1 Enabling Electric Propulsion for Flight Hybrid Electric Integrated System Testbed (HEIST) and LEAPTech?? Presented by: Andrew Gibson Empirical Systems Aerospace, Inc. For: Transformative Vertical Flight Concepts Joint Workshop Highly Coupled Distributed Electric Tools, Analysis, and Testing Capabilities Panel Discussion August 27 th, 2014
3 DEP Hardware Efforts Hardware Efforts to Demonstrate Technology and Begin to Validate Tools Phase II SBIR (2014 2016) ephm System Development, Hardware-in-the-Loop Testing, Fault Tree, and Failure Mode, Effects, and Criticality Analysis Applied to and Integrated on NASA Hybrid Electric Testbeds. Phase III SBIR (2013 2018) Design and Fabrication of a Hybrid Electric Integrated System Testbed (HEIST), Including LEAPTech.??
4 Sean Clarke Challenges to Advancing Electric Propulsion System TRL System Integration: Unexpected complexities surface on flight-like systems: Will DC buses remain stable with high-frequency loads? What grounding issues will only emerge when airframe installation compromises are considered? Will EMI/EMC effects emerge in volume/weight constrained applications? Standards Development: System design and implementation standards needed: What measurement techniques and sensor technologies are necessary or ideal? What V&V methodologies are most effective? What physics-based issues/phenomena cannot be predicted with simulation? How should subsystem performance be monitored? Size: Components are needed at higher energy/power density and smaller volume How will thermal management become a design driver at high power density? How will battery management and quality be affected by high energy density systems? Funding: Limited budgets in aeronautics R&D drive a spiral development approach How can we achieve the most research objectives with limited budgets? 4
5 Sean Clarke The Big Picture / Elec. Prop. Research Pathway at AFRC Airvolt Airvolt Hybrid Motor Generator Advances 2 MW Testbed HEIST LEAPTech Hardware-inthe-Loop Sims Iron Birds HEIST PMAD Advanced Flight Testbed Or Experimental Vehicle 5
6 HEIST Project Outline Goal: Design and assemble a DP test capability to conduct smaller scale testing of HEDP components/concepts to support development roadmaps that manufacturers can achieve. Near Term Emphasis LEAPTech (Large Electric Asynchronous Propeller Technology) Mobile Test Platform Power Management and Distribution (PMAD) Controller 2013 HEIST SBIR Task List: Task I HEIST System Design and Modeling Task II Distributed Propulsion Electronic Controller (Power Management and Distribution) Task III Instrumentation System Task IV Static Test Bench Task V AIRVOLT Mobile Test Platform Task VI Dynamic Test Platform (LEAPTech Team Seedling) COR Sean Clarke, AFRC
7 Sean Clarke HEIST Emphasis 1 - LEAPTech Leading Edge Asynchronous Propeller Technology (LEAPTech): First experiment to be conducted at Armstrong, Dec 2014 Funded by ARMD Team Seedling competition (partnership p between AFRC, LaRC, ARC, GRC) Obtain data to validate CFD tools for designing and optimizing distributed propulsion configurations Measure real flow physics associated with the proposed configuration Develop pphase 2 test objectives for higher fidelity test points and measurement goals
8 HEIST LEAPTech Participants NASA AFRC Oversight / Host Requirements Management Master motor controller Test Execution Safety Review Process NASA LaRC LEAPTech lead (PI) Wing aero design CFD analysis Structural analysis Empirical Systems Aerospace, Inc. Top level engineering Instrumentation System Integration System Shakedown Joby Aviation Wing Manufacturer Motors, motor speed controllers, propellers Test Rig (truck platform) fab, force balance design
9 Sean Clarke/Starr Ginn What do we learn from LEAPTech Seedling? Battery weight and durations versus HP and test time. Power profile versus battery drain. Experience with Motor/Motor Controller/BMS. Coefficient of Lift; Force balance calibration may be tricky. Power loss due to line length. Propeller fatigue due to vortex shedding from neighbor propeller. Minimum detailed Flow Measurement. Accelerometers for Frequency Validation. Qualitative Acoustics (ear), Not measuring. Controller Basic Individual Instrumentation t ti needs. Testing capability for future wing designs.
10 Sean Clarke HEIST LEAPTech Operations Operation Procedure still being developed. Joby Power System and ESAero/Armstrong Instrumentation Data Requirements will support multiple runs per day. 15/33 18/36 5/23 Mobile Test Platform will be Tested at NASA Armstrong on Dry Lake Bed Primary Runway is 5/23 Backups are 18/36 and a portion of 15/33. N
11 HEIST LEAPTech Instrumentation Aerodynamic Performance Pressure strips for upper surface pressure distribution High frequency pressure transducers for instantaneous pressure behind prop 3D pitot system for airspeed and AoA Aerodynamic Forces Load cells placed in an force balance system to acquire thrust, drag, lift, & yaw Aeroelasticity ty Accelerometers at multiple locations Temperature of Electronic Components Resistive Temperature Detectors (RTDs) place in key electronics for thermal monitoring Groundspeed GPS unit to monitor ground speed Data Storage and Telemetry Solid state hard drive for storage of video and sensor data S-band antenna for telemetry Motor/Controller Performance Motor and controller data gathered from CAN bus
12 HEIST Primary Data Acquisition TTC MCDAU-2000/F Teletronics MCDAU-2000 DAQ and several cards are being reused from Pad Abort 1 Flight Test from the NASA Orion Program in 2010. Location: Internally mounted in center wing section. Access: Hatch in center body between fwd and aft spar. MCDAU-2000 Length: 2.49 Width: 2.63 Height variable Weight: variable Data Rate: 5.0 Mbps @ 12-bit Power: 28V @ 230w Operating temperature: -35 C to +85 C Storage temperature: -55 C to +100 C. Random vibration: 15grms, 20-2kHz, 10min, any axis. Acceleration: 25g, indefinite duration, any axis. Shock: 15g, half-sine, 11 ms, 6 shocks, any axis. Humidity: 5-95% RH, non-condensing. Altitude: 0 to +200,000 ft. (unlimited).
13 HEIST Instrumentation and Harnesses Instrumentation Sensor Diagram
14 HEIST Surface Pressure MPSI-164 & 4 x 32 Channel ESP Provided by NASA Data: Cordwise Pressure Distribution Location: Up to 6 pairs of strips located between motors 4/5 and 5/6 and centered behind motor 5, 2 ESP units located above each access hatch (4 total). ESP- 64HD
15 HEIST/LEAPTech Force Balance Data: X, Z, Pitch and Yaw force measurement between wing and stand Location: Mounted to wing structural supports. Thrust Yaw Lift/Pitch
16 Mark Moore FY15 Risk Reduction Research ARMD Seedling Phase II (if funded) Collect Test Data and Validate Predictions (LaRC/AFRC/Ames/Joby/ESAero) Collect performance, acoustic, control, different failure modes, etc. data sets from the ground test rig. Validate aero-propulsive CFD predictions. Validate ground test rig data accuracy.
17 Sean Clarke HEIST Emphasis 2 PMAD (FY16) Power Management and Distribution ib ti (PMAD): Second experiment on the HEIST, Feb 2016 Static propulsion p test stand co-located with Airvolt Evaluate inherent issues with parallel-hybrid electrical bus architecture (bus stability given many dynamic loads and sources) Characterize aggregate thrust control of many motors o in parallel a (including coupling effect ec and reaction to motor-out scenarios) Research control approaches for integrating hybrid-generator Investigate algorithms for thrust augmented yaw control Assess power generation/consumption problems (incl. catastrophic load shedding)
18 Related Efforts ephm Phase II SBIR Phase II Goal: To advance the development of HEDP (or TeDP) aircraft development by establishing Health Monitoring (FMECA/PHM) capability for AirVolt and HEIST Subcontractor: General Atomics Intelligent Systems Emphasis: Detailed AirVolt and HEIST (LEAPTech) System Reliability and Failures Investigation for Existing Components. Systems Based Approach for ephm Requirements Integration onto HEIST System Architecture Future Full Air Vehicle Considerations (LEAPTech) Phase II SBIR Task List: Task I AirVolt and HEIST (LEAPTech) Component Gathering Task II FTA and FMECA on AirVolt and HEIST (LEAPTech) into PTC Windchill Task III Development of ephm System using HIL Virtual Model Task IV Integration of ephm System on HEIST Task V Reporting
19 Sean Clarke Some Thoughts/Conclusions Hardware Provides Pathway to high h Fidelity Simulators Based on initial test stand data: Derive models of power system component performance Formulate more detailed requirements for these complex systems based on lessons learned on initial tests Build more advanced data acquisition and analysis systems Simulate flight environments and mission constraints Hardware in the Loop: Integrate flight-like electric propulsion system hardware into simulated electric aircraft flight controls, real-time feedback on component loading (dynamometers) Aircraft in the Loop / Ironbird: Include control surfaces, flight-ready control system, flight-like energy storage components Hardware Provides Tool and Methodology Validation Multiple Conceptual Design and Tool Efforts are underway and have been for up to 5 years. Spiral Development of Electric Propulsion and Transformational Concepts will support near constant and increasing fidelity Tool and Methodology Validation. Will support the conceptual design and preliminary design phases of these highly coupled air vehicles, including future turboprop, regional and small airliner concepts. 19
20 Sean Clarke Questions? Hybrid Electric Propulsion Research Collaboration (Armstrong) Single String Efficiency Airvolt Propulsor Dynamic Performance Turbo- generator Hybrid- Electric HEIST - TeDP High Voltage Distribution System SBIR/METIS Generator vs Battery transient handling PMAD Instrumentation and Feedback Phase II Adjacent Propulsor Inlet Interaction SBIR/ESAero/GA ephm Phase II Distributed Propulsion Controller HEIST Phase III STTR/RHRC A/C Conversion Study GRC/Georgia Tech/NPSS Ground Test Data/Airvolt /HEIST LEARN/RHRC Boundary Layer Ingestion efficiency Phase II 6DOF Aero Model/ Seedling Hybrid Electric Propulsion Flight Simulator w/hil 20 Thanks to Sean Clark and Starr Ginn, AFRC, and Mark Moore, LaRC, for providing supporting material for this presentation.