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DEVILS (Development of Vhbr engines Innovative Lubrication System)

Periodic Reporting for period 4 - DEVILS (DEVILS (Development of Vhbr engines Innovative Lubrication System))

Reporting period: 2020-09-01 to 2021-05-31

Aircraft Engines usually comprise of a number of complementary systems that have to guarantee their performances throughout the whole flight envelope. Among those systems, the Oil lubrication system is one of the most important due to its roles:

• Remove the heat generated in the highly loaded rolling bearings and the gears found in the Engine power and accessory gearboxes;
• Lubricate bearing and Power and Accessory gear boxes.

The current trend of developing aircraft engines that consume less fuel put a lot of pressure on the oil lubrication system cooling requirements due to higher speeds, loads, and temperatures. For this reason Engine manufacturer are deeply looking to innovative design for oil lubrication system implementing architectures that are able to meet the new cooling and lubricating requirements without negatively impacting the Engine weight or operational and maintenance costs. The objective of DEVILS Project is to research, develop and validate the robustness of a new variable oil flow approach towards the design of an innovative variable flow oil pump to be integrated in a high performance aircraft lubrication systems architecture with the aim of reducing fuel and oil consumption.
DEVILS project has to fulfill four goals.

• Development of a model based systems engineering (MBSE) tool to aid the evaluation and selection of candidate VHBR system architectures.
• Development of methods and techniques required to achieve variable flows that allow oil feed and scavenge systems to be optimized around the flight envelope.
• Demonstration of a variable flow intelligent oil system and advanced control scheme showing how operation can be optimized across a range of simulated flight conditions.
• Research into autonomous fault detection and correction for future Oil Systems.
From the beginning of the project to the end of the period covered by the report tasks of WP 2 – Design activities – have been completed and tasks of WP 3 - Oil System Assembly - have been started and continued for all the project duration as also tasks of WP 1 – Project Management.

Project Coordination – completed
Dissemination and implementation activity – completed
Communication activity – completed
Consortium financial and administrative activity – completed

Requirements and architecture definition – completed (Inputs form Rolls Royce have been gathered and requirements for the innovative oil lubrication system and its components have been defined; a Requirements Document have been prepared).
Oil lubrication MBSE – completed (a Model Based System Engineering process/method has been established; a deliverable showing this method/process has been prepared).
Benefits of the variable oil flow pump- completed (1D and 3D CFD analysis have been carried out on the preliminary oil lubrication circuit and Pump geometry in order to assess the benefits of the variable oil flow. A Deliverable showing the analysis carried out has been prepared).
Variable oil flow pump design – completed (the preliminary and detailed design of the Oil Pump and the other major components of the circuit has been accomplished; CDR has been done and formally closed).
Heat exchange design - completed (the preliminary and detailed design of the Heat Exchange has been accomplished; CDR has been done and formally closed.
Electronic and Software Design - completed (the preliminary and detailed design of the Heat Exchange has been accomplished; CDR has been done and formally closed).
Fault detection and health monitoring algorithms - completed
Safety analysis - Completed. CDR has been done and formally closed.
Test rig design activities - completed. Design of the Test Rig has been completed and presented at the CDR.

All the Parts and Equipment for the demonstrator have been purchased
Oil Pump/Scavenge Manufacturing and Tuning Activities (Abete)
Numerical Tools has been updated based on the CDR conclusion.
Heat Exchanger has been manufactured
Electronic Control Unit has been manufactured.
Variable Oil Flow Pump has been manufactured.

Test Plan & Procedure have been defined.
Test Rig for final demonstrator has been manufactured.
Oil System Tests have been performed on the final project demonstrator.

Exploitation and dissemination:
Hereafter the list of stage/formation on the job carried out jointly by Abete S.r.l and University of Naples:
Development of an innovative variable flow-rate gerotor pump for i.c.e.: geometric modeling and 3d-cfd analysis of hypotrochoidal rotors.
Development of an innovative variable flow-rate gerotor pump for i.c.e.: 3d design, 1d simulation of the system characterization and doe optimization.
Development of an innovative variable flow-rate gerotor pump for i.c.e.: experimental analysis for system's dynamic characterization and its performances.
Communication Activities:
DEVILS projects objective, consortium and interim results have been presented by:
- University of Naples: 15th Scandinavian International Conference on Fluid Power – SICFP’17 Linköping University, Linköping, Sweden. - Presentation Title: "Development of an Innovative Variable Flow-Rate Gerotor Pump for Lubrication Circuit of I.C.E: Designing, Modelling and Testing"
- Abete S.r.l: AEROSPACE & DEFENSE Meetings Torino 2017

A section dedicated to DEVILS project has been created in PROTOM, CNR - Istituto Motori, Abete and Euro.sdft websites.
Also news have been disseminated through Social Media channels and newspaper.
The benefits of the DEVILS proposed variable displacement Gerotor pump have been evaluated by comparing them with those of a fixed geometry pump. The benefits can be summarized as follow:
Variable Flow Rate and Pressure with Fixed Pump Speed
Fixed Flow Rate and Pressure with Varia
Control of the Aeration/Cavitation phenomena by adjusting the flowrate of the pump.
Compensation of Viscosity Variation
Compensation of loss due to Components Wear
Compensation of loss due to physical
Reduction of torque adsorbed from the pump:
The reduction of the torque measured on pump shaft is of flowrate of 30%-35%.
Model Based System Engineering tool overview
Assembled Heat Exchanger
Pump + Scevenge 3D model
Assembled Variable Flow Oil Pump
Amesim 1D lubrication system model
Application of the MBSE to the pump
Assembled ECU