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DEVILS (Development of Vhbr engines Innovative Lubrication System)

Periodic Reporting for period 3 - DEVILS (DEVILS (Development of Vhbr engines Innovative Lubrication System))

Reporting period: 2019-06-01 to 2020-08-31

Aircraft Engines usually comprise of a number of complementary systems that have to guarantee their performances throughout the whole flight envelope. Among those systems, the Oil lubrication system is one of the most important due to its roles:

• Remove the heat generated in the highly loaded rolling bearings and the gears found in the Engine power and accessory gearboxes;
• Lubricate bearing and Power and Accessory gear boxes.

The current trend of developing aircraft engines that consume less fuel put a lot of pressure on the oil lubrication system cooling requirements due to higher speeds, loads, and temperatures. For this reason Engine manufacturer are deeply looking to innovative design for oil lubrication system implementing architectures that are able to meet the new cooling and lubricating requirements without negatively impacting the Engine weight or operational and maintenance costs. The objective of DEVILS Project is to research, develop and validate the robustness of a new variable oil flow approach towards the design of an innovative variable flow oil pump to be integrated in a high performance aircraft lubrication systems architecture with the aim of reducing fuel and oil consumption.
DEVILS project has to fulfill four goals.

• Development of a model based systems engineering (MBSE) tool to aid the evaluation and selection of candidate VHBR system architectures.
• Development of methods and techniques required to achieve variable flows that will allow oil feed and scavenge systems to be optimized around the flight envelope.
• Demonstration of a variable flow intelligent oil system and advanced control scheme showing how operation can be optimized across a range of simulated flight conditions.
• Research into autonomous fault detection and correction for future Oil Systems.
"From the beginning of the project to the end of the period covered by the report tasks of WP 2 – Design activities – have been completed and tasks of WP 3 - Oil System Assembly - have been started and will continue in the next reporting period as also tasks of WP 1 – Project Management. Hereunder a detailed list of the tasks with the status.

WP1:
Project Coordination – ongoing (deadline: end of the project)
Dissemination and implementation activity – ongoing (deadline: end of the project)
Communication activity – ongoing (deadline: end of the project)
Consortium financial and administrative activity – ongoing (deadline: end of the project)

WP2:
Requirements and architecture definition – completed (Inputs form Rolls Royce have been gathered and requirements for the innovative oil lubrication system and its components have been defined; a Requirements Document have been prepared).
Oil lubrication MBSE – completed (a Model Based System Engineering process/method has been established; a deliverable showing this method/process has been prepared))
Benefits of the variable oil flow pump- completed (1D and 3D CFD analysis have been carried out on the preliminary oil lubrication circuit and Pump geometry in order to assess the benefits of the variable oil flow. A Deliverable showing the analysis carried out has been prepared)
Variable oil flow pump design – completed (the preliminary and detailed design of the Oil Pump and the other major components of the circuit has been accomplished; CDR has been done even and formally closed.
Heat exchange design - completed (the preliminary and detailed design of the Heat Exchange has been accomplished; CDR has been done even and formally closed.
Electronic and Software Design - completed (the preliminary and detailed design of the Heat Exchange has been accomplished; CDR has been done even and formally closed.
Fault detection and health monitoring algorithms - completed
Safety analysis - Completed. CDR has been done even and formally closed.
Test rig design activities - completed. Design of the Test Rig has been completed and presented at the CDR.

WP3:
During the third reporting period started tasks of WP3

Parts & off-the shelf Equipment Purchasing - ongoing (deadline date 31/12/2020) - some parts and components necessary for the final demonstrator test rig have not yet been received, but will be received by the end of the 2020.
Oil Pump/Scavenge Manufacturing Activities- completed. the Variable Flow Oil Pump has been manufactured and Assembled. Preliminary test on the pump started to be then installed on the final test rig for final testing.
Heat Exchange Manufacturing Activities - completed - Heat Exchanger to be installed don the final demonstrator test rig has been manufactured and ready to be installed don the final test rig.
Electronic Control Unit Assembly - completed - ECU has been manufactured and preliminary testing with pump integration started.
Oil Lubrication & Heat Management System Prototype Assembly for Testing- ongoing (due date 15/01/2021)

On April 2018 the DEVILS consortium achieved the PDR milestone – the Preliminary Design Review: freezing of the oil lubrication system architecture and geometry of the variable flow rate pump.
on June 2019 it has been done the CDR meeting with the Topic Manager and all design evidence and deliverable have been provided, CDR Milestone has been formally accepted on September 2019.

Exploitation and dissemination:
Hereafter the list of stage/formation on the job carried out jointly by Abete S.r.l and University of Naplels (name of the students involved and title of the thesis are listed):
DEVELOPMENT OF AN INNOVATIVE VARIABLE FLOW-RATE GEROTOR PUMP FOR I.C.E.: GEOMETRIC MODELING AND 3D-CFD ANALYSIS OF HYPOTROCHOIDAL ROTORS.
DEVELOPMENT OF AN INNOVATIVE VARIABLE FLOW-RATE GEROTOR PUMP FOR I.C.E.: 3D DESIGN, 1D SIMULATION OF THE SYSTEM CHARACTERIZATION AND DOE OPTIMIZATION.
DEVELOPMENT OF AN INNOVATIVE VARIABLE FLOW-RATE GEROTOR PUMP FOR I.C.E.: EXPERIMENTAL ANALYSIS FOR SYSTEM'S DYNAMIC CHARACTERIZATION AND ITS PERFORMANCES.

Communication Activities:
DEVILS projects objective, consortium and interim results have been presented by:
University of Naples at
- 15th Scandinavian International Conference on Fluid Power – SICFP’17 Linköping University, Linköping, Sweden. - Presentation Title: ""Development of an Innovative Variable Flow-Rate Gerotor Pump for Lubrication Circuit of I.C.E: Designing, Modelling and Testing""
Abete S.r.l at
- AEROSPACE & DEFENSE Meetings Torino 2017
A section dedicated to DEVILS project has been created in PROTOM, CNR - Istituto Motori, Abete and Euro.sdft websites (url can be found in the Technical report attached to this reporting period.
Also news have been disseminated through Social Media channels and news paper has is better detailed in the Technical Report attached to this reporting period."
The benefits of the Innovative DEVILS Variable Oil Flow Pump are listed below.
• Adjustment of Circuit Pressure
• Variable Flow Rate and Pressure with Fixed Pump Speed
• Fixed Flow Rate and Pressure with Variable Pump Speed
• Compensation of Viscosity Variation
• Compensation of loss due to Components Wear
• Compensation of loss due to physical-chemical properties of the oil
So, a variable flow control can improve the efficiency of the overall oil lubrication circuit of a turbofan. In fact, the capability of the system to adapt itself independently from the pump speed allows different strategies to optimize and control the complete lubrication circuit according to the engine request and with respect of the temperature limits.
Model Based System Engineering tool overview
Assembled Heat Exchanger
Pump + Scevenge 3D model
Assembled Variable Flow Oil Pump
Amesim 1D lubrication system model
Application of the MBSE to the pump
Assembled ECU