Periodic Reporting for period 2 - ORCHESTRA (Optimised Electric Network Architectures and Systems for More-Electric Aircraft)
Periodo di rendicontazione: 2022-08-01 al 2024-01-31
The development and implementation of advanced technologies that allow for energy efficient solutions with reduced environmental impact is of extreme importance.
ORCHESTRA will target the challenges of airborne Electrical Power Systems (EPS) for current and next generation aircraft, supporting both incremental changes and addressing the needs of disruptive future aircraft configurations.
An innovative approach involving modular scalable ‘Technical Building Blocks’ (TBBs) that incorporate emerging technologies and breakthrough design ideas will be taken.
The key quantitative objectives of ORCHESTRA will include overall EPS weight reduction by 25% and improvement in EPS efficiency by 10% compared to the current state-of-the-art.
ORCHESTRA will target the challenges of airborne Electrical Power Systems (EPS) for current and next generation aircraft, supporting both incremental changes and addressing the needs of disruptive future aircraft configurations.
An innovative approach involving modular scalable ‘Technical Building Blocks’ (TBBs) that incorporate emerging technologies and breakthrough design ideas will be taken.
The key quantitative objectives of ORCHESTRA will include overall EPS weight reduction by 25% and improvement in EPS efficiency by 10% compared to the current state-of-the-art.
The top-level aircraft requirements and aircraft configuration were determined in WP2 Requirements & Specifications.
WP3-Innovative M2EA Electrical Power Systems (EPS) – a two-stage network based optimisation framework was proposed for the EPS topology designed to reduce weight (but enables minimum power losses) by adopting the minimum number of components. Novel concepts of Integrated Convertor Component concept and de-centralised energy management architecture were proposed. Concepts were verified by case studies.
WP4-Electrical Power Distribution Technologies- innovative harness shielding designs have been developed which were included in the new IEEE P2855 standard. Teflon-PFA based composites filled with Graphine Nano Platelet were found to most effective at dissipating heat. Distribution boxes are been designed and are being tested to verify their functionality.
WP5- Optimised Electric Machines- the dual-rotor radial surface Permanent Magnet machine was deemed topology of choice, together with the use of direct-cooling technologies, high frequency windings and high temperature insulation. Thermal management technologies proposed involve a thermal oil (on each side of the generator) to cool stator windings. Work is ongoing on manufacture and development of effective control techniques and modularity concept.
WP6- Onboard Power Conversion- an innovative scalable Power Electronic (PE) module has been designed (a bi-directional convertor between the KVDC and HVDC bus) and the manufacturing process has begun. Additionally, a bi-directional convertor has been designed to operate between a HVDC and LVDC bus to satisfy multi-MW design requirements (although only plan to use as a unidirectional convertor). Manufacture is ongoing and the convertor is in the final testing stage at SKLE. A solution using inline pins heatsink has been proposed to optimise thermal management. A design for a demonstrator has been proposed to validate the multi-MW design with similar topology and control technologies. An AC/DC convertor to connect the generator to DC bus has been designed. Three modules of Active Neutral Point Clamped structure is proposed as the solution. Work is ongoing on optimised convertor controls.
WP7- Advanced Energy Storage- prototype Solid State Batteries have been designed and manufactured based on the development of a Hybrid Solid Electrolyte and cathode cell. Recipes were optimised for NMC622 cathode composite, graphite anode and hybrid solid electrolyte.Numerical models were developed to represent the thermal and electrical properties of a representative cell. Models were built and simulated in Modelica, considering two different concepts for pack cooling . Work is ongoing on designing a Battery Management System (to be emulated on the Test Rig) to include temperature and voltage sensing as well as battery management functionality.
WP8- Thermal Management Demonstration- data on expected thermal loads of equipment in future M2EA fuselage were collected. Thermal maps were created which were enriched with identified heat loads and simulated at cruise and hot day on ground scenarios. Test scenarios were derived that validated the aircraft level thermal modelling. Work is ongoing on the Virtual Reality model definition, integration of the validated thermal model and selection and testing of the most suitable demonstrator.
WP9- Smart Supervision Control- a suitable Electric Power Management system with hierarchically arranged supervisors was proposed. Innovative control methods such as Model Predictive Control and Smart Grid were defined to satisfy operational constraints and power requirements. Work is ongoing on developing a Smart Supervisor System (SSS) that can be run in real-time. Specifically, CAD design of the SSS has been carried out, a working equipment is currently available . The other aspect involves software design using model-based design to generate reliable codes, programmed and ready for integrative testing, which is ongoing. This will be enhanced with computer decision making techniques using Artificial Intelligence.
WP10-Validation and Integrative Testing- work is ongoing on developing models of the EPS TBBs in the ORCHESTRA Virtual Test Rig. Work is focussed on virtual integration of the developed TBBs and on demonstration performance and capability at higher power levels. Hardware In the Loop (HIL) testing will enable SSS to be tested individually using real-time machines hosting the simulation models of other TBBs l. This should enable SSS to be effectively pre-tested with preliminary validation of PM logics. Ongoing work is focussed on bringing all physical hardware developed into a Physical Test Rig at LDO VEL which will enable demonstration of key M2EA EPS functionalities. Subsequently, experimental results will be assessed to validate the scalable modular TBB approach.
WP3-Innovative M2EA Electrical Power Systems (EPS) – a two-stage network based optimisation framework was proposed for the EPS topology designed to reduce weight (but enables minimum power losses) by adopting the minimum number of components. Novel concepts of Integrated Convertor Component concept and de-centralised energy management architecture were proposed. Concepts were verified by case studies.
WP4-Electrical Power Distribution Technologies- innovative harness shielding designs have been developed which were included in the new IEEE P2855 standard. Teflon-PFA based composites filled with Graphine Nano Platelet were found to most effective at dissipating heat. Distribution boxes are been designed and are being tested to verify their functionality.
WP5- Optimised Electric Machines- the dual-rotor radial surface Permanent Magnet machine was deemed topology of choice, together with the use of direct-cooling technologies, high frequency windings and high temperature insulation. Thermal management technologies proposed involve a thermal oil (on each side of the generator) to cool stator windings. Work is ongoing on manufacture and development of effective control techniques and modularity concept.
WP6- Onboard Power Conversion- an innovative scalable Power Electronic (PE) module has been designed (a bi-directional convertor between the KVDC and HVDC bus) and the manufacturing process has begun. Additionally, a bi-directional convertor has been designed to operate between a HVDC and LVDC bus to satisfy multi-MW design requirements (although only plan to use as a unidirectional convertor). Manufacture is ongoing and the convertor is in the final testing stage at SKLE. A solution using inline pins heatsink has been proposed to optimise thermal management. A design for a demonstrator has been proposed to validate the multi-MW design with similar topology and control technologies. An AC/DC convertor to connect the generator to DC bus has been designed. Three modules of Active Neutral Point Clamped structure is proposed as the solution. Work is ongoing on optimised convertor controls.
WP7- Advanced Energy Storage- prototype Solid State Batteries have been designed and manufactured based on the development of a Hybrid Solid Electrolyte and cathode cell. Recipes were optimised for NMC622 cathode composite, graphite anode and hybrid solid electrolyte.Numerical models were developed to represent the thermal and electrical properties of a representative cell. Models were built and simulated in Modelica, considering two different concepts for pack cooling . Work is ongoing on designing a Battery Management System (to be emulated on the Test Rig) to include temperature and voltage sensing as well as battery management functionality.
WP8- Thermal Management Demonstration- data on expected thermal loads of equipment in future M2EA fuselage were collected. Thermal maps were created which were enriched with identified heat loads and simulated at cruise and hot day on ground scenarios. Test scenarios were derived that validated the aircraft level thermal modelling. Work is ongoing on the Virtual Reality model definition, integration of the validated thermal model and selection and testing of the most suitable demonstrator.
WP9- Smart Supervision Control- a suitable Electric Power Management system with hierarchically arranged supervisors was proposed. Innovative control methods such as Model Predictive Control and Smart Grid were defined to satisfy operational constraints and power requirements. Work is ongoing on developing a Smart Supervisor System (SSS) that can be run in real-time. Specifically, CAD design of the SSS has been carried out, a working equipment is currently available . The other aspect involves software design using model-based design to generate reliable codes, programmed and ready for integrative testing, which is ongoing. This will be enhanced with computer decision making techniques using Artificial Intelligence.
WP10-Validation and Integrative Testing- work is ongoing on developing models of the EPS TBBs in the ORCHESTRA Virtual Test Rig. Work is focussed on virtual integration of the developed TBBs and on demonstration performance and capability at higher power levels. Hardware In the Loop (HIL) testing will enable SSS to be tested individually using real-time machines hosting the simulation models of other TBBs l. This should enable SSS to be effectively pre-tested with preliminary validation of PM logics. Ongoing work is focussed on bringing all physical hardware developed into a Physical Test Rig at LDO VEL which will enable demonstration of key M2EA EPS functionalities. Subsequently, experimental results will be assessed to validate the scalable modular TBB approach.
WP3 - Develop mathematical methodologies to optimise the design of the electrical power system to minimise weight, improve efficiency, or to guarantee power availability.
WP4 – Develop a large spectrum characterization, non-destructive method for cables and harness shielding and definition of a communication protocol combining Orthogonal Frequency-Division Multiplexing (OFDM) and Tim Division Multiple Access (TDMA) with spread spectrum and multiple carriers.
WP5-Optimised Electric Machines-Development of topologies to achieve high power densities.
WP6 - Optimisation and choice of the power converter topology and semiconductor device selection for the target application and load requirements, going beyond the headline full load figures.
WP7 - Develop a first electrical and thermal numerical system model of the HER battery that considers advanced, energy dense Li-metal battery cell technology (AIT).
WP8 - Zonal modelling enables quick set up of a thermal aircraft model based on simple requirements such as number of passengers and flight duration. Such models allow an early prediction of future thermal loads enabling an aircraft level thermal management strategy to be developed (FhG).
WP9 – Develop a Smart Supervisory System to implement in real-time the energy management logics, considering also Artificial Intelligence for fine tuning of the energy management supervisors.
WP10 - Elaboration of the models developed by the previous WPs through the verification of the functionalities of them, including the aircraft thermal model.
WP4 – Develop a large spectrum characterization, non-destructive method for cables and harness shielding and definition of a communication protocol combining Orthogonal Frequency-Division Multiplexing (OFDM) and Tim Division Multiple Access (TDMA) with spread spectrum and multiple carriers.
WP5-Optimised Electric Machines-Development of topologies to achieve high power densities.
WP6 - Optimisation and choice of the power converter topology and semiconductor device selection for the target application and load requirements, going beyond the headline full load figures.
WP7 - Develop a first electrical and thermal numerical system model of the HER battery that considers advanced, energy dense Li-metal battery cell technology (AIT).
WP8 - Zonal modelling enables quick set up of a thermal aircraft model based on simple requirements such as number of passengers and flight duration. Such models allow an early prediction of future thermal loads enabling an aircraft level thermal management strategy to be developed (FhG).
WP9 – Develop a Smart Supervisory System to implement in real-time the energy management logics, considering also Artificial Intelligence for fine tuning of the energy management supervisors.
WP10 - Elaboration of the models developed by the previous WPs through the verification of the functionalities of them, including the aircraft thermal model.