Periodic Reporting for period 2 - FloCoS (Development and Manufacturing of a Smart AFC Drive and Control System)
Reporting period: 2018-08-01 to 2020-06-30
The project FloCoS will focus on an integrated flow control actuator driving system considering the specific requirements of piezoelectrically driven Synthetic Jet Actuators. The solution will not only provide smart, but also efficient power amplifier system. State-of-the-art power recovery technologies will be used to minimize the needed power for driving the piezoelectric elements. In addition, the ability to highly integrate and miniaturize the electronic module for fluidic AFC actuators will be evaluated. The final output of this project is a powerful and easy to control power supply system, that can be used for flow control actuator evaluation as well as wind tunnel testing of a large number of actuators.
In the frame of FloCoS, a rack integrated (and therefore mobile) high voltage power supply system was designed, manufactured and tested. The hardware was delivered to the partners and will be used for further investigation of flow control actuators and techniques. Due to the high-power density and the relatively high necessary currents in piezo actuated flow control actuators, the use of miniaturize electronic modules was not expedient. The new architecture was developed and manufactured using specialized and concerted COTS components. With the new system, it is now possible to drive a high number of scale one flow control actuators in parallel in order to perform scale one wind tunnel tests for active flow control.
For the fluidic actuator (ZNMF) system, drive and control hardware and software system was specified in the requirements working assumption document. This includes the power and performance requirements as well as the power supply and also interfaces and space constraints. Based on these specifications, an overall system design was developed and discussed. The system comprises actuators (piezoelectric), sensors, HV supply, data processing units (DPU) and wires. The main outcome of WP 2 is the functional design, that was completed for the amplifier board, MCU board, and electronic rack backplane board. Block diagrams were made to define the structure between all the functions.
In WP3, the system architecture was defined and the main components of the HV power supply system were designed. This included the definition of an updated overall system concept including the different parts of the system: HV-IC and PCB, U/ I-Monitoring system, I/O-System, HV-Supply system. The overall system concept was influenced by the design of the several subcomponents, which are developed with the different tasks in WP2 and 3. Therefore the work packages were carried out in parallel. Based on the overall system definition and also based on the specific requirements for the drives and control system, a block diagram was developed to define the overall signals routing between the electronics boards of the rack. In addition, the communication concept as well as the general GUI for the control software was designed. Based on these general concepts, the drive and control software for the high voltage supply system was developed. The communication is based on TCP/IP in order to ensure the ability to drive the system over higher distanced, e.g. in large scale wind tunnel facilities.
In WP4, the HW component purchasing and the HW assembly was performed. This includes the manufacturing and pre-test of the single components of the system (HV-IC and PCB, U/ I-Monitoring system, I/O-System, HV-Supply system) as well as the assembly of the components to the full system integrated in an rack-mounted and actively cooled housing.
In the testing WP (WP5), first measurement conducted by the CS LPA partners were analysed in order to support the activities in WP1 and WP2. After the final delivery of the HW was fully tested with dummy capacitances as well as real AFC HW.
In parallel to all the technical work packages, the management WP was carried out. The activities were the monitoring and communication within the consortium as well as the communication with the CS JU as well as the TM. In addition, reporting and dissemination and exploitation activities were carried out. Especially the challenging situation during COVID19 and its effect, made a confident management necessary.