Progress in Motion Air Management. Actuation and Flight Control. Landing Gear. www.liebherr.com

Power Optimised AircraftA keystone in European research in More Electric Aircraft Equipment Systems

Aerodays 2006 Vienna, 20 June 2006

Lester Faleiro, PhD, MIEE Liebherr Aerospace

Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006DO-06-T-F&T 0601 / 20.6.2006 1

ContentsWhat are Aircraft Equipment Systems (AES)? Lessons learned so far in POA The way forward in AES research

GlossaryAES Aircraft Equipment Systems MEA More Electrical Aircraft POA Power Optimised Aircraft

Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006DO-06-T-F&T 0601 / 20.6.2006 2

What are Aircraft Equipment Systems (AES)? Systems required to ensure safe and comfortable flight

Primary Controls Secondary Controls

Primary Controls APU

Commercial Loads Electrical Distribution

Engine systems

Central Hydraulics Environmental Control

Mechanical Power Pneumatic PowerGenerator

Hydraulic Power Electrical Power

Gearbox Landing Gear

Wing Anti-Ice

Engine

Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006DO-06-T-F&T 0601 / 20.6.2006 3

POA Project GoalsThe target of Power Optimised Aircraft (POA) is to validate, at aircraft level and both qualitatively and quantitatively, the ability of next generation aircraft equipment systems to enable the reduction in consumption of non-propulsive power Drivers Safety Standards Objectives Reduction of peak non-propulsive power by 25% Reduction of total non-propulsive power Reduction of fuel consumption by 5% Reduction of total equipment weight Constraints Maintenance Costs Equipment production costs Reliability

Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006DO-06-T-F&T 0601 / 20.6.2006 4

The ConsortiumTimeframe: Total Budget: Consortium: 2002 - 2006 (5 years) 99,2 million (Part funded by the European Union 5th Framework Programme) 46 partners

Airframe Manufacturers Aircraft Equipment System and Engine Manufacturers Subsystem Manufacturers Component Manufacturers Tools and Service Providers

Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006DO-06-T-F&T 0601 / 20.6.2006 5

Conventional Aircraft Architecture

Primary Controls Secondary Controls

Primary Controls APU

Commercial Loads Electrical Distribution

Mechanical Power Pneumatic Power Hydraulic Power

Engine systems

Central Hydraulics Environmental Control

Generator

Electrical Power

Gearbox Landing Gear

Wing Anti-Ice

Engine

Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006DO-06-T-F&T 0601 / 20.6.2006 6

Optimised Aircraft Architecture?

Primary Controls

Primary Controls

Secondary Controls

Commercial Loads Electrical Distribution

Cabin Expansion generator

No GearboxEngine systems

Local Compressor Reduced Engine Bleed

Environmental Control

Local Hydraulic source More Electrical Power

Landing Gear

Starter Generator Engine

Wing Anti-Ice

Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006DO-06-T-F&T 0601 / 20.6.2006 7

Engine Electrical SystemsElectric Actuators Fan Shaft Generator High Pressure Starter/Generator ~ 200kW Motor for Engine Starting. Will Generate Power after Engine Start LP to HP Power Transfer may Improve Fuel Burn and Reduce Thrust During Descent. ~ 150kW main Power Generation at Idle and Above Emergency Power Generation from Windmilling Fan to Airframe (engine-out) or HP Machine for Assisted Windmill Relight.

DC Power Bus on EngineSimplified Airframe/Engine Interface Each Machine will have a Power Electronic Drive Each Drive will Appear as a Node in a Distributed Control System

Active Magnetic BearingInvestigate Potential for Removal of Oil System Monitoring of Shaft Rotordynamics

Electric Oil Pump/Scavenge SystemOptimise Oil Flow to Bearings over Engine Cycle

Electric Fuel Metering Unit ~ 100kW Motor Simplified Fuel System

Electric Oil Breather ModelLIEBHERR-AEROSPACE 2006

Power Optimised Aircraft Lower Heat Input to Fuel Aerodays 2006, Vienna, 20 June 2006DO-06-T-F&T 0601 / 20.6.2006 8

Actuation SystemsThe Objective is to achieve lower life cycle costs, through power costs, optimisation, reduced weight and maintenance costs optimisation,

Primary & Secondary Flight Control Systems Derivation of StandardsHardware and model verificationLarge wide-body thrust reverser ball and screw EMA

Electro-Hydraulic Actuation (EHA) Electro-

Nacelle SystemsMore Electrical Thrust Reversal Alternative to pneumatic and hydraulic thrust reversal systems Mechanical and data bus synchronisation

Hurel-Hispano test facility 10-12 kW EHA

Spoiler actuator ~25 kW

Electro-Back-up Hydraulic Electro- BackActuation (EBHA)Novel and versatile hybrid actuationAirbus A300/A310

Landing Gear SystemsLanding Gear system integration Decentralised actuation for Nose Wheel More Electrical Actuation for Main Gear More Electrical Wheel BrakingWide-body aileron actuator ~2 kW

Trimmable Horizontal Stabiliser Actuation (THSA)Proof of concept More electrical actuation with innovative mechanical technologiesTypical wide-body stabiliser actuator

Electro-Mechanical ElectroActuation (EMA)Distributed High-Lift systems Comparison of hinge line versus rotary technologies

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LIEBHERR-AEROSPACE 2006

Pneumatic SystemsThe Objective is to reduce and optimise the effect of bleed air off-take on power usage, as this is a large consumer of non-propulsive power. Bleed Air Off-Takes are mainly used for the Environment Control System and for Wing Ice Protection.

Env. Conditioning System (ECS)To increase the efficiency of the ACS The main innovation is the combination of a Vapour Cycle (containing an environmentally neutral fluid) with an electrical driven Air Cycle. A variable speed motor for the re-circulation fan and a Cabin Energy Recovery Device will be used. The main outputs are a Model of a complete ACS and the Test of a Hybrid ACS (Vapour +Air Cycle)

Wing Ice Protection (WIP)To Increase the efficiency of WIP Systems The main innovation is the use of ultrasonic surface ice sensors (WIP on demand) and hybrid wing heating (electrical and hot air) The main outputs are Model of WIP Systems and Test of an innovative WIP System Wing heat distribution using: Ultrasonic sensors, Electro-thermal devices, On demand active intelligence control and Monitoring of unprotected surfaces Ice detection sensor

Fuel Cells (FC)Re-circulation Fan To Increase the efficiency of electrical power generation for pneumatic systems The main innovation is the validation of a Solid Oxide Fuel Cell (SOFC) with its reformer for use with kerosene The main outputs are a Model of FC System and the Test of a 5 kW Fuel Cell System

Motorised Air Cycle machine

LIEBHERR-AEROSPACE 2006

CO2 Compressor

Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006

SOFC Principle

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A Total Aircraft Representative PhilosophyModelsI - Each of the Technical Work Packages will produce validated hardware and models from their respective systems areas. These will be integrated into the ESVR, ASVR and VIB II - The ESVR and ASVR will each be run to validate systems integration (an identical generator will be used on both in order to produce comparable results). Hardware absent from the ASVR will be modelled in real-time on the VIB and run together with the ASVR to realrepresent a total aircraft. III - The VIB will be used to validate that the resulting aircraft system is optimised

Engine Electrical Systems

Engine Systems Validation Rig (ESVR) at INTA

Selected suite of Validated Hardware subsystems and components

Full suite of Validated system and subsystem models

Aircraft Electrical Power Systems

Primary Controls Secondary Controls

Primary Controls Commercial Loads Electrical Distribution APU

Actuation SystemsModels

Models

Aircraft Systems Validation Rig (ASVR) at Hispano-Suiza Hispano-

Engine systems

Central Hydraulics Environmental Control Generator Gearbox Landing Gear

Virtual Iron Bird (VIB), first at DLR, then in real-time at Hispano-Suiza realHispano-

Wing Anti-Ice

Pneumatic SystemsModelsNote: Pictures shown do not necessarily indicate the exact hardware involved in POA

Engine

Engine Systems Validation Rig (ESVR), Madrid

Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006DO-06-T-F&T 0601 / 20.6.2006 12

Aircraft Systems Validation Rig (ASVR), Paris

Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006DO-06-T-F&T 0601 / 20.6.2006 13

Virtual Iron Bird (VIB), Munich

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POA Project Goals for a more-electrical aircraft configurationObjectives Reduction of peak non-propulsive power by 25% Reduction of total non-propulsive power Reduction of fuel consumption by 5% Reduction of total equipment weight Constraints Maintenance Costs Equipment production costs Reliability achievable achievable achievable achievable achievable achievable achievable

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Why is POA a keystone?Previous projects concentrated on systems level research POA was the first big European integration level project POA confirmed the feasibility of MEA POA showed that we need to concentrate onUnderstanding the management of electrical loads Solving thermal management issues Enabling technologies such as power electronics

This led to More Open Electrical Technologies (MOET, FP6)Examine electrical architectures Explore thermal management Utilise current advances in power electronics technologies

The next step is Clean Sky (FP7)Validation of total energy management Maturation of the work begun in POA Validation of the ideas generated in POA

Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006DO-06-T-F&T 0601 / 20.6.2006 16

Why is POA a keystone?IHPTET IHPTET VFG VFG VFCFC VFCFC DEPMA DEPMA EABSYS EABSYS HEAT HEAT LEMAS LEMASREACTS REACTS

Systems for MEASystems projects EPAD EPAD

EEFAE EEFAE

VAATE VAATE

MEA Integration

MEA Process

EPICA ELISA EPICA ELISA

Integration projects EU framework programmes

MEA (US AFRL) TIMES (UK) MEA (US AFRL) TIMES (UK) F-16/F-18 demo F-16/F-18 demo POA (EC) POA (EC) C-141 demo C-141 demo A320 demo A320 demo

MEA II (US AFRL) MEA II (US AFRL) Clean Sky (EC) Clean Sky (EC) MOET (EC) MOET (EC)

FP4

FP5

FP6

FP7

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1996

2000

2004

2008DO-06-T-F&T 0601 / 20.6.2006

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Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006

More information on POA project resultsTEOS forum, 28-30 June 2006Technologies for Energy Optimised Aircraft Equipment Systems

POA results in the form of seminars, workshops, exhibition Hotel Novotel Tour Eiffel, Paris, France

Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006DO-06-T-F&T 0601 / 20.6.2006 18

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Power Optimised Aircraft Aerodays 2006, Vienna, 20 June 2006LIEBHERR-AEROSPACE 2006DO-06-T-F&T 0601 / 20.6.2006 19