HTS-Technology for hybrid electric aircraft ECD-IWCHTS 2017 Dr. Mykhaylo Filipenko, KIT

Transcription

1 HTS-Technology for hybrid electric aircraft ECD-IWCHTS 2017 Dr. Mykhaylo Filipenko, KIT Restricted Siemens AG 2017

2 Siemens eaircraft part of Coorporate Technology Overview of Siemens eaircraft locations Dinslaken, Germany Airfield for Extra 330LE flying testbed Erlangen, Germany Headquarters and design organization for certified applications Munich, Germany Testing labs Taufkirchen, Germany Airbus-Siemens collaboration Budapest, Hungary Design organization for general aviation Matkópusztai airfield, Kecskemét, Hungary Airfield for efusion flying testbed Page 2 April 2017 Restricted Siemens AG All rights reserved Airfield Office location

3 Electric Aircraft Why? Save the Planet! Flightpath 2050 Goals: 75 % CO2 emission reduction 90 % NOx emission reduction 65 % noise reduction Page 3 April 2017

4 Electric Aircraft Why? Also a business case! Cost (M$)/aircraft (example ) $/gal 300 (Nov. 07) 7% 4% 1% 2% 15% % 100% % 0 Purchase Fuel Crew Direct maintenance Burden maintenance Modifications Taxes, insurance and fees Total cost of ownership Reduction of fuel consumption is main lever to reduce aircraft TCO Note: Calculated using hourly operational costs from September 2007 Form 41 data for all US carriers currently operating s (Continental, American, Delta, Sun Country, ATA, Alaska). Assumes uptime avg block hrs/day, 20-year lifecycle, and 8-10 year modification cycle. Source: Carrier Form 41 reports, IATA, airfinancejournal.com, TeamSai, Aerostrategy; BCG Page 4 April 2017

5 LiIon/LiPo commercially available Short History of Electric Aircraft Taurus G4 EXTRA 330LE MB-E1 egenius Solair 1 E-FAN 1.0 E-FAN Image Courtesy of Airbus Group Page 5 April 2017

6 Siemens eaicraft flight test history Hybrid electric Diamond Aircraft estar 1 and estar 2 Fully electric Pipistrel WattsUp trainer Fully electric Magnus efusion Record motor SP260D in the Extra 330LE Page 6 April 2017 Restricted Siemens AG All rights reserved

7 Magnus efusion - fully electric aircraft propulsion system installed firewallforward Magnus efusion maiden flight Summer 2016 Battery system Auxiliary system Controller Aircraft Data Empty weight including batteries and parachute MTOW 410 kg 600 kg Wingspan 8.4 m Electric Motor with Bearing Length Height 6.6 m 2.4 m Inverter Cooling Power N max -link voltage (nominal) Torque M Boost Propulsion System Data 45 kw MCP 60 kw MTOP 85 kw max rpm 350 V ( V) 324 Nm Battery Max. airspeed 10.1 kwh 97 KIAS Page 7 April 2017 Restricted Siemens AG All rights reserved

8 Flying testbed for ¼-MW class electric propulsion systems Extra 330LE - maiden flight summer 2016 MTOW Wingspan Aircraft Data 1000 kg 8.0 m Height 2.6 m Length 7.5 m Wing area 10.7 m 2 Propulsion System Data + * Source: flyer.co.uk P max P cont N cont M cont 260 kw 230 kw 2250 rpm 1000 Nm η Mot max. 95% m Mot, including propeller bearing 50 kg * As rated in the Extra 330LE Page 8 April 2017 Restricted Siemens AG All rights reserved

9 We expect electric propulsion to be the standard solution by 2050 Outlook for electric propulsion market Increasing dominance of electric propulsion Today Experimental flight with small aircraft demonstrated 2018 Market entry for ultra-light and military due to less strict certification rules 2022 Market ramp-up for certified systems, e.g., two- and fourseaters 2025 Fully electric flying for medium range (energy storage capacity sufficient) 2030 Airlines offering scheduled flights based on hybrid-driven aircraft 2050 E-propulsion is the standard solution for all aircraft segments Today 2050 Source: eaircraft market evaluation Page 9 April 2017 Restricted Siemens AG All rights reserved

10 Comparison of Drive Trains High Gains in Efficiency Possible! Page 10 April 2017

11 Challenge One Energy Storage Energy Density of Various Energy Sources in kwh 1. Batteries could provide sufficient storage capacity in the far future Energy Density of Various Energy Sources in kwh 2.Commercial development ongoing but it is still a long way Kerosine Li-Ion Li-Air Al-Air ST Al-Air LT LH2 3. In the meantime hybrid electric concepts could be used for electric aircraft Page 11 April 2017

12 Challenge Number Two Weight of Drivetrain Equipment Energy Storage Battery Packs Converter BMS 2) Storage Extended eaircraft portfolio Core eaircraft portfolio Generator 1) AC Power Distribution AC Motor 1) Turbine / ICE Power Generation Generator Inverter Controller Turbine/ICE 3) Power Distribution Circuit Breaker Switches Cables Connectors 1) E-machines are capable to fulfill power generation and/or propulsion depending on e.g. mission profile, requirements and/or mode of operation, 2) Battery Management System (BMS), 3) Internal Combustion Engine (ICE) Propulsion Unit Motor Inverter Propeller Gearbox Propulsion System Page 12 April 2017

13 Challenge Number Two Weight of Drivetrain Equipment Energy Storage Battery Packs Converter BMS 2) Storage Extended eaircraft portfolio Core eaircraft portfolio Generator 1) AC Power Distribution AC Motor 1) Turbine / ICE Power Generation Generator Inverter Controller Turbine/ICE 3) Power Distribution Circuit Breaker Switches Cables Connectors 1) E-machines are capable to fulfill power generation and/or propulsion depending on e.g. mission profile, requirements and/or mode of operation, 2) Battery Management System (BMS), 3) Internal Combustion Engine (ICE) Propulsion Unit Motor Inverter Propeller Gearbox Propulsion System Page 13 April 2017

14 Cold Power Cables Examples from Vision Electric and Nexans Weight reduction of up to an order of magnitude for multi-mw systems (~ 2-10 t to 0.2t to 1t) Voltage independency => high flexibilty for motor, PE design and switch design Almost of-the-shelf technology Page 14 April 2017

15 Challenge Number Two Weight of Drivetrain Equipment Energy Storage Battery Packs Converter BMS 2) Storage Extended eaircraft portfolio Core eaircraft portfolio Generator 1) AC Power Distribution AC Motor 1) Turbine / ICE Power Generation Generator Inverter Controller Turbine/ICE 3) Power Distribution Circuit Breaker Switches Cables Connectors 1) E-machines are capable to fulfill power generation and/or propulsion depending on e.g. mission profile, requirements and/or mode of operation, 2) Battery Management System (BMS), 3) Internal Combustion Engine (ICE) Propulsion Unit Motor Inverter Propeller Gearbox Propulsion System Page 15 April 2017

16 Cold Power Electronics Least mature field concerning application at cryogenic temperatures Increasing efforts in particular in USA: Development of 200 kw multi-level inverter for cryogenic application at University of Illinois with GaN modules Boeing 1 MW inverter Efficiency: 99.3 % Power-to-Weight: 26 kva/kg Overview from PhD Thesis Leong, University of Warwick, 2011 R. H. Jansen et al.: Overview of NASA Electrified Aircraft Propulsion Research for Large Subsonic Transports (AIAA Conference 17) Page 16 April 2017

17 Challenge Number Two Weight of Drivetrain Equipment Energy Storage Battery Packs Converter BMS 2) Storage Extended eaircraft portfolio Core eaircraft portfolio Generator 1) AC Power Distribution AC Motor 1) Turbine / ICE Power Generation Generator Inverter Controller Turbine/ICE 3) Power Distribution Circuit Breaker Switches Cables Connectors 1) E-machines are capable to fulfill power generation and/or propulsion depending on e.g. mission profile, requirements and/or mode of operation, 2) Battery Management System (BMS), 3) Internal Combustion Engine (ICE) Propulsion Unit Motor Inverter Propeller Gearbox Propulsion System Page 17 April 2017

18 Motor Weight Today Motor Data P cont = 261 kw n max = 2500 rpm M cont = 1000 Nm η 260kW = 95 % D = 416 mm L = 300 mm P/M ~ 5.2 kw/kg The best we can do up to now is the world record but we can t stop there! Page 18 April 2017

19 Motor Weight Future P M = 1 1+K Φ m m 1 π 2 K e K i K p λ 0 2 B g A f η Topology Superconducting Materials Page 19 April 2017

20 Motor Weight Future P M = 1 m π 1+K Φ m 1 2 K e K i K p λ 2 0 B g A f η Example: Topology optimization using NX Nastran Topology Superconducting Materials Page 20 April 2017

21 Motor Weight Future P M = 1 m π 1+K Φ m 1 2 K e K i K p λ 2 0 B g A f η CFK Bearing Shield 2.3 kg Example: Topology optimization using NX Nastran Topology Superconducting Materials Page 21 April 2017

22 Motor Weight Future P M = 1 m π 1+K Φ m 1 2 K e K i K p λ 2 0 B g A f η CFK Bearing Shield 2.3 kg Example: Topology optimization using NX Nastran Topology Superconducting Materials Siemens HTS-III Machine rpm Page 22 April 2017

23 Cryogenic propulsion system Biggest leverage Advanced Cryogenic Materials HTS Tapes & Wires HTS-Bulks Filamented Wires MgB2, YBCO YBCO, GdBCO MgB2, 5N-Cu, 5N-Al Allows very high current densities in the stator or high fields in the rotor allows very high magnetic fields in the rotor allows very high current densities in the stator with high frequencies Page 23 April 2017

24 R&D all around the globe Page 24 April 2017

25 The case for superconctivity.. Develop [..] rotating machines in the range of kw/kg for motors and kw/kg for high rotation speed generators.. Page 25 April 2017

26 The case for superconctivity.. Develop [..] rotating machines in the range of kw/kg for motors and kw/kg for high rotation speed generators.. Hardly possible with superconducting technology Expensive and complex technology Page 26 April 2017

27 The case for superconctivity.. Develop [..] rotating machines in the range of kw/kg for motors and kw/kg for high rotation speed generators.. Hardly possible with superconducting technology Aircraft industry has used very expensive and complex technologies for decades Expensive and complex technology Page 27 April 2017

28 The case for superconctivity.. Develop [..] rotating machines in the range of kw/kg for motors and kw/kg for high rotation speed generators.. Potential killer application Hardly possible with superconducting technology Aircraft industry has used very expensive and complex technologies for decades Expensive and complex technology Page 28 April 2017

29 Major reason for hybrid electric propulsion: Radically New Aircraft Design??? Page 29 April 2017

30 Last slide Invest in Lithium, because the future is (hybrid) electric! Page 30 April 2017

31 Thank you Dr. Mykhaylo Filipenko Head of center of competence electrical machines 1 eaircraft Siemens Corporate Technology CT N47P AIR AS mykhaylo.filipenko@siemens.com Internet siemens.com/corporate-technology Page 31 April 2017