In the beginning of the project, the system concept of the aircraft electric compressor system was determined after a broad trade-off analysis of architectures and reviews with experts from Leonardo Helicopters, the Topic Manager for ELECTRA. Subsequently, the concept was advanced into a preliminary design using extensive system simulations in MATLAB and in SimScape, and the design was optimised specifically for the target aircraft application using a multi-parameter optimisation platform for electric compressors, yielding optimal weight, power consumption and outlet temperature rise. After the preliminary design review, the design was matured into a detailed design of the complete aircraft electric compressor pack, suitable for flight test. After the critical design review by the team together with Leonardo Helicopters, manufacturing of the components started, yielding the engineering model of the cabin air compressor pack (see photo), the dedicated test rig and all associated documentation including test planning. Testing started after a test readiness review of the engineering model. Goal of the engineering testing was the discovery of any functional deviations from the requirements and any performance shortcomings so that they could be fixed in the subsequent design iteration for the flight model. Testing included pre-compliance testing of environmental effects. Through testing, the necessary modifications were identified, designed and then reviewed at the critical design review for the flight model. The agreed modifications were manufactured and implemented on the compressor packs, converting them to qualification / flight models. Readiness for testing was reviewed at the test readiness review for the qualification model.
The project results, consisting of detailed insight into aircraft compressed air applications, advanced pack models and hardware design, valuable information from performance and qualification testing, allow further development of this technology towards commercial products: cabin air compressor packs for conventional aircraft as originally foreseen in the project scope, and also cabin air compressor packs for new aircraft with electric motors which inherently do not provide bleed air. In addition, the packs can be redesigned for compressed air delivery to fuel cells used for aircraft propulsion.
The pack has been on display at the Farnborough Air Show 2022 and the Paris Air Show 2023.
