Periodic Reporting for period 2 - IMPERIAL (Innovative Modules for PowER conversIon on Aircraft pLatform)
Periodo di rendicontazione: 2022-07-01 al 2023-09-30
Main ambition of IMPERIAL project is to deliver breakthrough highly efficient and compact DC/DC and DC/AC converters, able to perform power transmission, monitoring, diagnosis and communications, exploiting the benefits of a full modular approach.
The system will be designed to be highly efficient, reliable, compact, light and cost effective, hence contributing towards higher performances, more efficient and greener future passenger aircraft.
IMPERIAL will deliver rackable modular converters, which is an advanced concept for aircraft electrical networks. The programme of research and technological innovation activities at PST, IRTSE and AER, paterns of the IMPERIAL project will lead to the creation of new knowledges such as:
• Advanced digital control of power converter
• Real time communication with health monitoring
• Novel optimised thermal design and implementation of novel materials
• High power density and efficient power electronic converters design
• Novel integrations of power electronics
The system will be designed to be highly efficient, reliable, compact, light and cost effective, hence contributing towards higher performances, more efficient and greener future passenger aircraft.
IMPERIAL will deliver rackable modular converters, which is an advanced concept for aircraft electrical networks. The programme of research and technological innovation activities at PST, IRTSE and AER, paterns of the IMPERIAL project will lead to the creation of new knowledges such as:
• Advanced digital control of power converter
• Real time communication with health monitoring
• Novel optimised thermal design and implementation of novel materials
• High power density and efficient power electronic converters design
• Novel integrations of power electronics
The period 1 has covered basically all definition stages for the converter 1 AC-DC including:
- definition with the TM of the specifications including technical request vs ABD standard
- mechnical , volume , estimation
- topologies definition
- functional simulation
- components characterization
1) Converter #1 (115VAC --> 540 VDC + 28 VDC)
It is composed by three different converters:
- Single phase PFC non isolated unidirectional AC/DC converter
- Non isolated unidirectional DC/DC converter
- Isolated unidirectional DC/DC converter
For each of these three converters, connected together to compose Converter #1 topology, preliminary architectural design, components selection and estimation of performances has been performed. Compliance Matrix has been filed to assure alignment with requirements required by TM. Moreover, MATLAB/Simulink simulations have been performed on a Converter #1 preliminary model, to verify specific details related to control aspects, as also required by TM. The full electrical schematic is done and layout of the pcb is in process.
The Period 2 July 22 to Sept 23 has covered the industrialization of the solution including:
- model definition
- electrical schematic definition for the power train
- electrical schematic definition for the control carrier board
- Layout of the differents boards with the CAD system
- mechanical drawings
- realisation of the software control
- Manufacturing the 2 converters
- Functional Testing of the solution
All the above stages have been covered up to the fonctional testings.
As this report is the final one, the achieved results is that we have a DAB secondary stage converter working properly either for the power train and control with regard to defined specification, in tem of efficiency and behavior.
The primary stage ( PFC) is working in term of hardware, verified by open loop validation but it is still not working properly in term of Digital control.
The exploitation and dissimation is detailed on the associated report but can be sumarized by having today the ability to develop a very high efficiency , inovative solution with the latest components technology, bridging a real gap for the embedded solutions. Future developments for each of the consortium companies will integrate part of the Imperial knowledges. This has been communicated to the avionic community through different events and supports to emphasize the benefit of these brand new technologies for such fuure applications.
- definition with the TM of the specifications including technical request vs ABD standard
- mechnical , volume , estimation
- topologies definition
- functional simulation
- components characterization
1) Converter #1 (115VAC --> 540 VDC + 28 VDC)
It is composed by three different converters:
- Single phase PFC non isolated unidirectional AC/DC converter
- Non isolated unidirectional DC/DC converter
- Isolated unidirectional DC/DC converter
For each of these three converters, connected together to compose Converter #1 topology, preliminary architectural design, components selection and estimation of performances has been performed. Compliance Matrix has been filed to assure alignment with requirements required by TM. Moreover, MATLAB/Simulink simulations have been performed on a Converter #1 preliminary model, to verify specific details related to control aspects, as also required by TM. The full electrical schematic is done and layout of the pcb is in process.
The Period 2 July 22 to Sept 23 has covered the industrialization of the solution including:
- model definition
- electrical schematic definition for the power train
- electrical schematic definition for the control carrier board
- Layout of the differents boards with the CAD system
- mechanical drawings
- realisation of the software control
- Manufacturing the 2 converters
- Functional Testing of the solution
All the above stages have been covered up to the fonctional testings.
As this report is the final one, the achieved results is that we have a DAB secondary stage converter working properly either for the power train and control with regard to defined specification, in tem of efficiency and behavior.
The primary stage ( PFC) is working in term of hardware, verified by open loop validation but it is still not working properly in term of Digital control.
The exploitation and dissimation is detailed on the associated report but can be sumarized by having today the ability to develop a very high efficiency , inovative solution with the latest components technology, bridging a real gap for the embedded solutions. Future developments for each of the consortium companies will integrate part of the Imperial knowledges. This has been communicated to the avionic community through different events and supports to emphasize the benefit of these brand new technologies for such fuure applications.
IMPERIAL will deliver both DC/DC and DC/AC electrical energy conversion converters. In the Clean Sky 2 Joint Technical Programme, the overall benefits expected from Systems ITD outputs are:
✓ Direct contributions to environmental objectives: optimised green trajectories, electrical taxiing, more electrical aircraft approach, and have a direct impact on CO2 emissions, fuel consumption, perceived noise, air quality, weight gain.
✓ Enablers for other innovations: for example, bleedless power generation, actuators, innovative power distribution systems are necessary steps for the implementation of innovative engines or new aircraft configurations.
✓ Enablers for air transport system optimization: many of the major improvements identified in SESAR, NextGen and Clean Sky for greening, improved mobility or ATS efficiency can only be reached through the development and the integration of on-board systems such as data link, advanced weather systems, trajectory negotiation, and flight management predictive capabilities.
✓ Smart answers to market demands: systems and equipment have to increase their intrinsic performance to meet new aircraft needs without a corresponding increase in weight and volume: kW/kg, flux/dm3 are key indicators of systems innovation; competitiveness is at stake.
More specifically, IMPERIAL will contribute to the delivery of ITD platform “Major loads from Systems” by providing a novel power electronic DC/AC & DC/DC converter from the HVDC power generation system. The power converters developed within this topic will demonstrate high-power density, high reliability and be able to work in a high-temperature environment.
IMPERIAL project will contribute to the achievement of the environmental targets (a 20-30% reduction in CO2, a 20-40% reduction in NOX and a up to 75% noise reduction in 2035) . The innovative IMPERIAL modules converters will enable high-voltage DC distribution with decentralized conversion. This innovative technology will significantly decrease the weight associated with power distribution, i.e. cabling AWG and weight associated with power conversion with a 5kW/kg ratio. The power electronic converter solutions proposed in IMPERIAL based on WBG devices will be more reliable compared to the conventional silicon solution, especially in harsh environment. The power conversion system will be able to convert more power with less consumption and improved reliability and maintainability (rackable modules). This means next generation aircraft will be operated with reduced Time Between Overhaul and less maintenance, more electrical power available for passenger services thus with less delay and more reliable scheduling enabling seamless mobility for passengers
✓ Direct contributions to environmental objectives: optimised green trajectories, electrical taxiing, more electrical aircraft approach, and have a direct impact on CO2 emissions, fuel consumption, perceived noise, air quality, weight gain.
✓ Enablers for other innovations: for example, bleedless power generation, actuators, innovative power distribution systems are necessary steps for the implementation of innovative engines or new aircraft configurations.
✓ Enablers for air transport system optimization: many of the major improvements identified in SESAR, NextGen and Clean Sky for greening, improved mobility or ATS efficiency can only be reached through the development and the integration of on-board systems such as data link, advanced weather systems, trajectory negotiation, and flight management predictive capabilities.
✓ Smart answers to market demands: systems and equipment have to increase their intrinsic performance to meet new aircraft needs without a corresponding increase in weight and volume: kW/kg, flux/dm3 are key indicators of systems innovation; competitiveness is at stake.
More specifically, IMPERIAL will contribute to the delivery of ITD platform “Major loads from Systems” by providing a novel power electronic DC/AC & DC/DC converter from the HVDC power generation system. The power converters developed within this topic will demonstrate high-power density, high reliability and be able to work in a high-temperature environment.
IMPERIAL project will contribute to the achievement of the environmental targets (a 20-30% reduction in CO2, a 20-40% reduction in NOX and a up to 75% noise reduction in 2035) . The innovative IMPERIAL modules converters will enable high-voltage DC distribution with decentralized conversion. This innovative technology will significantly decrease the weight associated with power distribution, i.e. cabling AWG and weight associated with power conversion with a 5kW/kg ratio. The power electronic converter solutions proposed in IMPERIAL based on WBG devices will be more reliable compared to the conventional silicon solution, especially in harsh environment. The power conversion system will be able to convert more power with less consumption and improved reliability and maintainability (rackable modules). This means next generation aircraft will be operated with reduced Time Between Overhaul and less maintenance, more electrical power available for passenger services thus with less delay and more reliable scheduling enabling seamless mobility for passengers