Periodic Reporting for period 2 - IMITAES (Insulation monitoring for IT Aerospace Electrical Systems)
Berichtszeitraum: 2022-07-01 bis 2023-06-30
Current large passenger aircrafts use low voltage (below 1kVac rms or 1.5kVdc) distribution systems to transmit a relatively modest amount of power (below 1MW) for use in aircraft subsystems such as cabin conditioning and actuation. The existing power distribution systems often use the metallic airframe as the earthing system.
In the future, all electric aircrafts will need higher voltages to meet the increased needs for higher efficiency and power density.
With an increase in the predicted demand for high voltage electrical power in large passenger aircraft and other more electric aircraft concepts, new electrical distribution systems will be required to enable safe, light, highly efficient electrical propulsion systems.
To make electric or hybrid propulsion systems feasible, greater electrical power transmission at high voltage will be required. These higher voltage, however, create additional stresses to the electrical insulation of cables, electrical machines and components.
Monitoring the state of health of the insulation and detecting faults becomes crucial in safety critical systems such as aircrafts' power systems.
High power electrical systems in high reliability applications often utilise IT (Isolation Terra) earthing. IT earthing brings known advantages of fault current management and continued operation post fault. It also brings the challenge of correctly determining when an insulation fault has occurred, allowing the system to safely reconfigure or shutdown.
Despite their importance, insulation monitoring technologies have not been tested, proven, optimised and made commercially available for aerospace applications.
IMITAES has designed, optimised and increased the Technology Manufacturing level of innovative insulation monitoring systems specifically based on the requirements of the aerospace sector.
In the future, all electric aircrafts will need higher voltages to meet the increased needs for higher efficiency and power density.
With an increase in the predicted demand for high voltage electrical power in large passenger aircraft and other more electric aircraft concepts, new electrical distribution systems will be required to enable safe, light, highly efficient electrical propulsion systems.
To make electric or hybrid propulsion systems feasible, greater electrical power transmission at high voltage will be required. These higher voltage, however, create additional stresses to the electrical insulation of cables, electrical machines and components.
Monitoring the state of health of the insulation and detecting faults becomes crucial in safety critical systems such as aircrafts' power systems.
High power electrical systems in high reliability applications often utilise IT (Isolation Terra) earthing. IT earthing brings known advantages of fault current management and continued operation post fault. It also brings the challenge of correctly determining when an insulation fault has occurred, allowing the system to safely reconfigure or shutdown.
Despite their importance, insulation monitoring technologies have not been tested, proven, optimised and made commercially available for aerospace applications.
IMITAES has designed, optimised and increased the Technology Manufacturing level of innovative insulation monitoring systems specifically based on the requirements of the aerospace sector.
IMITAES has established the specifications and completed a gap analysis to understand the requirements of the sector and evaluate the state-of-the art at the beginning of the project. A list of over 80 requirements to be considered for the development of the Insulation Monitoring Device (IMD) was compiled following extensive discussions between the partners and the Topic Manager, Rolls Royce.
IMITAES has developed a simulation framework for the analysis of the aircraft power system and insulation monitoring devices: A gap analysis has been conducted to identify any potential gap between requirements and functionalities already implemented in Bender IMD equipment. A detailed investigation and understanding of aerospace standards and applications has been completed. The simulations models developed has guided the development of the IMD and has also resulted in a black-box that can be provided to other potential users for testing and sizing.
IMITAES has conducted extensive simulations including several fault scenarios with detailed simulations of a representative electrical network and IMDs. Analyses of various fault conditions, multichannel tests, and test of the IMD in a representative aircraft system have been conducted. Multiple measurement techniques have been tested in different conditions to identify possible options for the implementation on the IMD prototype.
A multi-channel test rig emulating an aircraft power distribution channel with starter-generator and motor drives has been constructed for the purpose of testing the developed IMD. Functionalities have been developed for testing multiple operating scenarios and multiple faults conditions.
The developed IMDs have been designed and manufactured at Bender and tested extensively. Detailed environmental tests have been conducted including thermal, vibration, EMC, compliance with relevant standards etc. Detailed functional tests have been completed including tests to evaluate accuracy and fault detection capabilities in multiple operating scenarios.
IMITAES has developed a simulation framework for the analysis of the aircraft power system and insulation monitoring devices: A gap analysis has been conducted to identify any potential gap between requirements and functionalities already implemented in Bender IMD equipment. A detailed investigation and understanding of aerospace standards and applications has been completed. The simulations models developed has guided the development of the IMD and has also resulted in a black-box that can be provided to other potential users for testing and sizing.
IMITAES has conducted extensive simulations including several fault scenarios with detailed simulations of a representative electrical network and IMDs. Analyses of various fault conditions, multichannel tests, and test of the IMD in a representative aircraft system have been conducted. Multiple measurement techniques have been tested in different conditions to identify possible options for the implementation on the IMD prototype.
A multi-channel test rig emulating an aircraft power distribution channel with starter-generator and motor drives has been constructed for the purpose of testing the developed IMD. Functionalities have been developed for testing multiple operating scenarios and multiple faults conditions.
The developed IMDs have been designed and manufactured at Bender and tested extensively. Detailed environmental tests have been conducted including thermal, vibration, EMC, compliance with relevant standards etc. Detailed functional tests have been completed including tests to evaluate accuracy and fault detection capabilities in multiple operating scenarios.
IMITAES has identified gaps in the current product design, testing methodologies and modelling that make them not yet suitable for applications in aircraft power systems.
IMITAES has developed novel simulation models that will aid future design of insulation monitoring for aircraft applications.
Bender has now made significant improvements to their IMD products that will help fill the gaps identified and will provide the basis for the first IMD specifically designed for the aerospace sector.
The University of Sheffield has significantly expanded its capabilities and knowledge in the field of high reliability aircraft power systems.
IMITAES has demonstrated the first IMD specifically designed for the aircraft sector and validate its use in operating conditions typical of aircraft applications. The IMD will enable the use of high voltage IT power systems on-board which, in turn, will result in significant improvement in efficiency and reliability of future aircrafts. The project will benefit the European industry directly by enabling Bender to access a new market with potential significant growth. The European aerospace industry will also indirectly benefit through improved practices and an enabling product.
IMITAES has also enabled the partners to access several opportunities for communication and dissemination, helping to demonstrate the benefit of IT systems and IMD to the wider aerospace community. The participation to standardization committes will be particularly useful to embedd the technologies into future more electric aircrafts.
IMITAES has developed novel simulation models that will aid future design of insulation monitoring for aircraft applications.
Bender has now made significant improvements to their IMD products that will help fill the gaps identified and will provide the basis for the first IMD specifically designed for the aerospace sector.
The University of Sheffield has significantly expanded its capabilities and knowledge in the field of high reliability aircraft power systems.
IMITAES has demonstrated the first IMD specifically designed for the aircraft sector and validate its use in operating conditions typical of aircraft applications. The IMD will enable the use of high voltage IT power systems on-board which, in turn, will result in significant improvement in efficiency and reliability of future aircrafts. The project will benefit the European industry directly by enabling Bender to access a new market with potential significant growth. The European aerospace industry will also indirectly benefit through improved practices and an enabling product.
IMITAES has also enabled the partners to access several opportunities for communication and dissemination, helping to demonstrate the benefit of IT systems and IMD to the wider aerospace community. The participation to standardization committes will be particularly useful to embedd the technologies into future more electric aircrafts.