Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - AMPS (Aircraft Modular Power Converter Solutions)

Teaser

Issues being addressedWith the overall objective to reduce CO2 emissions for aviation and the reduction of the overall costs of building, operating, and maintaining aircraft, one of the key enablers towards this objective, is the adoption of higher levels of electrification on...

Summary

Issues being addressed
With the overall objective to reduce CO2 emissions for aviation and the reduction of the overall costs of building, operating, and maintaining aircraft, one of the key enablers towards this objective, is the adoption of higher levels of electrification on aircraft. This higher level of electrification, more commonly known as More Electric Aircraft (MEA), looks at replacing traditional non electrical systems with lighter and more efficient electrical alternatives.

As a consequence of this progression towards MEA, there is an increasing requirement for power conversion methods in the power distribution network, which provide high density, and higher levels of efficiency. In addition, the push towards standardization of components, avoiding bespoke designs for each new application, means that any solutions which are module based will be preferred. Traditionally, the only viable solution for power conversion requirements was to use passive solutions with transformers and controlled rectifiers, such as TRU and ATRU units, which results in a heavy and inefficient power conversion system. By replacing the passive system with active power conversion, the weight and power density of each power conversion stage can be significantly reduced, thus leading to the overall goal to reduce system weight and costs.

benefits

The introduction of standard modular power systems in generation and distribution applications, will yield a number of benefits for airframe manufacturers, around lower cost solutions, improved reliability and lower weight. The reduction in weight will have a direct impact on fuel consumption providing direct financial benefits to the airliner as well as additional resulting environmental benefits. The cost reductions from reduced maintenance and overall system costs will assist in reducing the overall costs of air travel with the subsequent societal benefits.

Objectives

The objectives of the AMPS project is to demonstrate the use of integrated hybrid power modules in the design of aircraft power converters. The project aims to show that by using a standardized power module for various converter topologies, how this will give numerous benefits, including higher power density, lower cost, and higher reliability. The first part of the project entails the design and manufacture of a family of power modules which will form the building blocks for two different power converter types which can be used in commercial aircraft power distribution applications.

The second part of the project is the demonstration of the use of one of these power module types, developed in the first part of the project. This module will be used as the principle building block for a matrix contactor converter. This demonstrator will show the benefits of the modular approach, including small size, higher efficiency and ease of integration into the power distribution system.

Work performed

Work Package 1 Program Management
Task 1.1 – Project Management Activities
This task is currently on-going and no issues have been found. Communication with the Topic manager is clear and fluid.
Task 1.2 – Dissemination & Implementation Activities
The communication, dissemination and exploitation plan was submitted in June 2019 as deliverable D1.3
Task 1.3 – Communication Activities
Project team and communication matrix has been setup between project coordinators, Microchip, the Topic manager, Thales, and the CSJU.
Task 1.4 – Administrative & Financial Activities
This task will coordinate all the administrative activities between Microchip and the Topic Manager and CSJU.
Microchip have appointed person to coordinate this activity

WP 1 Deliverables and Milestones summary
D9 - Implementation Agreement. A signed implementation agreement between the Topic Manager and the Lead Beneficiary. - complete.
D1.1 : Report on the signature of the Consortia Agreements - complete.
D1.2 : Data Management Plan – Due project + 24m
Publication of data relating to specific findings and results from the design, manufacture and test of the matrix converter demonstrator.0
D1.3 : Plan for Communication, Dissemination and Exploitation of project results – complete
This plan is currently awaiting approval by the CSJU.
D1.4 : Report on Communication, Dissemination and Exploitation actions – Due project + 24m
MS1 Kick-Off Meeting 1 - MSC 1 Kick-off Meeting dates and results – complete

Work Package 2 Power module Design & Manufacture
Task 2.1- Trade-off Study
Completed as of June 2019 and part of deliverable D2.1
Task 2.2 – Preliminary Design Analysis
This task was completed over the period from December 2018 to end of January 2019, PDR was held Jan 2019.
Task 2.3 – Detailed Design
This task was completed in May 2019. with Critical Design Review (CDR) on June 20th. No issues were noted.
Task 2.4 – Module Prototype Manufacturing - scheduled completion by September 2019
The task has already started with the procurement of all material to complete the prototype build of the modules.
Task 2.5–Module Qualification - Scheduled October 2019
For this task deliverable D2.2,test plan, has been completed and approved by the Topic manager as of July 2019.

WP 2 Deliverables and Milestones
D2.1 : Specifications and report on reasoned trade-off study results – complete Submitted July 2019
D2.2 : Design report and final qualification test plan. - complete Submitted July 2019
D2.3 : Final qualification test report – Scheduled for completion February 2020
MS2 Preliminary Design Review – Completed 2/2/2019
MS3 Critical Design Review – Completed 20/6/2019
MS4 Test Readiness Review – Scheduled July 2019
MS5 Qualification Review – Scheduled February 2020
MS6 Power modules prototypes – Scheduled September 2019

Work Package 4 Matrix Contactor Demonstrator
Task 4.1 – HVDC contact matrix demonstrator design report
Requirement reviews have taken place with the topic manager from January 2019 to May 2019. It is expected that by August 2019 a full design review will be carried out.
A thermal modelling of the proposed contact matrix heatsink design has been carried out.
Task 4.2 – HVDC contact matrix demonstrator validation report
To date the Thermal and electrical modelling is ongoing has been carried out and the current design has been shown to comply with the Topic managers requirement. Due November 2019
Task 4.3- Matrix Contactor Prototype Manufacture
Following from the detail design the schedule for PCB subassemblies will be completed by October 2019.
Task 4.4– Design and Construct AC/AC Test Bench
Procurement of specific test bench items is currently underway and on Schedule.
Task 4.5 – Contactor Test and Design Validation
This task will utilize the test bench to run a range of tests on the matrix contactor to validate the design concept.

WP4 Deliverables and Milestones summary
D4.1 : HVDC contact

Final results

Currently there are no baseless power modules qualified to aerospace standards available in the market place. We will expect to build and demonstrate the modules as part of a switch matrix and show how the benefits of decreased size and weight and increased efficiency. The expected impact will be reduced weight, cost and efficiency for aircraft electrical distribution systems.

Website & more info

More info: http://www.microchip.com.