Efficient and environmentally friendly aircraft engine (EEFAE)

ANTLE project result is the integration and the demonstration of the distributed and electrically controlled lubrication system for which design rules have been produced in the former ATOS project. The main parts of this result are: electric motors, pumps, sensors, power electronics and control electronics The result details are: Control system This first integration of electrically driven pumps mechanically independent of the NHP speed resulted in the: - Design from scratch and the demonstration of an alarm strategy in order to protect the different engine components. A hierarchy of the failures, the associated damages and reconfiguration strategies was defined. - Design and the validation of a control strategy of the engine parameters for each engine condition. The control of the bearings generated heat flow, of the housing outlet temperature and of the housing has been demonstrated. Open loop (based on a model) and closed loop (based on engine measurements) control strategies have been successfully demonstrated. - Design and the validation of the integration of the oil system controller as a node on a distributed architecture bus. - Electric motors that were designed built and validated in a environment representative of a production engine. According to the different parts of the engine, different strategies were developed for cooling (oil or air wrt the temperature) and bracketing (damping or stiffening wrt vibration and temperature).

The results are usable for further development of small engines incorporating centrifugal compressors. Measured data and following analysis have been used for correcting of the design method (developed for centrifugal compressor stage and used at WALTER ENGINES a.s.) to obtain more accurate results, primarily for the impellers with higher angle of backswept vanes at the outlet. Significant experience with system of compressor mass flow control operating as a part of gas generator especially water injection in front of the combustion chamber has been gained during the test and it has brought in addition a new knowledge of small engines gas generator thermodynamical behaviour. Design of gas generator as a test device for compressor testing proved design possibilities and difficulties of similar arrangement especially from the dynamic behaviour of complicated rotor system point of view.

The ability to control the thermal environment to which a system is exposed can greatly enhance the performance and reliability of that system. The concept of "peak lopping" to remove both high and low temperature excursions reduces the thermal stress on components and has been demonstrated to be effective for aerospace applications. Within the down hole instrument market this has been used to operate tools at greater temperatures and for longer deployment periods. It is this technology that has been fed back into the aerospace application to improve the on-engine performance of the electronics systems through custom thermal packaging. A patent application has been made. This packaging has been further adapted to address the needs of the solar panel market where peak daytime temperatures greatly reduce the efficiency of the panels. A patent application has been made.

The potential benefits that the engine new technologies could deliver to the whole aircraft user community (i.e. engine manufacturer, aircraft manufacturer, airline, and passenger) and to the EC citizen is investigated. ANTLE and CLEAN vehicles benefit are evaluated for a typical aircraft mission through the following steps: - definition of the reference aircraft, a 200 seats long range twin engines based on the 2010 expected technology level; - definition of the reference engine, sized for the reference aircraft, based on 1990�s technology level. This reference engine will be used together with the reference aircraft to define the reference installed performance for technology evaluation; - definition of engine models, sized for the reference aircraft, representative of ANTLE technology and the two steps of CLEAN technology (i.e. geared turbofan and a geared turbofan with intercooled recuperator); - optimisation of the aircraft equipped with ANTLE and one CLEAN vehicle in order to take maximum advantage of engine new technologies. Evaluation of the ANTLE and the two CLEAN vehicles benefits on overall aircraft performance and economics with respect to the reference aircraft. ANTLE optimised Aircraft shows 11.1% reduction of Fuel consumption & CO2 @ 4000nm mission, Cash Operating Cost reduction of 4% and Direct Operating Costs reduction of 2.3% with respect to the EEFAE reference aircraft. CLEAN1 GTF optimised Aircraft shows 10% reduction of Fuel consumption & CO2 @ 4000nm mission, Cash Operating Cost reduction of 5.4% and Direct Operating Costs reduction of 3.1% with respect to the EEFAE reference aircraft. CLEAN2 IRA non-optimised Aircraft shows 15.8% reduction of Fuel consumption & CO2 @ 4000nm mission with respect to the EEFAE reference aircraft.

Eldim successfully manufactured a New Design of LPT Interstage Seal in accordance with the OEM requirements. A leading OEM has now adopted a hybrid of the conventional and New Design on a new production engine. Eldim will consider performing further Manufacturing trials on an Interstage Seal based entirely on a sheet metal configuration.

The novel turbine rear frame structure technologies using advanced manufacturing technologies have developed tools around simulation of the manufacturing processes. Today analytical tools as finite element and computational fluid dynamics are extensively used in the design of all types of components. The development of a similar set of tools for the manufacturing processes will in the future allow the control of the effect of manufacturing aspects The development of manufacturing simulation tools in WP 1.6 have focused on weld simulation tools in the design process and the development have been performed in partnership with the university of Lulea allowing the distribution of knowledge to other areas. The tool used have allowed simulation of a full weld sequence of a complex fabrication and helps answer questions like, what is the optimal design to minimize deformation due to welding and what welding sequence should be applied. The application of these tools on a real component has been essential to establish criteria for efficient use of this kind of tools. The application of the weld simulation in the development process is applicable to all types of process development of welding not only within the aeronautical industrial.

In order to fulfil the requirements of the ANTLE test, INTA has developed and funded a Data Acquisition System that has been successfully used in the test of the ANTLE. Software, of modular construction and easy handling, has been developed to capture, registry, display test data in real time and process different signal applications. The unlimited capacity registry systems have recorded in a evaluation test up to 6,000 parameters by continued periods of 6 hours, at a rate of 200 samples per second. Above 6 different modes of registry have also been built, each registry mode can be triggered by databases and operated in manual and automatic way. A system of 32 analogical outputs, based on digital capture of parameters, has been developed. The analogical outputs are isolated among them and can be refreshed at a rate of 20 samples per second and channel. The system is modular and equipped with an algorithm to find the average of and filter the signals at different rates of sampling. It is also able to integrate the outputs to non-referenced systems among them. For the diagnosis of the temperature measurement system of thermocouples by blocks of cold or hot reference joints, a remote control system has been developed to detect the opened circuits of thermocouples. This system is based on the coexistence of the thermocouple temperature measurement system with other alternative systems to read the signal of the reference blocks. A system has been developed to collect data from different digital sources. This system transfers massive quantity of bytes by reflective memory and draws up maps of great amounts of information in microseconds to provide output data in real time. This technological development is mounted in platform to standard platform of Windows to migrate data to any other technological field of measurement. A system has been finally developed to capture bandwidth dynamic signals up to 50 Khz. During the ANTLE test, the requirements have been determined to develop a new system to capture, registry and display test data in real time and process dynamic signals.

Eldim fulfilled the design criteria by specifying a relatively new Honeycomb material FeCrAlY(MI2100-sole proprietary usage rights of the Eldim/Sulzer Metco Division) which offers improved High Temperature Oxidation Resistance than other products currently available. This honeycomb material is also to be trailed on LPT Outer Air Seals by two other OEM's. Work is on going within the Sulzer Metco Group and a leading UK University to optimise the choice of filler material for use in brazing MI2100. In addition the hot forming techniques needed to process ODS (Oxide Dispersion Strenghtened) sheet materials for seal applications will be further investigated.

The air riding carbon seal is an advanced, extremely tight design of seal. ANTLE project resulted in the demonstration performance by the integration of two air riding carbon seals on a bearing housing. The detail result is: - Demonstration of the air riding seal performance - No wear - No leak (even under negative delta pressure) - Extremely low air consumption (one order of magnitude lower than the existing technology of labyrinth seals) - Integration of the air riding carbon seals in an unvented compartment - Demonstration of the performance under a production engine representative environment - Design rules for the management of a tight unvented housing (impact of the scavenge pump speed on the housing pressure).

ANTLE project result is a validated tool and procedure to build and calibrate a model of a lubrication system. This tool is able to model the steady-state behaviour of the parameters (temperature, pressure, flow, air/oil ratio) of a complex oil circuit like the ANTLE one. ANTLE oil circuit is a complex system due to the lubrication under bearings inherited from the T500 3 shafts engine, and to the ANTLE specificity (spitted oil pumping system and slave cooler). In order to have a representative model, complex phenomena have been taken into account (churning, windage).

Exploitable results

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