NASA Electric Aircraft Testbed (NEAT) Overview Boeing SUGAR Volt 2040 In-line Turbo/Electric NASA AATT N+3 Concept Boundary Layer Ingestion Airbus/RR E-Thrust 2036 Distributed Hybrid Gas-Electric Propulsion November 28, 2016
Executive Summary As large airline companies compete to reduce emissions, fuel burn, noise, and maintenance costs, it is expected that more of their aircraft systems will shift from using turbofan propulsion, pneumatic bleed power, and hydraulic actuation, to instead using electrical motor propulsion, generator power, and electrical actuation. This requires new flight-weight and flight-efficient powertrain components, fault tolerant power management, and electromagnetic interference mitigation technologies. And NEAT is the first reconfigurable hybrid gas-electric propulsion testbed capable of supporting full-scale single-aisle electrified aircraft powertrain technology including: High fidelity turbo-generation and ducted fan transient emulation, Establishing baseline power quality and electromagnetic interference levels, Validating aircraft powertrain modeling tools Demonstrating single-aisle flight-weight powertrains Ground test research motors and inverters under flight altitude conditions at full power levels Reduce single-aisle aircraft carbon use, noise and emissions in US airspace 2
Extending Turbine Driven Propulsion to Hybrid Gas-Electric Propulsion Category Aircraft Bus Voltage Power Level More Electric Boeing 787 540V 1.4MW All Electric GA 1-2kV <1MW Hybrid Gulfstream 1-2kV 2MW Hybrid Boeing 737 2-4.5kV 22MW Boeing 787 Boeing 737 Gulfstream 150
Power to Propulsion Configurations Parallel Hybrid Turboelectric Electric Bus Turbofan Turboshaft Electric Bus Battery Fuel Generator Distributed Fans Fuel Fan Series Hybrid Turboshaft Electric Bus Generator Distributed Fans Battery All Electric (s) Electric Bus Fuel Battery 1 to Many Fans NEAT supports all four basic configurations
Near Term Electrified Propulsion Options Parallel - with Engine Turboelectric Distributed
Flight-Weight Powertrain Technology Paths Ambient Parallel Hybrid Podded GE MW Rectifier OSU Ambient Turbo-electric Turbo-generator GE MW Inverter NASA MW Univ. Illinois Superconducting Turbo-electric Turbo-generator Boeing MW Inverter NASA MW SC
Distributed Propulsion Hybrid Electric System Many Possible Architectures Turboelectric Hybrid Electric Distributed Propulsive Power Tube & Wing or Blended Wing Example of a Distributed Concept in the NEAT Testbed Airbus E-Thrust distributed concept 7
STARC-ABL Turbo-Electric Configuration Fuel 13 MW Turbine Engine 1.4 MW Generator Rectifier Thrust and Power 2.6MW Fan BLI Thrust Fuel 13 MW Turbine Engine 1.4 MW Generator Rectifier Rectifier 2 Generator 2 Inverter Fan Circuit Inverter Protection Or Devices Rectifier Generator 1 Rectifier 1 Cables 8
Electric Aircraft Testbed Portfolio GRC/Cleveland Capability List PEGS 1MW CRC NEAT HEIST Max Power Level 3kW 1MW 24MW 200kW Components Tested Scaled Electric Grid Cryo, Drives Flight- Weight Powertrain Wing Integration, Flight Controls TRL Demo 3 4 6 7 Aircraft Size NA NA 150 PAX 2 PAX Cryogenic 500 gal. 3000 gal. No LH2 LH2,LN,LNG No Chiller No No Yes No HVAC No No Yes No Aerodynamic Loading No No No Yes Thermal No Yes Yes Yes Control No No Yes Yes Atmospheric Pressure No No No No TLC Operation YES NA Yes Yes GRC/Cleveland AFRC/Palmdale GE/Dayton RR/Singapore
Research and Technology Overview Primary purpose of the testbed is to enable the high power ambient and cryogenic flight-weight power system testing that is required for the development of the following components to Technology Readiness Level 6: High voltage bus architecture Insulation, geometry, 600V up to 4500V High power MW Inverters, Rectifiers- Commercial, In-House, NRAs High power MW s, Generators- Commercial, In-house, NRAs System Communication Aircraft CAN, Ethernet, Fiber-optics System EMI Mitigation and Standards Shielding, DOD-160, MIL-STD-461 System Fault Protection Fuse, Circuit Breaker, Current Limiter System Thermal Management Active/Passive, Ambient/Cryo, Distributed/Mixed Gulfstream Iron-Bird
Facility Selection and Repurposing Aerial View Required Infrastructure & Con Ops Available
HTF Overview Hot Train and Chamber Steam Ejector Graphite Heater 5-story basement
Recent HTF Refurbishments Exterior Views Paved lot, updated signage, new windows Interior Views Painted walls, HVAC, updated floor Updated for Initial Tests in FY16 13
Testbed Layout Office/Storage Area Altitude Chamber ~ 20 x 16 Shop Area and Cabin Converted to Testbed ~ 27 x 88 27 x 100 Testbed Power Cooling Safety Expansion Altitude Up to 48MW MW Chillers and LH2 Remotely located Wall Extension Up to 120,000 ft
Distributed Powertrain Installed 56 feet Modular and Scalable Reconfigurable testbed 2+ MW powertrain systems Ambient and Cryogenic 15
Notional Single-Aisle Powertrain Installed Modular and Scalable Reconfigurable testbed Parallel Hybrid and Turbo-Electric MW powertrain systems Ambient and Cryogenic Atmospheric Testing Turbo-Electric Parallel Hybrid 16
NEAT Fundamental Architecture Propulsor Load Speed and Torque Control Mapping Utilize electric motor pairs connected via shaft
Incorporating Turbofan Physics Modeling Plant and Control System ERJ-190 100 PAX Utilize Speed & Torque Maps under TLC Conditions
NEAT Modularity and Regeneration Building Power 1MW Turbine Simulator 200kW Battery Simulator 1MW Turbine Simulator 900kW 1 MW MW Generator 1900kW MW Generator Rectifier Rectifier Re-use Generated Power Circuit Inverter Protection Or Devices Rectifier Bolted reconfigurable wing Rib supported, light-weight Machine Pair Interfaces 1MW 10MW 4X250kW 19
Propulsor System: Inboard motors/inverters/turbogenerator COTS motor COTS inverter Ducted fan replaced by regenerative motor load
Wing Generators and Tail-Cone Thrusters: 1MW up to 10MW John Deere PD400 Inverter Drive s Generator s Turbo-generator replaced with motor driven generator Parker 250 kw
System Power Distribution Testing Stability, Efficiency, Mass, and Voltage Optimization 22
System Bus Communication Testing Response, Bandwidth, Shielding, Standards, and Topology 23
System Thermal Management Testing Active/passive Cooling, Insulation, Mass, Efficiency
Flight Altitude Compatibility Testing Tailcone inserted in cabin for motor/inverter flight environment testing STARC-ABL Tail-cone s Installed in Cabin Cabin Tail-cone Side View Paschen Curve, Corona Discharge, EMI, EMC, Flight Profile Stresses Top View 25
NEAT Scientific Development Path Single-String Two-Bus Full Aircraft Flight-Weight
CF34 Flight Profile Validation Completed Confirmed Flight Speed/Torque Profile Gradients Achievable 27
X-57 Bus Radiated EMI Results Confirmed Relative Bus Radiated EMI for MAXWELL
FY17 Capability Updates Transformer, Reactor Loading, Cooling Upgrade, STARC-ABL Relocate current tower near Pump Bldg. Reactor Field for Standalone MW Testing Second Tower Expansion for 1650 KW. Towers will share cold basins. Allows staging based on loading. Pump Building to house CT pumps, NEAT closed loop cooling components and electrical/control interfaces in building. 29
Conclusions The NASA Electric Aircraft Testbed is a key enabler of flight-weight powertrain development. Its high power, remote location, large footprint, conditioned atmosphere, cryogenic infrastructure, atmospheric chamber, and extensibility make it a unique testbed for full-scale aircraft powertrain development. It addresses and fills a unique role not currently available with existing test facilities. And when used in conjunction with the other government, industrial, and academic facilities, it provides an important next step in the path towards electrification of future single-aisle aircraft. 30
Questions? Thank you. 31
References ARINC Specification 825 - The General Standardization of CAN for Airborne Use Michael Armstrong, Rolls-Royce North American Technologies Inc, Cryogenic Engineering Conference / International Cryogenic Materials Conference, Superconducting Turboelectric Distributed Aircraft Propulsion, July 1, 2015, Contract Number NNC13TA7T http://forums.pelicanparts.com/off-topic-discussions/679966-oye-solar-power-plant-good-vs-bad-2.html http://www.embraercommercialaviation.com/pages/ejets-190.aspx http://www.janis.com/ http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20140010471.pdf http://roadwarriorvoices.com/2015/06/15/airbus-unveils-nearly-silent-emissions-free-electric-plane-at-paris-air-show/ Clarke, S.; Lin, Y., Kloesel K., Ginn, S. Enabling Electric Propulsion for Flight: Hybrid electric aircraft research at AFRC, NASA Armstrong Flight Research Center, 14th AIAA Technology Conference, Tranformational Flight- Electric Propulsion Development and Testing, Wed., June 18, 2014 Armstrong, M. Superconducting Turboelectric Distributed Aircraft Propulsion, Rolls-Royce North American Technologies, Inc., Cryogenic Engineering Conference, International Cryogenic Materials Conference, July 1, 2015 Jansen, R., Brown, G., Felder, J., Kirsten, D. Turboelectric Aircraft Drive Key Performance Parameters and Functional Requirements, AIAA Propulsion & Energy 2015, 27-29 Jul. 2015 Choi, B., Morrison, C., Dever, T., Brown, G. Propulsion Electric Grid Simulator (PEGS) for Future Turboelectric Distributed Propulsion Aircraft, 12th IECEC, July 28-30, 2014 SAE-ARP-1870 (8/2012) Aerospace Systems Electrical Bonding and Grounding for Electromagnetic Compatibility and Safety NASA-STD-4003A (2/2013) Electrical Bonding for NASA Launch Vehicles, Spacecraft, Payload NFPA 70 National Electric code, and NFPA 70E Standard for Electrical Safety in the Workplace NPR 7150 Software Assurance DOE-160 MIL-STD-461 32