HTS Machines for Applications in All-Electric Aircraft
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1 University Research Engineering Technology Institute on Aeropropulsion & Power Technology Power Engineering Society General Meeting 2007 HTS Machines for Applications in All-Electric Aircraft Philippe Masson Cesar Luongo FAMU/FSU College of Engineering Center for Advanced Power Systems Tallahassee, FL
2 Outline Motivation UAPT Project More/All-Electric Aircraft Applications and design examples System Approach Examples of electrical system sizing Conclusion
3 Motivation: Environment Preservation Need to develop environmentally friendly transportation systems (emissions and noise) Electrical energy is very attractive Need to design high power density electrical components Objective : Revolutionize Aviation Increase Safety Reduce Emissions Reduce Noise Increase Capacity Increase Mobility
4 URETI on Aeropropulsion and Power Technology All-Electric Aircraft Aircraft Design & Optimization Power Generation Power Management & Electric Propulsion /Actuation AeroSpace Design Laboratory GATech Revolutionary Concepts, Architectures & Technology GATech Research Institute Solid Oxide Fuel Cells Florida A&M University / Center for Advance Power Systems Integrated Power Management Aircraft Design & Modeling Development of high power density fuel cells High Power Density Superconducting Motors Electrical Network simulation Superconducting motor design FC Voltage (V) FC Current (A)
5 UAPT HTS Machine Development HTS Motor Design -General Aviation - HALE ROA - Small Jet HTS Motor Sizing Model POWER RPM MATERIAL OPTIMIZATION CONSTRAINTS GLOBAL OPTIMIZATION ELECTROMAGNETIC MODEL THERMAL MODEL best states weight k MINIMUM WEIGHT OR VOLUME All-Electric Aircraft Propulsion System Studies
6 Towards Electric Aircraft Propulsion Allows the inter-connected issues of noise, emissions and energy to be addressed simultaneously Gossamer Penguin Pathfinder More Mars Flyer Sunrise II Pathfinder Plus Solar Challenger Electric Aircraft Centurion Airship HALSOL Helios E-Plane Power Optimized Aircraft GT Fuel Cell Demonstrator and beyond Future Challenges: power density of electric motors and aircraft design with new technology
7 Modern All-Electric Aircraft Subsystems Thrust Generation Fuel System Electric Drive Accessories Environmental Control System Engine Accessories Fault Tolerant Electrical Power Distribution System Electrical Power Generation Electric Anti-Ice Electric Actuation Electric Actuated Brakes
8 Electrical gear box concept Turbo-generator motor drive Electrical gear box concept Turbine main shaft speed not limited by fan (better efficiency) Redundancy should improve reliability Better control of thrust generation More flexibility in the turbine location Need high power density electric machines: HTS technology is an obvious choice
9 What Fuel / / Energy Storage? Liquid hydrogen exhibit the highest energy density Hydrogen can feed fuel cells or gas turbines Storage temperature is ideal for HTS material Gasoline (maximum) 6.4 Methanol (maximum) Liquid Hydrogen (maximum) Lead Acid Battery Lithium Polymer Battery 2.65 Jet Fuel in a Solid Oxide Fuel Cell Cryogenic machines represent the best solution and a good synergy
10 LH2 Powered Aircraft Liquid Hydrogen (LH2) powered aircraft Hydrogen cryogenically stored Power generated by fuel cells or turbo-generators Ducted fan or propeller Generator 1 Gas Turbine 1 Propulsion motor PMAD Propulsion System Power Management And Distribution Flow of LH2 Controller Generator 2 Gas Turbine 2 Power Generation H2 Tank Energy Storage Electrical gear box concept
11 Electrical Ducted Fan / Thrust Generation Latest engines have very high bypass ratios Most of the thrust comes from fan rotation Replacing gas turbine by electrical motor should be possible Bypass Fan Section of Aircraft Engine Superconducting Drive Motor Superconducting Motor Replaces Turbine High bypass turbofan Electrical Ducted Fan
12 Cryogenic and HTS Motors 100 Weight (klb) 10 1 Turbofan w/o Prop. Reciprocating engine Industrial motors SR motors non-cryo SR motor in LN2 expected Axial-gap PM motor Cryo generator tested Cryo sync motor design Helios Motors 1 hp/lb 10 hp/lb Shaft Power and Equivalent Shaft Power (khp) Cryogenic copper wound motors could work HTS machines would provide better efficiency and lower weight and volume Specific power (hp/lb) Improved heat transfer copper coils for cryogenic machines Conventional machine Cryogenic machine Superconducting machine Gas turbine Model predictions Power (shp)
13 UAPT Designs for Electric Ducted Fan Application Small Jet RPM Flux trapping and concentration Bi2223 coils and YBCO TFM Small Jet Aircraft Iron shield Insulation layer Superconducting coil Stator support Stator coils Bulk HTS plates Rotor support (Displayed as wireframe) B (T) HALE Hurricane tracker 14 day mission RPM Axial flux configuration Trapped flux magnets (YBCO) Shaft Cryostat (Displayed as wireframe)
14 Power Generation: Fuel cells or Turbo-generator? Fuel cells No emissions (NOx and CO2) Power density around 1 kw/kg (SOFC) Low efficiency balance of plant Efficiency ~ 55% Too heavy for large aircraft Fuel nin Hydrocarbon Fuels Depleted fuel e O H 2 2 H + H H + 2 H 2 O H 2 Anion 2 O conductor 2 H 2 O O 2 Electrolyte (Ionic conductor) Anode Cathode Oxidant in Depleted oxidant Turbo-generators Reduces emissions (high RPM) High power density Low efficiency (~30%) Specific power (hp/lb) Conventional turbogenerator Cryo-turbogenerator Superconducting turbogenerator Power (hp) Hybrid systems may be a solution (heat recuperation)
15 Superconducting turbo generators Requires: development of high RPM HTS machines Robust thermal insulation between gas turbine (1000C) and HTS generator (-250C) Stationary HTS excitation coils are preferred to allow for high RPM (> 10 krpm) such as HIA or Supersat configurations Example of axial flux supersat configuration
16 Example of Actuators: HTS/PM linear Motor Application: Nose Landing Gear Conventional copper windings Rare earth permanent magnet Model Weight = 1000 Length = 1m kg YBCO coated conductors Operating temperature 77K (LN2) Rare earth permanent magnet excitation Volume Volume Conventional Superconducting 5.97 Weight Weight Conventional Superconducting 8.77
17 Power Management and Distribution Weight and volume of power converters and drive have to be maximized for airborne applications Off the shelf components exhibit ~ 11 kw/kg power density Weight can be decreased Weight VS. Power for Converters by modifying power 1000 quality (harmonics 3 kw/kg 100 IPT ELECTRONICS filtering) BALLARD Cryocooling should generate a three fold increase of power density Reliability needs to be increased Weight (kg) kw/kg Ground base Appl. 11 kw/kg / Standard automobile kw/kg Airak Inc. DOE SBIR 11 kw/kg EE TECH TEAM ROADMAP kw/kg Namuduri et al. IEEE Shaft Power and Equivalent Shaft Power (kw)
18 System Approach / Reliability 100% of power is only needed during take off Propulsion requires ~50-70 % of take off power during cruise Redundancy of components can lead to improved efficiency Different configurations possible Fan Generator Gas Turbine Motor PMAD Generator Gas Turbine Fan Motor PMAD Generator Generator Gas Turbine Gas Turbine
19 Sizing Examples ELECTRIC SYSTEM SIZING FOR ALL-ELECTRIC UAV (GLOBAL HAWK) System Weight (kg) Volume (dm 3 ) Propulsion (motors) PMAD (converters, busses) 690 (220) 690 (220) Power plant (turbo-generator) Total 1870 (1400) 3744 (3274) Boeing Thrust: lb.t. Weight: lb = 1585 kg Volume: dm3 Global Hawk: Thrust: lb.t. Weight: lb = 717 kg Volume: dm3 ELECTRIC SYSTEM SIZING FOR ALL-ELECTRIC BOEING System Weight (kg) Volume (dm 3 ) Propulsion (motors) PMAD (converters, busses) 960 (300) 960 (300) Power plant (turbo-generator) Total 3226 (2566) 3697 (3037)
20 Available Technology Power density (kw/kg) Oswald TF62 Oswald TF46 Oswald TF36 Oswald TF Oswald TF20 Oswald TF13 Conventional 4 URETI cylindrical 1.5 URETI axial flux 450 URETI cylindrical 170 GE HIA Siemens 4 Siemens 400 AMSC 3.7 AMSC 5 AMSC 36.5 Torque optimized commercial Conventional HTS Designed for airborne applications Actual HTS motors Torque density (Nm/kg) Power density (kw/kg) Torque density (Nm/kg)
21 Conclusion HTS machines can be design to match power density of gas turbine Many different topologies to fit different applications Liquid hydrogen as fuel and HTS components are in good synergy Hydrogen cooling should enable the use of fully superconducting motors ( free cooling system ) HTS is an enabling technology for all-electric aircraft propulsion
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