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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - ACHIEVE (Advanced mechatronics devices for a novel turboprop Electric starter-generator and health monitoring system)

Teaser

Summary

The aim of ACHIEVE is to develop an innovative mechatronic system that is able to perform motoring, generating, power transmission, diagnosis and communications. The system will be efficient, reliable, compact and lighter and hence contributing towards higher performance, more efficient and greener turboprops.

The specific objectives are:
o To identify the system design specifications and requirements in terms of torque-speed performance, reliability and power density with the aim of developing an innovative mechatronic device for power system management;
o To perform a set of trade-off studies and conceptual designs in order to identify the best combination of electrical machines, power electronic converters and power management control to achieve maximum power density and optimized performance of the mechatronic device;
o To design and develop a novel electrical machine (structure/topology), with high robustness and mechanical strength, that can be easily integrated and manufactured. The machine will be developed with innovative magnetic, electrical, mechanical and thermal materials to achieve the highest efficiency, reliability and mechanical strength while minimising the overall cost, size, weight and cooling effort;
o To develop and design a novel and integrated power electronics converter considering emerging semiconductor devices such as SiC and GaN and innovative thermal technologies with smart heat management in order to increase cooling performance and reduce power losses. The design will focus on improved controllability, reliability, reduction of dv/dt and minimisation of size and weight;
o To design an innovative and integrated cooling loop for the mechatronic device with efficient and intelligent thermal management with focus on minimisation of system weight and size;
o To develop an intelligent and advanced control algorithm to optimise the overall system performance. This will allow the mechatronic system to achieve maximum torque per amp operation, maximum efficiency, fault tolerant operation, semiconductor devices and machine winding health monitoring and diagnosis, system protection. An innovative power management strategy will also be developed to reduce overloading and mechanical stress on engine gearbox;
o To manufacture at least two integrated mechatronic devices aiming for TRL5/TRL6 level. The developed system prototype will be tested in the UNOTT laboratories initially to validate the design and then will be delivered, integrated and tested within the Turbomeca engine;
o To perform extensive functional and environmental tests of the mechatronic system. The functional tests will include motoring, generation, power transmission, diagnosis and health monitoring, electromagnetic conduction as well as mechanical vibration, noise and heat generations;
o To develop functional and behavioural dynamic models of the power electronics converter, electrical machine and their interface with the mechatronic system to support the system design. The developed dynamic models will also be used to provide the ability to design and tune engine control laws in the future. The models will be developed in the Simulink environment with the capability to be interfaced with other well-known simulation software such as Saber, MagNet etc.;

This project is important for reducing aircraft emissions during the taxi phase of flight as the resultant operation from the ACHIEVE motor-generator will ultimately reduce reliance on jet fuel during this phase of a flight mission.

Work performed

Until review 1, the requirements for the ACHIEVE system and its integration into an aircraft engine design have been elicited and processed by the research teams at UNOTT, PST and NEMA to deliver an innovative power electornic and electrical motor that can fit into the limited space within the specified engine and deliver the perofrmance required to operate as a motor during the taxi pahse of an aircraft mission, and as a generator during flight.

Final results

Progress beyond the state of the art is based around the following outcomes:
Multiple functionalities Compared with the state-of-the-art conventional brushed 28V dc generator, the developed mechatronic system within this project will be brushless and with more functions including generator, motor, power transmission, diagnosis and signal communication.

Advanced electrical machine design Flexible multi-domain sizing tool for novel electrical machine types and topologies able to output a range of solutions reflecting the trade-offs between weight, volume, efficiency and reliability. The tool can be conveniently interfaced with overall system models to ensure optimization at system level

Development of high-power density and fault tolerant electrical machines Permanent-magnet, induction, switched reluctance or flux reluctance machine will be considered. Different topologies (magnetic systems, novel materials) will be used for improved mechanical integrity, torque density, thermal management and fault tolerance.

High efficient and compact power electronic converters Optimised electronic converter design will be studied during ACHIEVE to ensure integrated design and increased power density. Emerging switching devices for power conversion (such as SiC and GaN) and advanced packaging technologies for high temperature devices will be considered during ACHIEVE to ensure reliability requirements.

Advanced thermal management A range of thermal management technologies will be considered including air cooling, oil spray cooling for the machine rotor, liquid cooling suing ducts in the machine stator and power electronics cooling using cooling plate with appropriate liquid. Advanced materials will be used to improve conduction heat transfer and reduce weight. Optimised design of the cooling passage will allow maximum heat transfer.

Optimised integrated system Through integrated simulation between Finite-Element Machine models and controlled electronic converters. The system developed during ACHIEVE will enable optimised system design to achieve maximum power density, minimum weight and volume of the developed mechatronic system.

Dynamic models The development of the ACHIEVE mechatronic system will be supported by intensive modelling effort using multi-level modelling techniques. As part of the project, a set of new models with different complexity/ accuracy level will be delivered.

The current state of the project is progressing well towards achieving these.