NASA LEAPTech and X-57 Prototyping

Transcription

1 NASA LEAPTech and X-57 Prototyping Sean Clarke, P.E. X-57 Principal Investigator

2 X-57 Participating Organizations NASA Langley: Vehicle, Wing, Performance, Controls IPTs NASA Armstrong: Power, Instrumentation IPTs, Flight Ops NASA Glenn: Battery Testing, Thermal Analysis Empirical Sys. Aero.: Prime contractor Scaled Composites: Mod 2 Integration (batteries, motors, controllers, cockpit) Joby Aviation: Motor & Controller and folding prop development Xperimental: Wing design and manufacturing Electric Power Sys.: Battery development TMC Technologies: Software certification Tecnam: Baseline COTS airframe without engines Joby ESAero Electric Power Systems Xperimental Scaled Composites NASA AFRC NASA GRC TMC Technologies of West Virginia NASA LaRC Tecnam Italy 2

3 HEIST/LEAPTech: Propulsion-Airframe Integration Validation

4 LEAPTech Volume Constraints After wing close-out, operating space became very limited Troubleshooting was significantly hindered Hatch openings were particularly susceptible Speed controllers did not fit inside nacelles, reducing available volume inside nacelles for lines and instrumentation Power and instrumentation wiring in close proximity has contributed to EMI issues

5 Traction Bus Redundant traction buses. Each high-lift motor alternates buses, cruise motors pull 50% power from each bus. Buses protected in separate ducts for isolation, shielding and protection Command and Instrumentation systems routed and shielded separately to avoid interference and common failures Xperimental, LLC 5

6 LEAPTech COTS Controller, advanced motor 6

7 X-57 Cruise Motor Torque Controllers Prototype Running at 200% of rated power Heatsink Uses Cruise Motor Exhaust To Cool Inverter Gates Software initial release in preliminary verification and validation testing Environmental screening (shake and bake) of prototype unit in progress at AFRC CMC Environmental Testing at NASA Communication, Power and Sensor Interface High Voltage DC (Input) and AC (Output) Interface to the Inverter 7

8 X-57 Cruise Motor Development Mod II Integration Into Existing Cowling Flight motor fabrication in progress, first unit delivery in April Out-runner design further optimized for X-57 based on prototype performance (demonstrated large margins) Prototype Cruise Motor (Design Iteration J, Flight Units Will Be Rev K) Cruise Motor Inverter Environmental Testing at NASA 8

9 LEAPTech Electromagnetic Interference / Compatibility Propulsion system generates EMI as a function of controller power This impedes control and instrumentation buses Eventually, control commands over CAN Bus can no longer be verified for transmission 9

10 X-57 Traction Power Distribution Redundant bus design supports Mod IV (branches to each high lift motor) Thermal model for traction bus validates wire sizing and duct venting Custom "flat cable" for lower inductance and Electromagnetic Interference (EMI) EMI radiated emittance tests and thermal dissipation tests performed at the NEAT facility (Plum Brook Station) Isolated Ducts Protect Redundant Power and Command for Cruise and DEP Systems X-57 EMI Testing At Plum Brook Station/NEAT Contactor Pallet Includes Smart Prechargers and "Primary Objective" Power Measurement Flat Cable Custom X-57 Design for Electric Propulsion Systems 10

11 X-57 Mod III Wing Design NASA and Xperimental finalizing design (CDR March 7-8) Current design considerations: Mod III wing / fuselage interface Load Test Plan: Full-scale test article vs. sub-assembly tests Aileron & flap resizing due to manufacturing concerns Analyses: Structural, classical flutter, whirl flutter analysis Aileron, Flap, High Lift Nacelle Interface (Nacelle's Empty in Mod III) Remote Control Quick Look Stability & Control Model Mod III Spar/Rib Layout, Power and Instrumentation Ducts 11

12 X-57 Flight Controls and Simulation Synchronized with Vehicle Mass Properties Model for both Mod II and Mod III Models electric prop system dynamics in addition to vehicle stability and control Aero model validation plan is in work (CFD cases to validate wind tunnel data and to build up uncertainty model Includes failure scenario modeling (e.g. engine out) Piloted Simulator at AFRC Includes Flight Like Instrument Panels, Switches, MFD Unpowered Stability and Control Dynamics Test in the 12' Tunnel at LaRC 12

13 X-57 Battery System 461 V nominal, 47 kwh capacity 790 lbs. (8 Modules, 95 lbs. each) 2 packs supports redundant X-57 traction system Battery destructive testing conducted Dec JSC Test Unit With Interstitial Barrier and Heat Spreader (Design Template) X-57 Thermal Runaway Unit (2 Trays; ½ Module) X-57 Battery Module (¼ Pack) before Short Circuit Test One Battery Pack (4 Module, ½ Ship Set) 13

14 High Lift Folding Propellers 14

15 Throttle Quadrant Electric Motor Mount & Cowling Completed 15

16 Hybrid Electric Integrated System Testbed (HEIST) SDB 1 SDB 2 SDB 3 SDB 4 DC Electric Power Legend Wing Trailer Traction Bus SIS PDB To motors 1 & 2 Dyno Trailer (phase 3 only) To motors 3 & 4 Battery (AV900) Power Source to Traction Bus C-65 + AC/DC Converter to Traction Bus From Traction Bus to Switch Disconnect Boxes From Switch Disconnect Boxes to Motors Phase 1 only SDB = Switch Disconnect Box SIS = Simulation Interface System PDB = Power Distribution Box SDB 5 SDB 6 SDB 7 SDB 8 Battery Trailer (phase 3 only) near Wing Trailer AV900 (phase 1 & 2) stationed inside 4840 bay 5 AC/DC Converter C-65

17 Hybrid Electric Integrated System Testbed (HEIST)

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