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FP7

TSA Report Summary

Project ID: 323494
Funded under: FP7-JTI
Country: Portugal

Periodic Report Summary 2 - TSA (Telemharsh - Telemetric System Acquisition in harsh Environment)

Project Context and Objectives:
Periodic preventive maintenance activities associated with aircraft subsystems is a significant part of the high costs associated with through life aircraft operations. Also, the understandably conservative approach to risk management, leads to premature component retirement, which is both highly inefficient and leading to a considerable carbon footprint. Minimizing maintenance costs and carbon footprint are both major concerns within the whole of the aerospace industry.
If key components such as turbine engines had the ability to robustly, autonomously and continuously evaluate their structural health, and anticipate potential failures, maintenance costs could drastically decrease without compromising aircraft’s safety and reliability. This new maintenance paradigm of real-time in-situ health monitoring, would eliminate the need for the usual periodic preventive actions, allowing maintenance activities to evolve into a reactive paradigm, with extremely high savings as a result.
In order to provide useful data to optimize the development of each part of the turbo engine, Active Space Technologies SA proposes an innovative telemetry solution for measuring in situ strain and temperatures of the engine shaft, and transmit energy and data through wireless links. The rotating unit must resist up to 45,000 RPM at 150 ºC.

Project Results:
The project started with a thorough analysis of the technological SOTA, which included a literature research related to the most critical items of the development. This study was very important to the project, because it demonstrated that the initially planned development would not comply with the Telemharsh requirements, and it also presented a couple of alternatives that increases the likelihood of the project success.
The second major task was the specification of the project requirements, based on the information of the Call for Proposals and the discussions with Turbomeca.
It was designed a high speed test bench that is a key success factor for Telemharsh, mostly in terms of risk reduction, because the testing phases can be performed in-house, in a non-critical and controlled environment.
The effective design of the Telemharsh system started by a preliminary study, prototyping and testing of the most critical functions of the system, such as: wireless power transfer, high data rate wireless communications for high speed rotating engines, bare dies and wire bonding structural resistance to high centrifugal accelerations, and elementary software blocks required to integrate everything. After the validation of the concept, the design progressed to the detailed design of all the electronic, mechanical and software components of the Telemharsh, in such a way that they had to fit in the small available volume inside the Turboshaft engine.
At the end of the second reporting period, the final system design had been achieved, and the manufacturing of the final prototype components was started.

Potential Impact:
Within the framework of Clean Sky, the proposed project will contribute to the above objectives developing a system to acquire parameters in harsh environment, which can provide parameters on rotating assemblies and therefore offer information that can be used to optimize the development of each components of the turbo engine. From a technical point of view, the project is expected to contribute to the development of knowledge in the design and manufacturing of telemetry systems which are required by the European aeronautical industry to improve its competitiveness regarding sensing, deeper understanding and measurement of turbo engine behaviour, and optimization of turbo engine components.
The knowledge created by developing this system will allow for a significant reduction of weight, noise and emissions through enabling optimized lower pressure systems. The project will contribute to the development of an industrially working prototype of a mechanism with currently available cutting edge technologies, leveraging on available academic R&D work. Further, the project will also identify technology gaps and bridge to current developments at R&D level and to future technologies currently being developed (e.g., energy harvesting, telemetry/wireless for high rotation speeds, reliable high-g and high temperature electronics, thermal management, etc.).
Finally, the project will contribute to a number of spin off applications related to sensing of harsh environments, such as nuclear reactors, tanks, a number of combustion engines and rotors, spacecraft and re-entry capsules, etc. This will have a multiplier effect in the European industry and enable advancements and enhancements in preventive maintenance, significantly reducing maintenance costs and breakdowns and therefore improving performance. A secondary effect is to significantly reduce harnessing via energy harvesting localized centrals.

Contact

Dina Gaspar, (EU & Public Funding Manager)
Tel.: +351304505505
Fax: +351304505506
E-mail
Record Number: 191724 / Last updated on: 2016-11-21
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