Periodic Reporting for period 2 - HYPNOTIC (HYbridization via Parallelization based on NOvel Topologies for Innovative Converters)
Reporting period: 2021-09-01 to 2023-03-31
HYPNOTIC project relied on the extensive research, management and technical expertise of the Consortium, to achieve a substantial breakthrough in the field of aircraft electrical hybridization, requiring more HVDC power sources to be simultaneously active on a single electrical network. The accomplishment of the hybridization is strictly related to the ongoing More Electrical Aircraft (MEA) research activities. This initiative, which has major implications for the future aircraft design, eliminates much of the pneumatic and hydraulic fluid and power systems required in today's traditional heavy, maintenance-intensive systems, but increases the demand of electrical power onboard.
One of the most challenging technological problems faced by the aircraft related research is therefore the integration of tailored electronic conversion equipment, which shall be designed according to the very specific constraints that the current European aerospace industry is pursuing. An outstanding effort shall be made between all EU players to boost the technology development of new electronic conversion equipment, which shall increase the efficiency and reduce the weight of final equipment.
In this context, HYPNOTIC has been focused on the development of a set of DC/DC bidirectional converters, acting together as only one equipment. The HYPNOTIC converter is connected to HVDC network of the aircraft on one side, and to a HVDC battery on the other side, for providing paralleling of the HVDC battery on the main HVDC bus.
Specifically, the equipment composed by several DC/DC bidirectional converters (i.e. the “modules”) plus a Master, is able to reconfigure itself in terms of delivered power on the HVDC network as a consequence of load/source variations, or as a reaction to a fault. This feature is achieved by using droop control, which assure an optimal power sharing between the HVDC main generator(s) and the HVDC battery connected via the HYPNOTIC converter.
This modular architecture support the design of a scalable converter (30 to 60KW) which could be used to support the integration of new HVDC sources, even beyond the scope of the HYPNOTIC project itself. Moreover, modularity has been a key point to achieve the demanding targets of the project, related to high efficiency (>99%) and power density (higher than 25 kW/kg).
The scope of the project can be therefore summarized as the design and development of a modular bi-directional converter, composed by hardware and software acting together in order to achieve paralleling of additional DC sources in any HVDC network.
Main objectives of HYPNOTIC project included:
•Development of DC/DC converter cells with enhanced performances, including power density and reconfiguration capabilities - Achieved (WP3-WP4).
•Development of accurate simulation models, at both “behavioural” and “functional” levels, integrated with external environments for the aims of energy management functionalities verification - Achieved (WP2).
•Implementation of reliable control laws to allow the parallelization of several HVDC sources - Achieved (WP3-WP4)
•Demonstration of the operation of such converter inside any suitable HVDC network - Partially Achieved (WP4 – WP5 incomplete. Only demonstrated in Skylife Engineering facilities (emulating final test bench) and not in PROVEN Test Bench, Toulouse)
One of the most challenging technological problems faced by the aircraft related research is therefore the integration of tailored electronic conversion equipment, which shall be designed according to the very specific constraints that the current European aerospace industry is pursuing. An outstanding effort shall be made between all EU players to boost the technology development of new electronic conversion equipment, which shall increase the efficiency and reduce the weight of final equipment.
In this context, HYPNOTIC has been focused on the development of a set of DC/DC bidirectional converters, acting together as only one equipment. The HYPNOTIC converter is connected to HVDC network of the aircraft on one side, and to a HVDC battery on the other side, for providing paralleling of the HVDC battery on the main HVDC bus.
Specifically, the equipment composed by several DC/DC bidirectional converters (i.e. the “modules”) plus a Master, is able to reconfigure itself in terms of delivered power on the HVDC network as a consequence of load/source variations, or as a reaction to a fault. This feature is achieved by using droop control, which assure an optimal power sharing between the HVDC main generator(s) and the HVDC battery connected via the HYPNOTIC converter.
This modular architecture support the design of a scalable converter (30 to 60KW) which could be used to support the integration of new HVDC sources, even beyond the scope of the HYPNOTIC project itself. Moreover, modularity has been a key point to achieve the demanding targets of the project, related to high efficiency (>99%) and power density (higher than 25 kW/kg).
The scope of the project can be therefore summarized as the design and development of a modular bi-directional converter, composed by hardware and software acting together in order to achieve paralleling of additional DC sources in any HVDC network.
Main objectives of HYPNOTIC project included:
•Development of DC/DC converter cells with enhanced performances, including power density and reconfiguration capabilities - Achieved (WP3-WP4).
•Development of accurate simulation models, at both “behavioural” and “functional” levels, integrated with external environments for the aims of energy management functionalities verification - Achieved (WP2).
•Implementation of reliable control laws to allow the parallelization of several HVDC sources - Achieved (WP3-WP4)
•Demonstration of the operation of such converter inside any suitable HVDC network - Partially Achieved (WP4 – WP5 incomplete. Only demonstrated in Skylife Engineering facilities (emulating final test bench) and not in PROVEN Test Bench, Toulouse)
- WP1 PDR: Consortium members have completed all WP initially programmed task (Specification Review and Compliance Matrix, Topology Design, Components Selection/Design, FIltering and Thermal Solution Design, Preliminary HW and Preliminary SW Design) during this WP duration.
- WP2 MATLAB/Simulink Model: Leaded by UCAMP, in the WP, Behavioural and Functional Model of HBBCU have been created for MATLAB/SIMULINK. This models have been used to emulate the HBBCU response to the upcoming Tests. Also this models were used to autogenerate the FPGA Codes for Master Module State Machine.
-WP3 Critial Design Review: During this work package, the final design of the HBBCU were created, also the first Slave Module Mock-up. In order to close the final design, the consortium was focused in Electrical and Mechanical Interfaces, Voltage and Current control and Power Management Laws.
- WP4 Prototype Manufacturing: The consortium made significant progress, producing four Slave Modules (three for HBBCU installation, one spare) and the final Master Control Board (V3) installed in the HBBCU. The manufacturing process involved designing and testing filtering for the enclosure. Despite challenges, the full HBBCU prototype aided hardware/firmware integration. Due to demanding requirements, the prototype scope was scaled down to one Slave Module. WP4 concluded with the release of D4.1 - HBBCU Prototype.
- WP5 DC/DC Integration in Proven Test Bench Support: WP5's main task, integrating DC/DC in the Proven Test Bench, was hindered by the degraded performance of the final HBBCU. Consequently, the commissioning in the PROVEN Test Bench in Toulouse was canceled. Task 4.2 of HYPNOTIC was extended to replicate conditions in SKYLIFE premises for realistic testing. Results are in the D5.1 Integration Report.
Exploitation Results:
The HYPNOTIC consortium plans to leverage gained experience for various benefits. SKYLIFE focuses on increasing capabilities in DC/DC converter manufacturing, supporting Airbus, and elevating technologies' TRL. AEROMECHS enhances automatic code generation for aerospace power converters, UNICAMP advances knowledge on controllers, and IRT develops tools for optimal DC/DC converter selection. Results are compiled in the D6.4 Exploitation Report.
Dissemination Results:
A dedicated page/area on IRTSE, SKLE and AER public websites were set up and are maintained by each partners’ IT or communication departments. It explains the context, developments and ambitions of the project to our stakeholders and the general public. There is a list of dissemination activities collected in D6.3 Communication and Dissemination Report (Workshops, Direct Visit to Clients, Conference Exhibitions, Conference Attendance, journal Papers, Conference Papers, Industrial Events, etc)
- WP2 MATLAB/Simulink Model: Leaded by UCAMP, in the WP, Behavioural and Functional Model of HBBCU have been created for MATLAB/SIMULINK. This models have been used to emulate the HBBCU response to the upcoming Tests. Also this models were used to autogenerate the FPGA Codes for Master Module State Machine.
-WP3 Critial Design Review: During this work package, the final design of the HBBCU were created, also the first Slave Module Mock-up. In order to close the final design, the consortium was focused in Electrical and Mechanical Interfaces, Voltage and Current control and Power Management Laws.
- WP4 Prototype Manufacturing: The consortium made significant progress, producing four Slave Modules (three for HBBCU installation, one spare) and the final Master Control Board (V3) installed in the HBBCU. The manufacturing process involved designing and testing filtering for the enclosure. Despite challenges, the full HBBCU prototype aided hardware/firmware integration. Due to demanding requirements, the prototype scope was scaled down to one Slave Module. WP4 concluded with the release of D4.1 - HBBCU Prototype.
- WP5 DC/DC Integration in Proven Test Bench Support: WP5's main task, integrating DC/DC in the Proven Test Bench, was hindered by the degraded performance of the final HBBCU. Consequently, the commissioning in the PROVEN Test Bench in Toulouse was canceled. Task 4.2 of HYPNOTIC was extended to replicate conditions in SKYLIFE premises for realistic testing. Results are in the D5.1 Integration Report.
Exploitation Results:
The HYPNOTIC consortium plans to leverage gained experience for various benefits. SKYLIFE focuses on increasing capabilities in DC/DC converter manufacturing, supporting Airbus, and elevating technologies' TRL. AEROMECHS enhances automatic code generation for aerospace power converters, UNICAMP advances knowledge on controllers, and IRT develops tools for optimal DC/DC converter selection. Results are compiled in the D6.4 Exploitation Report.
Dissemination Results:
A dedicated page/area on IRTSE, SKLE and AER public websites were set up and are maintained by each partners’ IT or communication departments. It explains the context, developments and ambitions of the project to our stakeholders and the general public. There is a list of dissemination activities collected in D6.3 Communication and Dissemination Report (Workshops, Direct Visit to Clients, Conference Exhibitions, Conference Attendance, journal Papers, Conference Papers, Industrial Events, etc)
The HYPNOTIC project has contributed to the hybrid electric landscape by introducing an innovative power conversion device into the HVDC distribution architecture. The power converter developed in this project allows the use of an energy storage component such as a battery or a BoSC (Bank of SuperCapacitor) in parallel with a primary power source. The use of WBG semiconductors, together with state of the art control and modulation techniques, allows fine control of the current flow to/from the battery. As a result, the battery could be used as an energy reservoir to inject energy into the main HVDC distribution bus during peak demand, while slowly absorbing and storing energy during periods of lower demand.
This technological building block plays an important role on the road to aircraft electrification. It demonstrates the use of hybrid power sources in aviation, which could be applied to conventional electrical generators and an innovative power source such as H2 fuel cells. Potentially, the results of the project could be matured to a higher TRL within national clean aviation research programmes to develop an important voltage stability element in future aircraft power distribution networks.
This technological building block plays an important role on the road to aircraft electrification. It demonstrates the use of hybrid power sources in aviation, which could be applied to conventional electrical generators and an innovative power source such as H2 fuel cells. Potentially, the results of the project could be matured to a higher TRL within national clean aviation research programmes to develop an important voltage stability element in future aircraft power distribution networks.