Community Research and Development Information Service - CORDIS


TEMGIR Report Summary

Project ID: 641463
Funded under: FP7-JTI
Country: Spain

Periodic Report Summary 1 - TEMGIR (Thermal and electrical Mock-ups for Thermal Management of a Ground Integration Test Rig)

Project Context and Objectives:
In the framework of “Clean Sky”, within project referenced in CS-2013-03-SGO-04-006, AERTEC, in consortium with CEIT and SERTEC, will develop the TEMGIR “Thermal and electrical Mock-ups for Thermal Management of a Ground Integration Test Rig”. This project is for the design and development of Thermal and Electrical Mock-ups for the validation of the thermal behaviour in the electrical air systems architecture at aircraft level.
Management of Aircraft Energy is a key point of the framework of JTI/Clean Sky Systems for Green Operations (SGO-ITD). The More Electrical Aircraft (MEA) philosophy will be developed since the use of all-electric equipment system architectures will allow a more fuel-efficient use of secondary power, from electrical generation and distribution to electrical aircraft systems. The objective is less fuel consumption and thus reduced environmental impacts. The Thermal Management System (TMS) is closely related to electrical energy consumption and heat needs at all levels of the overall aircraft solutions: hot spots in large power electronics, motor drive system cooling, air-conditioning, heat load for kitchen…Therefore, the TMS on aircraft has taken a critical importance. High point heat loads have to be thermally managed in the most efficient way and this trend is forecast to continue for the foreseeable future.
At A/C level it is required a global thermal transfer. On one hand, some A/C loads need to be cooled and others need to be heated. While on the other hand, incoming air to the A/C is cold and unpressurised but it is required: hot and pressurized, for fuselage crew, and cold and pressurized, for cooling electrical equipment. Thus, during the transformation the air is heated and energy is required. Additionally, quick temperature changes or large slew rates (e. g from -20ºC to 30ºC) could damage power electronics.
These reasons bring the need of new equipment to be developed and a complex thermal management concept (what, how, many, when and where). Consequently, the AVANT test rig (as part of WP4.2.2) will feature electrically powered air systems architectures and its thermal management. In this framework, it has been detected the need of building Thermal and Electrical Mock-ups within TEMGIR project that will be dedicated to components’ Thermal Behaviour Emulation of the air systems, while the new equipment are available to be integrated for concept validation.
Note the AVANT test bench is fully representative for the thermal system and represents the electrical system only to the extent that is necessary to set up the relevant environment for the thermal system. The whole electrical network will be tested on another test rig of Clean sky (WP4.2.1) PROVEN. In that global set up both rigs together become fully complementary to each other and cover the full scope of electrical and thermal system.
TEMGIR is itself an independent test bench which supplies energy to equipment and includes electrical and thermal dummies to provide a fully integrated replacement for aircraft hardware, which is not currently available. Its aim is to create a test set up with the most representative environment of all equipment which are cooled or temperature controlled by the Air and Thermal Management Systems. The TEMGIR will provide consumers with a heat dissipation similar to airborne equipment but without temperature closed control loop.

The TEMGIR will be composed of:
• Power Distribution Centre that supplies the power needed until the reception of the A/C Electrical Power Distribution Centre (EPDC).
• Thermal Loads that simulate the thermal model and heat losses of A/C equipment.
• Electrical Loads that simulate the equipment under test not available nowadays.
• Control and Monitoring SW System to perform the scenario selection, load the loads profiles, monitor their response and storage the data.
Dummy equipment will be used for initial test in order to simulate the desired behaviour of some equipment to achieve the correct load profile to the power electronics and therefore the thermal behaviour for the cooling loop.
This test rig will be used for validating design of innovative systems for new aircraft and improvements to current models.
Additional power energy is required for this equipment since a real power generator (motor) cannot be installed in the AVANT test rig, hence all units will be electrical powered: 28vdc, 115Vac, 230Vac or 270HVDC.
The related mock-ups will be dedicated to the Thermal Management of the AVANT ground demonstrator located at ZAL facility in Hamburg.

Project Results:
Since the beginning of the project, the consortium has defined and described the specifications and the design of the TEMGIR test rig, based on the initial requirements given during the negotiation phase and improved during the common work with Topic Manager.
From the requirements catalogue generated in the previous phase, the designers and specialists started to work on the technical solution and the design. They designed and detailed a product that meets customer requirements as well as standards and regulatory requirements, so that once manufactured or assembled, the product meets customer expectations.
With this aim, the partners have started the development of the complete prototypes to be provided to AERTEC for the relevant manufacturing, in order to go in depth on the thermal and electrical behaviours needed.
The exact quantity and power request of these units depend on the aircraft to be emulated. The total number of units and their power will be 8. The total power estimated 10kW. The reason is that on aircraft, 8 individual heat sources are expected, so the same number of heat loads will be available on the TEMGIR: All of them will be designed with the same power and since 1.25 kW might not be enough for some equipment simulation, 2kW heat loads will be considered.
The TEMGIR has been structured in different blocks or products that are needed to build the final product, and they are linked in logical groups: see Figure 2.
Each subsystem has been detailed and described to the most minimum element. Every part of the product is complemented by series of drawings done in CAD, in order to detail the design and help for the manufacture and the assembly activities. The design includes also a Part List where all the components are detailed, with its identification number correlated to the drawing, the specific model, the provider, and other interesting data.
Moreover, the internal interfaces between each part and subsystem of TEMGIR are represented in Figure 3.

Within the main results achieved so far:
• The Power Distribution Centre (PDC) will have a Main Panel: an electrical panel that will be the interface between the building power and the Power Sources.
• The power sources for the PDC have been selected: 28 Vdc, +/-270 Vdc, 115/200 Vac; 400 Hz; 3P and 230/400 Vac; 400 Hz; 1P and 3P.
• The PDC will have Front Panels that are the interface between the Power Sources and the real or dummy loads. They will be electrical cabinets with flexible point to each power source’s output, including protections and connectors,
• The PDC will include an Emergency Module that is a Stop Button that shuts down the electrical power inside the room and all the TEMGIR functions stop.
• The Electrical Loads will be composed of Eight AC voltage stabilizers with a common internal topology, that will be connected to a line to neutral 230 VAC output voltage. Each AC voltage stabilizer will have a maximum power capability of 20 kVA (nominal power capability of 15 kVA). The connection of each AC Voltage Stabilizer with the 115 VAC output voltages will be made through one 20 kVA 130/230 VAC power transformer.
• The Electrical Loads will be composed of Eight Dummy Devices with the same internal power electronic topology, that will have a maximum power capability of 20 kW (Nominal power capability of 15 kW) and their input voltage operative range will be defined by the maximum and minimum output voltage of the DC Power Source and the AC voltage stabilization systems. They will implement a flexible control in order to allow a dynamic master/slave behaviour.
• The Electric Dummy will receive one RMS Power reference from the TEMGIR central control system and will follow this reference dynamically.
• The Test Server computer is the central point of all communication between equipment. The Test Server is both the data acquisition from TEMGIR and the access point for users. All variables and parameters will be sent to the Control Room through VCOM, where tests will be defined.
• Commercial equipment does not implement VCOM protocol (Topic Manager property) but usually RS232, GPIB , USB or TCP protocol. So the TestServer will work as a “bridge” between its native protocol and VCOM, and this “bridge” is able to reduce the data length (such as 32 bits on Modbus RTU power meters).
• Additionally, the Test Server computer will allocate an application simulation which will receive information from Control Room and Power Distribution Centre to calculate the efficiency to be emulated in the Thermal Loads.
• Data recording faster than VCOM will be stored in TXT/CVS files for post-analysis.

Potential Impact:
This TEMGIR rig will be used for validating design of Thermal Management innovative systems for new aircraft and improvements to current models.
The components to be electrically and thermally emulated within the TEMGIR’s loads are the power generators and the main loads: the electrically driven ECS (consisting of an air cycle pack and a vapour cycle system VaCS), including its electrical drives, and the power electronics to drive those systems. There are also necessary electrical loads that complement the previous ones such as main engine starter, fuel pumps, commercial loads, etc.
Simulation results of the improvement changes implemented in electrically powered air systems architectures (e.g. coming from electronic PROVEN test bench of ATA24 in Toulouse) will be emulated over the flexible TEMGIR dummies in order to demonstrate the full test thermal behaviour and management for these architectures in the AVANT test rig.
The use of this test bench will permit the validation of A/C thermal efficiency in a representative environment, by combining and optimizing the heat sinks and sources at aircraft level. For instance, a change in the cooling loop, such that each component is refrigerated by a dedicated heat sink provided by its manufacturer, may weigh less than a global heat sink involved in thermal management systems (ATA21 Air conditioning), however this dedicated heat sink maybe less thermal efficient. This issue, and similar ones, requires a deep analysis from the design team, in order to prove which one is greener in terms of fuel consumption.
The TEMGIR is planned to be installed in a new test facility located in Hamburg (Germany), the ZAL TechCenter. The ZAL is under construction but it is planned to be an Applied Aeronautical Research Center. Shareholders are P3 (Private Public Partnerships) and research topics are oriented to the core competences of the Topic Manager: cabin concepts and technologies, environmental control and power systems, fuselage assembly and system integration. 700m2 are available for R&T Plateau of Environmental Control Systems.
This ground testing environment will include a control room in the floor next to the equipment layout, in order to monitor the exercises and start/stop procedures, if hazardous problems appear during test executions.
The TEMGIR is conducted to be part of the AVANT test rig (Architecture Validation for Air system of New Technologies) to be deployed in this building as part of the SGO WP4.2.2. The AVANT is a ground demonstrator for validation of the full thermal behaviour of several ATA systems (mainly from ATA 21 Air Conditioning and Pressurization) in the MEA framework. It is also known as ATMS and it will be used for rising new technologies from development process (TRL3 / TRL 5) to demonstration (TRL 5 / TRL6), looking for an energy balance at A/C level. (These TRL levels are the aircraft system designs target but not for the test bench itself).
Main components of AVANT are shown in figure 4.
Not all electrical consumers and thus not all heat sources will be available as part of the tests systems. Some of this equipment is not under R&D and can be used from previous aircrafts, such as Recirculation Fans or even a cabin mock-up (Humidifier & Heat block simulation people behaviour). While, others are under new development and they will be delivered stepped in time: VapourCycle System (VaCS), Heat Exchanger (HX), electrical Environment Control System (e-ECS) or Power Electronic (PE).

Related information


Pedro Becerra Rubio, (Director)
Tel.: +34951013900
Record Number: 184308 / Last updated on: 2016-06-16
Information source: SESAM