Periodic Reporting for period 3 - ROTATOR (Electro-mechanical magnetic blade pitch control)
Reporting period: 2022-12-01 to 2024-01-31
Open-rotor aero-engines offer an alternative configuration to conventional high-bypass gas turbine engines, They offer significant CO2 reductions, and for an industry producing over 600 million tonnes of CO2 yearly, adopting this engine could save 180 million tonnes/year - a huge leap for the aviation industry and for the protection of our planet. Open rotor engines can also be configured to operate with future bio-fuels to remove fossil fuels entirely from flight.
The engine requires accurate control of the angle of the engine blades, and it is this area of control that requires the greatest attention in order to realise the potential fuel savings. Current hydraulic systems transfer fluid to the rotating actuator components in order to control the blade angle, requiring high-maintenance dynamic seals with potential for leakages.
The key areas of innovation in this project centre around the development of a fault tolerant electro-mechanical pitch control mechanism utilizing an ultra-high torque density magnetically geared motor. The system is designed to be fault tolerant (it will remain in operation even after a number of systems failing) from the rotating electrical power transfer device through to the mechanical actuator.
Innovative lightweighting technology has delivered a significant weight saving for the motor and actuator components, with this TRL4 demonstrator only 15% over the target mass.
A full-size actuator has been built and tested and a number of components and sub-assemblies of the actuator have been vibration tested and tested at high rotational speed to de-risk novel components and electronics.
The full-sized Pitch Control Mechanism developed in the project has demonstrated that the technical performance specification has been met
The engine requires accurate control of the angle of the engine blades, and it is this area of control that requires the greatest attention in order to realise the potential fuel savings. Current hydraulic systems transfer fluid to the rotating actuator components in order to control the blade angle, requiring high-maintenance dynamic seals with potential for leakages.
The key areas of innovation in this project centre around the development of a fault tolerant electro-mechanical pitch control mechanism utilizing an ultra-high torque density magnetically geared motor. The system is designed to be fault tolerant (it will remain in operation even after a number of systems failing) from the rotating electrical power transfer device through to the mechanical actuator.
Innovative lightweighting technology has delivered a significant weight saving for the motor and actuator components, with this TRL4 demonstrator only 15% over the target mass.
A full-size actuator has been built and tested and a number of components and sub-assemblies of the actuator have been vibration tested and tested at high rotational speed to de-risk novel components and electronics.
The full-sized Pitch Control Mechanism developed in the project has demonstrated that the technical performance specification has been met
A large number of concepts were considered, including mechanical actuation methods without a screw. Detailed analysis, modelling and simulation tasks have been undertaken to determine whether the PCM system meets the specification in terms of mass, size, dynamic performance, fault tolerance etc. within the challenging operating environment.
Key developments include fault tolerant electric drives, rotating electrical power transfer device, magnetically geared motor and development of lightweight mechanical actuation components.
The fault tolerant electrical drive uses silicon carbide technology to reduce losses and allow high operating temperatures. The fault tolerant, rotating, contactless power transfer uses high frequency methods of electromagnetic power transfer. Complex models and hardware have been built and tested.
A digital twin (a method of using a computer model to predict behaviour and lifetime of physical systems) has been created to support the design of the actuator. The digital twin is based on commercially available software that will be exploited through commercial sales..
The unique environment is challenging for designers, as the electronics must work at high rotational speed and the high forces generated need to be controlled to prevent damage.
An ultra-lightweight magnetically geared motor has been designed, built and tested and shows good performance. Both metallic and composite parts have been the subject of significant research efforts in order to provide a lightweight and reliable PCM.
The developed components have been tested under high vibration conditions to aerospace test standards.
A full-scale rotating PCM has been designed, manufactured. The novel PCM cwas tested on a bespoke test-rig designed to replicate the rotating environment of an open-rotor engine. Comparisons have been made between measured and predicted results. The PCM was tested over the most challenging parts of the duty cycle of the engine and the results show that the electro-mechanical magnetic PCM is capable of meeting the performance requirements of the open rotor engine with a total mass only 17% higher than the target. With further developments of the technologies, further mass saving is possible and the target is capable of being met.
The full impact of the project will be realised through further development, with application to new aircraft engines predicted to save 180 million tonnes of CO2 per year.
Project results have been disseminated in leading international conferences (IEEE) and through institutional publications and magazines all available through open access sites.
Key developments include fault tolerant electric drives, rotating electrical power transfer device, magnetically geared motor and development of lightweight mechanical actuation components.
The fault tolerant electrical drive uses silicon carbide technology to reduce losses and allow high operating temperatures. The fault tolerant, rotating, contactless power transfer uses high frequency methods of electromagnetic power transfer. Complex models and hardware have been built and tested.
A digital twin (a method of using a computer model to predict behaviour and lifetime of physical systems) has been created to support the design of the actuator. The digital twin is based on commercially available software that will be exploited through commercial sales..
The unique environment is challenging for designers, as the electronics must work at high rotational speed and the high forces generated need to be controlled to prevent damage.
An ultra-lightweight magnetically geared motor has been designed, built and tested and shows good performance. Both metallic and composite parts have been the subject of significant research efforts in order to provide a lightweight and reliable PCM.
The developed components have been tested under high vibration conditions to aerospace test standards.
A full-scale rotating PCM has been designed, manufactured. The novel PCM cwas tested on a bespoke test-rig designed to replicate the rotating environment of an open-rotor engine. Comparisons have been made between measured and predicted results. The PCM was tested over the most challenging parts of the duty cycle of the engine and the results show that the electro-mechanical magnetic PCM is capable of meeting the performance requirements of the open rotor engine with a total mass only 17% higher than the target. With further developments of the technologies, further mass saving is possible and the target is capable of being met.
The full impact of the project will be realised through further development, with application to new aircraft engines predicted to save 180 million tonnes of CO2 per year.
Project results have been disseminated in leading international conferences (IEEE) and through institutional publications and magazines all available through open access sites.
Current hydraulic pitch control systems transfer fluid to the rotating actuator components in order to control the blade angle, requiring high maintenance with potential for leakages. This project seeks to entirely remove hydraulics from the PCM through the introduction of a magnetically geared drivetrain, extensively lightweighted mechanical systems and non-contact rotating electrical power transfer.
Research into magnetically geared motors (PDDs) and comparison with permanent magnet motors has shown that the PDD has a significantly higher torque density, resulting in a lighter and smaller machine. Test results show good agreement with predictions.
Novel methods of construction of the PDD motor have been studied to enable a robust but lightweight design.
Novel methods of providing mechanical fault tolerance in the case of a jammed nut/screw have been investigated.
Mechanical simulation models of the full PCM system have allowed designs to be pushed harder which results in further weight reduction.
Hybrid braided composite/metallic parts, additive manufacturing and investment casting of complex geometries have resulted in significant mass reduction. Significant developments have been made in fibre placement research.
Novel lightweight, fault tolerant, high frequency rotating control power electronics and rotating transformers have been designed, built and tested, showing good performance.
Modelling and environmental testing of the electronics at high-speed with components exposed to over 1000g has been successfully completed.
A digital twin has been created of the PCM that is able to predict lifetime of the various component parts when subjected to the high force and temperature cycles.
The project has delivered a full-scale PCM with novel sub-assemblies tested on a rotating test rig. A fully electric PCM will help deliver the goals of the Open Rotor Engine which will transform the aircraft industry in terms of CO2 and NOx reduction. Specifically, it could save 180 million tonnes of CO2 per year - a huge leap for the aviation industry and for the protection of our planet.
The project was also designed to promote job creation and diversity within the European Union, foster new ideas and intellectual property and develop technologies that will have a wider impact outside the aerospace industry. This approach will promote the technology developed within ROTATOR in driving further reduction in CO2 in other sectors.
Research into magnetically geared motors (PDDs) and comparison with permanent magnet motors has shown that the PDD has a significantly higher torque density, resulting in a lighter and smaller machine. Test results show good agreement with predictions.
Novel methods of construction of the PDD motor have been studied to enable a robust but lightweight design.
Novel methods of providing mechanical fault tolerance in the case of a jammed nut/screw have been investigated.
Mechanical simulation models of the full PCM system have allowed designs to be pushed harder which results in further weight reduction.
Hybrid braided composite/metallic parts, additive manufacturing and investment casting of complex geometries have resulted in significant mass reduction. Significant developments have been made in fibre placement research.
Novel lightweight, fault tolerant, high frequency rotating control power electronics and rotating transformers have been designed, built and tested, showing good performance.
Modelling and environmental testing of the electronics at high-speed with components exposed to over 1000g has been successfully completed.
A digital twin has been created of the PCM that is able to predict lifetime of the various component parts when subjected to the high force and temperature cycles.
The project has delivered a full-scale PCM with novel sub-assemblies tested on a rotating test rig. A fully electric PCM will help deliver the goals of the Open Rotor Engine which will transform the aircraft industry in terms of CO2 and NOx reduction. Specifically, it could save 180 million tonnes of CO2 per year - a huge leap for the aviation industry and for the protection of our planet.
The project was also designed to promote job creation and diversity within the European Union, foster new ideas and intellectual property and develop technologies that will have a wider impact outside the aerospace industry. This approach will promote the technology developed within ROTATOR in driving further reduction in CO2 in other sectors.