydraulic Power ATA29 Utilities ATA25 Landing Gear ATA32 Main Electrical Loads Concurrent breakthroughs in propulsion, systems & structures for MEA

7 6 / More Electrical Aircraft Electrification of systems is a major focus of aircraft architectures Variable Frequency AC network selected on the A380 Double Voltage Variable Frequency AC on A350 & B787 High Voltage DC network on B787 Electrification enables design, maintenance and manufacturing optimizations Overall system performance improvement Increased availability More flexible, reconfigurable Simplified maintenance operations Streamlined manufacturing and assembly Weight and reliability of electrical systems are major challenges

8 7 / MEA Technology stakes Power Generation : Low weight standalone High Speed / High Power AC Starter-Generators High reliability Power Converters for creating HVDC source from generators Embedded Starter/Generator technologies for the More Electric Engine & APU Distribution : High Voltage DC Power switching devices Improved load management for better electrical power availability Reliable Solid State Power Controllers for secondary distribution & specific loads Distributed power bays installed in uncontrolled environment Power Electronics : Highly reliable & efficient Power Converters for motor drives, power supplies High power density and high temperature operation Resource sharing allowing dynamic power management across multiple systems Modular, reconfigurable, fault-tolerant Motors AC & DC brushless fault-tolerant topologies High speed, High Power Reversible Cabling High voltage (partial discharge) capability Fault detection (arc tracking, Ground Fault, short/open ) Optimized weight through material change / system improvements

9 8 / THALES commitments to MEA Research & Technology Electrical Power Generation and Start System POA*: Electric main engine start, engine embedded technologies, HVDC architecture, high pressure shaft starter-generator, modular motor controller MEGEVE: Electric start and main generation GENOME/CLEANSKY: Hi-speed starter-generators for AC & HVDC networks High Speed Rotating Machines and related electronics ECS: Environmental Control System electrification Power Electronics and Power Conversion MODERNE, MOET: Electric start, Power conversion for all types of aircraft (weight reduction) PRISCA: Integrated Modular Power Electronics bay feasibility CLEANSKY: Major European program for mature environment-friendly MEA solutions for all market segments GENOME: Starter-Generators, power electronics and power conversion GETI: Combined optimization of MEA power and thermal systems Thales is a major aircraft manufacturer partner for designing cleaner, quieter and more efficient solutions with deep focus on MEA technologies Thales spearheads development of leapfrog MEA solutions

10 Active power conversion and motor control

11 10 / Challenges in active power conversion & motor control Performance, Weight savings, Maturity and Reliability Regulated 28VDC buses for aircraft cabling weight savings Robust, ruggedized, scalable and power dense Power Electronics Thermal management and cooling for power electronics, power bays Installation in unconventional areas (unpressurized and/or explosive atmosphere) Fault tolerance, Availability Reliability, Health monitoring, Maintainability

12 AC 28VDC bus 11 / Active Power Conversion : regulated 28VDC 28VDC feeder Node AC feeder BCRU charger 28VDC end users 28VDC system Small Energy storage Small Energy storage BATTERY Display Avionics BCRU(Battery Charger Rectifier Unit) includes multiple functionalities providing aircraft level optimization DC voltage regulation AC & DC feeder resizing allowing weight reduction AC and DC lightning protection 28VDC Battery Charger No Break Power and Battery management capabilities Substantial power density enhancement and aircraft cabling weight savings compared to conventional Transformer Rectifier Unit (TRU)

13 12 / Active Power Conversion upsides on Long Range aircraft Active power conversion on a Long Range aircraft helps : -doubling the power density of power conversion equipment -cutting aircraft weight by more than 100kg

14 13 / SAFT/THALES Cleansky project for BCRU DC Architecture Conversion Mutualized with Battery Equipment Optimized Li-Ion Battery RTRU System Objective : feasibility studies for optimized association of 28VDC active power conversion & energy storage architectures Analyze architectures combining no-break 28VDC power generation from AC power supply and battery charge function Battery Charger as part of a battery represents additional weight/volume and is subject to battery location and cooling constraints Analyze safety impacts of proposed architectures Consolidate the role of contactors or disconnection systems BCRU integrates battery charger for optimal 28VDC system performance

15 14 / Integrated Modular Power Electronics : Airframer perspective Rationale for Integrated Modular Power Electronics (IMPE) Bay Overall systems weight cannot be optimized if each system uses its own power electronics -Transient system operation results in dead weight penalty over aircraft life Integrated Modular Power Electronics Bay is the answer Power Electronic Modules address both active power conversion & motion control functions for multiple systems Engine start, air-conditioning, wing ant-ice, hydraulics Reconfiguration, redundancy : Improved functional «availability» & weight optimization IMPE Bay Power Electronics Module (PEM)

16 15 / Power Electronics Weight and Volume Stakes 2 kw/kg Baseline Weight New Tech Integration (Si/SiC igbt, packaging, ) Next Gen Modular Power Converters Multi-use Power Converters 9-15 kw/kg New Tech Target Weight Sensorless Control Unpressurized Areas Liquid Cooling Air Cooling Power Switches (SiC, GaN) Modular+Multi-use power converters = Integrated Modular Power Electronics

17 16 / THALES IMPE Road map THALES IMPE Bay concept THALES PEM for IMPE Bay (Gen1) Thales PEM for IMPE Bay (Gen2) 2-3kW/kg PEM 6kW/kg PEM(Gen 1) 9-15kW/kg PEM(Gen 2) THALES has demonstrated feasability of IMPE Bay concept THALES Gen 1 6kW/kg PEM with improved robustness : TRL5 reached in 2015

18 Thales portfolio for conventional and More Electric aircraft

19 18 / Our Thales product Products lines Electrical Power Generation AC Generators Generator Control Units DC brushless Generators Generator Control Units TopStart TM AC Generator, Generator Control Units, Start Box Unit DC Starter & Generator Electrical Power Conversion Passive conversion Auto Transformer Unit, Auto Transformer Rectifier Unit, Transformer Rectifier Unit Active conversion Regulated Transformer Rectifier Unit, BCU - Battery Charger Unit, SI - Static Inverter, DC/DC Converter Electrical Motors Actuators Motors & Controllers Air conditioning motors Pump motors Fans

20 19 / Thales on board the Boeing Power Conversion System (PCS) Forward E/E Bay Power Conversion Panels Cargo area GATU Galley Auto Transformer Unit AFT E/E Bay Lithium-Ion Main Battery ATU Auto Transformer Unit BCU Battery Charger Unit Lithium-Ion APU Battery SPU Start Power Unit ATRU x 4 Auto Transformer Rectifier Units BCU Battery Charger Unit MTRU x 2 Multitap Transformer Rectifier Units EBPSU x 2 E-Brake Power Supply Units World premiere advanced electrical power conversion

21 20 / Thales on board the Airbus A350 XWB Electrical Power Conversion System Main ATU x 4 Auto Transformer Units Advanced TRU x4 Transformer Rectifier Unit Emergency ATU x2 Auto-Transformer Unit SI Static Inverter CFFC Cockpit Fixed Frequency Converter Optimized architecture, mature power conversion technologies

22 21 / Thales on board the Falcon 5X Electrical Power Generation & Power Conversion System Static Inverter AC Starter Generator Generator Control Unit Start Box Unit (Motor Control Unit) TRU Transformer Rectifier Unit A world first with major technological breakthrough solutions

23 Closing comments

24 23 / MEA challenges Thales is committed to delivering power-optimized architectures through a combination of innovative solutions and mature technology Improved efficiency, reliability, and lower aircraft lifecycle costs Stakes For the aircraft manufacturers Reduce weight Optimize architecture allowing power management with greater flexibility, controllability and detectability Lower manufacturing costs For the operators and the airlines Lower operation costs Reduced fuel burn & environmental footprint (CO2, NOx, noise) Improved efficiency Higher reliability and maintainability Increased aircraft availability and safety levels Thales Expertise Field-proven expertise for every type of aircraft : air transport, business jets, regional aircraft, fighter, military aircraft, helicopter (both civil and military) Industrial means and qualified teams Active player in large scale R&T programs supporting MEA: CleanSky1/2, CORAC Genome, GETI Strategic partnership to develop an overall power optimized architecture The More Electrical Aircraft is a paradigm shift in aircraft performance and economics

25 24 / THALES Electrical Power System Partner Provide innovations and industrial structure for power solutions Mature solutions at Entry into Service Across the complete aircraft lifecycle THALES constant technology effort Integrated Modular Power electronics Rotating machines (High speed rotors,embedded machines in power plants) Active power conversion / Energy storage optimization with smart functionalities Electrical Power Generation and Start System Electrical Power Conversion / Energy Storage and Power Electronics Electrical System Engineering and Architecture

26 25 / The More Electric Aircraft is at hand but needs steadfast & relentless global research!!! 夢の力 «The Power of Dreams» Tokugawa Ieyasu ( 徳川家康 ) 鳴かぬなら鳴くまで待とうホトトギス "If the cuckoo bird won't sing, let's wait until it does."