Periodic Reporting for period 2 - IDEN (Innovative Distributed Electrical Network)
Berichtszeitraum: 2019-11-01 bis 2021-11-30
With the advent of high fuel prices, the global warming problem and high operating costs there is a marked trend within the aerospace industry to move towards cleaner, more efficient and lower maintenance aircraft design.
One of the prime movers in this arena is the substantial electrification of the aircraft to replace hydraulic or pneumatic functions with electrical ones, as in the concepts of the More Electric Aircraft (MEA) and of the All-Electric Aircraft (AEA).
Dependent on aircraft size the electrical power requirements range from a few kW up to 800kW for the A380 and 1400kW for the B787. To manage the required higher power ratings in a feasible way, innovative Primary and Secondary Electrical Distribution Network architectures investigated over recent years include intelligent/smart power management systems, the presence of at least one high-voltage dc bus (HVDC, typically 270Vdc or +/-270Vdc) plus a low-voltage dc bus (LVDC, 28Vdc). The LVDC bus is typically generated through bi-directional power converters to interconnect and manage power transfer between the two bus levels, also enabling the addition of energy storage devices, such as batteries, super-capacitors or fuel-cells.
This innovative electrical power distribution network (EPDS) is part of a highly decentralized, modular and flexible, smart-grid, EPDS equipped with enhanced electrical energy management functionalities in order to reduce or even delete the overload capabilities of the main generators thus saving weight and reducing fuel consumption.
Another key objective of the innovative electrical power distribution network is safe and reliable distribution and protection of the electrical generation system and user equipment; with a focus on smart load management (E2-EM), system efficiency, weight reduction, improvement of modularity and reduction of the maintenance costs: better fuel usage will result in lower operational costs and better performances thus justifying the adoption of the innovative power distribution system for the Regional A/C and creating market opportunities for the European industry in face of emerging competitors in line with Clean Sky objectives.
IDEN project delivers an innovative solid-state electrical power distribution system representative of the future Regional A/C. IDEN sub-systems and components provide the backbone of the Regional A/C Iron Bird test rig: through IDEN it is now possible to convert the AC power source into a regulated +270Vdc to be distributed to the connected users through innovative primary and secondary power centres based on solid-state power controllers (SSPC).
Onboard each IDEN sub-system a dedicated controller allows the integration with the A/C CAN network thus actively supporting the implementation of innovative and flexible E2-EM strategies.
One of the prime movers in this arena is the substantial electrification of the aircraft to replace hydraulic or pneumatic functions with electrical ones, as in the concepts of the More Electric Aircraft (MEA) and of the All-Electric Aircraft (AEA).
Dependent on aircraft size the electrical power requirements range from a few kW up to 800kW for the A380 and 1400kW for the B787. To manage the required higher power ratings in a feasible way, innovative Primary and Secondary Electrical Distribution Network architectures investigated over recent years include intelligent/smart power management systems, the presence of at least one high-voltage dc bus (HVDC, typically 270Vdc or +/-270Vdc) plus a low-voltage dc bus (LVDC, 28Vdc). The LVDC bus is typically generated through bi-directional power converters to interconnect and manage power transfer between the two bus levels, also enabling the addition of energy storage devices, such as batteries, super-capacitors or fuel-cells.
This innovative electrical power distribution network (EPDS) is part of a highly decentralized, modular and flexible, smart-grid, EPDS equipped with enhanced electrical energy management functionalities in order to reduce or even delete the overload capabilities of the main generators thus saving weight and reducing fuel consumption.
Another key objective of the innovative electrical power distribution network is safe and reliable distribution and protection of the electrical generation system and user equipment; with a focus on smart load management (E2-EM), system efficiency, weight reduction, improvement of modularity and reduction of the maintenance costs: better fuel usage will result in lower operational costs and better performances thus justifying the adoption of the innovative power distribution system for the Regional A/C and creating market opportunities for the European industry in face of emerging competitors in line with Clean Sky objectives.
IDEN project delivers an innovative solid-state electrical power distribution system representative of the future Regional A/C. IDEN sub-systems and components provide the backbone of the Regional A/C Iron Bird test rig: through IDEN it is now possible to convert the AC power source into a regulated +270Vdc to be distributed to the connected users through innovative primary and secondary power centres based on solid-state power controllers (SSPC).
Onboard each IDEN sub-system a dedicated controller allows the integration with the A/C CAN network thus actively supporting the implementation of innovative and flexible E2-EM strategies.
Moving from the review of the high-level requirements and the assessment of installation and safety constraints, IDEN Partners have developed the architecture of IDEN system and sub-systems and derived the system and equipment requirements.
Thanks to the project reviews, the design data were reviewed and confirmed. In particular at PDR (Preliminary Design Review) the equipment requirements have been checked on consistency with the preliminary design and approved afterwards. The system and sub-systems architecture was defined according to performance, energy management and safety requirements. Design choices were validated while functional blocks were preliminarily sized and interface was in the meanwhile defined.
During the detailed design review (CDR) the electrical, mechanical and thermal design data and system / sub-system drawings were cleared up for production (detailed CAD drawings, energy management controls, supervision, etc.)
Following the successful completion of the CDR, the IDEN sub-systems were then manufactured: AC/DC converters, HV-PPC (HV primary power centre), LV-PPC (LV primary power centre) and SDUs (secondary power distribution units).
Unfortunately, this project phase was severely hit by the Covid-19 pandemic and consecutive lock-outs in all European Countries. An updated planning of the project was developed by the Partners and the TM to react to the pandemic effects at the conclusion of the epidemic.
The integration and commissioning of IDEN into the Iron Bird has represented and meant the successful conclusion of the project.
Project Management ran smoothly during the project. Although the dissemination and communication activities have been affected by the Covid-19 pandemic, the project contents and achievements have been spread out through social media, on-line publications, inclusion in our Partners’ presentation files. A relevant Poster was presented at the International Air-shows at Le Bourget in Paris 2019 and in UK Farnborough 2022.
Thanks to the project reviews, the design data were reviewed and confirmed. In particular at PDR (Preliminary Design Review) the equipment requirements have been checked on consistency with the preliminary design and approved afterwards. The system and sub-systems architecture was defined according to performance, energy management and safety requirements. Design choices were validated while functional blocks were preliminarily sized and interface was in the meanwhile defined.
During the detailed design review (CDR) the electrical, mechanical and thermal design data and system / sub-system drawings were cleared up for production (detailed CAD drawings, energy management controls, supervision, etc.)
Following the successful completion of the CDR, the IDEN sub-systems were then manufactured: AC/DC converters, HV-PPC (HV primary power centre), LV-PPC (LV primary power centre) and SDUs (secondary power distribution units).
Unfortunately, this project phase was severely hit by the Covid-19 pandemic and consecutive lock-outs in all European Countries. An updated planning of the project was developed by the Partners and the TM to react to the pandemic effects at the conclusion of the epidemic.
The integration and commissioning of IDEN into the Iron Bird has represented and meant the successful conclusion of the project.
Project Management ran smoothly during the project. Although the dissemination and communication activities have been affected by the Covid-19 pandemic, the project contents and achievements have been spread out through social media, on-line publications, inclusion in our Partners’ presentation files. A relevant Poster was presented at the International Air-shows at Le Bourget in Paris 2019 and in UK Farnborough 2022.
In the past years, several research and development programmes have initiated the concept of the More Electric Aircraft and All Electric Aircraft. In the H2020 framework several programmes are studying improved converters with higher power density, improved thermal solutions, advanced energy management and advanced power grids to increase the technology maturity in these areas.
The IDEN project has solved serious challenges to support the application of these concepts and developments to the integrated multi-systems Iron Bird of the regional aircraft:
• Management of highly decentralized smart grid, multiple power inputs multiple loads: this required extensive data processing and exchange between a number of different equipments. Every IDEN sub-system houses state-of-the-art processors, implements internal built-in testing, receives macro-commands and provides detailed telemetry data thus enabling real time monitoring of the system and predictive maintenance. The IDEN system provides more than 100 status words and receives more than 50 command words on the system communication bus.
• Use of solid-state technology (SSPC) for the contactors and circuit breakers included in both primary and secondary network. To provide an indication, it is highlighted that the IDEN system employs more than 120 low-voltage SSPC to manage the 28Vdc power grid and more than 70 high-voltage SSPC for the same function on the 270Vdc power grid.
• Weight optimization: the implementation of the power grid management structure would have required at least four times the mass achieved using electromechanical devices rather than state-of-the-art SSPCs.
By addressing the above challenges, the IDEN project has made a key contribution to technological advances beyond the state of the art of on-board power distribution systems providing the smart grid backbone for the regional aircraft.
The medium-term ambition embodied in the program is to develop IDEN equipment for use on board the regional aircraft contributing to sustainable mobility through safe, accessible and affordable regional air transport in Europe.
The IDEN project contributes to respect for the environment and the competitiveness objectives of Clean Sky 2 technology, demonstrating the potential for efficiency, reliability and availability of the innovative EPDS architecture.
The IDEN project has solved serious challenges to support the application of these concepts and developments to the integrated multi-systems Iron Bird of the regional aircraft:
• Management of highly decentralized smart grid, multiple power inputs multiple loads: this required extensive data processing and exchange between a number of different equipments. Every IDEN sub-system houses state-of-the-art processors, implements internal built-in testing, receives macro-commands and provides detailed telemetry data thus enabling real time monitoring of the system and predictive maintenance. The IDEN system provides more than 100 status words and receives more than 50 command words on the system communication bus.
• Use of solid-state technology (SSPC) for the contactors and circuit breakers included in both primary and secondary network. To provide an indication, it is highlighted that the IDEN system employs more than 120 low-voltage SSPC to manage the 28Vdc power grid and more than 70 high-voltage SSPC for the same function on the 270Vdc power grid.
• Weight optimization: the implementation of the power grid management structure would have required at least four times the mass achieved using electromechanical devices rather than state-of-the-art SSPCs.
By addressing the above challenges, the IDEN project has made a key contribution to technological advances beyond the state of the art of on-board power distribution systems providing the smart grid backbone for the regional aircraft.
The medium-term ambition embodied in the program is to develop IDEN equipment for use on board the regional aircraft contributing to sustainable mobility through safe, accessible and affordable regional air transport in Europe.
The IDEN project contributes to respect for the environment and the competitiveness objectives of Clean Sky 2 technology, demonstrating the potential for efficiency, reliability and availability of the innovative EPDS architecture.