Periodic Reporting for period 2 - ENIGMA (Supervisor Control for ENhanced electrIcal enerGy MAnagement)
Periodo di rendicontazione: 2019-10-01 al 2021-12-31
Recent trends towards More-Electric Aircraft (MEA) in R&D programs show an increasing role and importance of electrically powered functions instead of traditionally hydraulic or pneumatic powered systems. This has resulted in an increased on-board power generation capacity, in some cases exceeding 1 MW in civil aircraft. Further and even more increases in airborne energy usage above the few MW is expected from the partial or full electrification of aircraft propulsion. The increased use of electric power can result in weight savings, however the potential for weight savings and efficiency improvement of onboard EPS can only be unlocked if we consider the triage of the weight–efficiency–power and their interactions. Previous projects have demonstrated the importance of the Advanced Electrical Power Generation & Distribution System (AEPGDS) including regenerative storage and more electrical actuators as loads. However, most of the R&D effort was limited to the design, monitoring and control of the subsystems of an aircraft smart-grid, meaning that good performances were achieved by looking at each subsystem. Enhanced Electrical Energy Management (E2-EM) strategies are essential in achieving the above vision. E2-EM is the advanced control of aircraft electrical loads and power sources that aims at reducing generator weight and size, while also increasing reliability, by reducing the overload capability requirements of on-board generators can lead to substantial weight savings.
ENIGMA has delivered an innovative, centralised smart supervisor (CSS) embedding enhanced electric energy management (E2-EM) strategies of Electrical Power Distribution Systems (EPDS). The CSS is based on advanced EPS control and optimization methods that provide optimal management and sharing of available on-board electric power during overloading and failure conditions such that the overload capability requirement for main generators sizing can be removed leading to substantial reduction of generators’ mass. Modelling and Simulation tools for designing and testing the CSS in MIL and HIL studies were also developed and used to validate controller performance and integration with REG IADP Iron-Bird demonstrator. In addition, semi-automatic firmware generation was used to ensure reliability and safety of the CSS code. Finally, ENIGMA manufactured and integrated the CSS controller hardware in the REG IADP Iron-Bird demonstrator where integration and validation tests were performed. ENIGMA's concept, based on advanced controls is a key element in demonstrating the benefits of E2-EM functionalities and hence enabling the next wave of technology integration for Regional Aircrafts.
ENIGMA has delivered an innovative, centralised smart supervisor (CSS) embedding enhanced electric energy management (E2-EM) strategies of Electrical Power Distribution Systems (EPDS). The CSS is based on advanced EPS control and optimization methods that provide optimal management and sharing of available on-board electric power during overloading and failure conditions such that the overload capability requirement for main generators sizing can be removed leading to substantial reduction of generators’ mass. Modelling and Simulation tools for designing and testing the CSS in MIL and HIL studies were also developed and used to validate controller performance and integration with REG IADP Iron-Bird demonstrator. In addition, semi-automatic firmware generation was used to ensure reliability and safety of the CSS code. Finally, ENIGMA manufactured and integrated the CSS controller hardware in the REG IADP Iron-Bird demonstrator where integration and validation tests were performed. ENIGMA's concept, based on advanced controls is a key element in demonstrating the benefits of E2-EM functionalities and hence enabling the next wave of technology integration for Regional Aircrafts.
The objective of ENIGMA is to develop and demonstrate a CSS controller implementing E2-EM strategies that ensure the optimal management and sharing of available on-board energy storage and regeneration system (ESRS) and smart-grid network (SGN) systems during overloading and failure conditions such that the overload capability requirement for main generators sizing can be removed, leading to substantial reduction of generator weight. A conceptual architecture and formal mathematical formulation were developed for the CSS controller for real-time on-board control, based on optimization that considers safety and reliability rules. Topic managers design requirements were incorporated to form the final controller logic. The controller’s consistency with the overall EPS architecture and requirements of the demonstrator was assessed in a Preliminary Design Review, which helped identify possible discrepancies in the definition and implementation of the CSS. The Consortium carried out a successful process of model integration involving the partners of other CfPs of the REG IADP that developed the ESRS, PLB and SGN to create a full simulation environment for the MIL assessment of energy management algorithms.
The CSS firmware was generated by establishing a model-based design approach that used controller and system models developed in ENIGMA and in other REG IADP projects; particularly automatic code generation was followed to create the CSS code for deployment on the ENIGMA controller board. Safety and reliability tests were performed for the code coverage and fitness assessment. A thorough Critical Design Review (CDR) was performed to realise the final detailed system design including detailed controller software and hardware design and implementation, integration and testing plan on the Iron-Bird platform. The CDR was a key milestone for the project and was used as the basis for the pre-integration MIL and HIL testing and final integration of the ENIGMA controller.
The controller was first validated in a MIL campaign on various load and fault use-cases covering the full operating envelope of the controller, completing an important step in the pre-integration test. The controller hardware was manufactured and assembled following MIL-STD-704F and European standards for electrical power installations. HIL demonstrations of the controller hardware were performed to validate the integration and communication of the ENIGMA controller with AEPGDS sybsystems. Following the MIL and HIL validations, the controller was delivered to Leonardo Aircraft Division’s Iron-Bird test facility for the final integration and AEPGDS demonstration. The ENIGMA consortium provided integration and system optimization support of the controller by leading the testing of the communication configuration and performance of the system components highlighting issues and defects, and proposing and implementing optimization solutions. These final tests confirmed the successful integration and validation of the ENIGMA technology to the Iron-Bird system.
The CSS firmware was generated by establishing a model-based design approach that used controller and system models developed in ENIGMA and in other REG IADP projects; particularly automatic code generation was followed to create the CSS code for deployment on the ENIGMA controller board. Safety and reliability tests were performed for the code coverage and fitness assessment. A thorough Critical Design Review (CDR) was performed to realise the final detailed system design including detailed controller software and hardware design and implementation, integration and testing plan on the Iron-Bird platform. The CDR was a key milestone for the project and was used as the basis for the pre-integration MIL and HIL testing and final integration of the ENIGMA controller.
The controller was first validated in a MIL campaign on various load and fault use-cases covering the full operating envelope of the controller, completing an important step in the pre-integration test. The controller hardware was manufactured and assembled following MIL-STD-704F and European standards for electrical power installations. HIL demonstrations of the controller hardware were performed to validate the integration and communication of the ENIGMA controller with AEPGDS sybsystems. Following the MIL and HIL validations, the controller was delivered to Leonardo Aircraft Division’s Iron-Bird test facility for the final integration and AEPGDS demonstration. The ENIGMA consortium provided integration and system optimization support of the controller by leading the testing of the communication configuration and performance of the system components highlighting issues and defects, and proposing and implementing optimization solutions. These final tests confirmed the successful integration and validation of the ENIGMA technology to the Iron-Bird system.
ENIGMA proposed a comprehensive method for model-based design and testing, to hardware engineering and demonstration, to ensure increased reliability, safety and availability of the developed technology:
- ENIGMA CSS control and E2-EM logic follows formal mathematical formulations that take into account dynamic performance of all aircraft loads and power source and system constraints, and can be expanded to include interfaces with other lower-level systems
- Semi-automatic firmware generation methods were used with reliability and safety analysis to reduce software error rates increasing resilience, safety and availability
- MiL and HiL prototyping methods for performance, functionality and network communication assessment for the CSS controller prior to integration and real-life demonstrations
- Development and assembly of CSS hardware equipment via a rigorous manufacturing process for practical implementation and system integration to the Regional A/C Iron Bird demonstrator
The ENIGMA CSS strategy is designed and tested to clear aircraft power overloads within a period of 5 sec (the so-called 5 sec capability) and eliminate the need for the 5 min capability of an onboard overload generator. This will allow for significant generator size and weight reductions of up to 15% and in extension of the overall electrical power and distribution system. By impacting the weight and the size of the electrical and power distribution systems, ENIGMA CSS will further impact aircraft performance and efficiency by reducing energy consumption and ensuring safe and reliable electrical power and distribution operation, thus contributing towards the achievement of more efficient and greener aviation.
- ENIGMA CSS control and E2-EM logic follows formal mathematical formulations that take into account dynamic performance of all aircraft loads and power source and system constraints, and can be expanded to include interfaces with other lower-level systems
- Semi-automatic firmware generation methods were used with reliability and safety analysis to reduce software error rates increasing resilience, safety and availability
- MiL and HiL prototyping methods for performance, functionality and network communication assessment for the CSS controller prior to integration and real-life demonstrations
- Development and assembly of CSS hardware equipment via a rigorous manufacturing process for practical implementation and system integration to the Regional A/C Iron Bird demonstrator
The ENIGMA CSS strategy is designed and tested to clear aircraft power overloads within a period of 5 sec (the so-called 5 sec capability) and eliminate the need for the 5 min capability of an onboard overload generator. This will allow for significant generator size and weight reductions of up to 15% and in extension of the overall electrical power and distribution system. By impacting the weight and the size of the electrical and power distribution systems, ENIGMA CSS will further impact aircraft performance and efficiency by reducing energy consumption and ensuring safe and reliable electrical power and distribution operation, thus contributing towards the achievement of more efficient and greener aviation.