t-idg technology overview - sunjet iithe idg(integrated drive generator) is an aircraft power...

KHI PROPRIETARY

T-IDG® Technology Overview

March 26, 2015

Dr. Tatsuhiko GoiSr. Manager, Drive System EngineeringKawasaki Heavy Industries,Ltd.

Presentation ＠Europe-Japan Symposium

© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 2KHI PROPRIETARY

The IDG(Integrated Drive Generator) is an aircraft power generation device which houses a Continuously Variable Transmission(CVT) to generate 400Hz constant frequency power regardless of the engine speed.Traction Drive IDG (T-IDG® ) is an innovative IDG which employs a traction drive mechanism as the CVT instead of a hydro-mechanical CVT used in conventional IDGs.T-IDG® was selected as the main generator for JSDF P-1/XC-2 aircraft and have shown its good reliability since 2007.

Introduction

XC-2

P-1*IDG: Integrated Drive Generator


Principle of Traction Drive CVT

Speed Decreasing Mode Speed Increasing Mode

Typical Configuration of Traction Drive CVT*

Speed Ratio＝R1/R2

R2R1

INPUT DISC

OUTPUT DISC

R1R2

POWER ROLLERTRUNNION

Loading Cam

Engine Generator

TILTING

*Continuously Variable Transmission


Outline of T-IDG® MK III

T-IDG Cutaway

T-IDG Data•Cont.Rating：90kVA•5 min. Rating：112.5kVA•5 sec. Rating : 150kVA•Frequency：400±5Hz(3）•Voltage：115/200V•Size：375L×460W×330Hmm •Weight：54.0kgf(dry)

Traction Drive CVT（Speed Ratio 0.5~2.0）

Input Shaft(4500-9200rpm

variable)

Main Generator(90kVA；24000rpm const.)

Output Terminal


Major Features of T-IDG®

High Efficiency (Low Heat Rejection or Low Power Loss)= leads to low fuel consumption

smaller oil cooler (substantial weight reduction)

High Reliability

Compatibility with the existing IDG(interface, envelope, weight, overhang moment, etc.)

Growth Potential up to 200kVA

No straight thorough speed(no operational limitation)

Competitive Total Life Cycle Cost(TLCC) Aluminum Housing(high corrosion resistance) Less Maintenance

Longer Servicing Interval No intermediate checks such as oil level, filter condition, etc)No speed control adjustment


1999-2005: prototypes Mk I to Mk III were developed and tested (total 9 prototype IDGs were used). A series of development tests as well as an actual engine test using RR Trent 500 were performed.

In 2005 the qualification test for Mk IV versionfor P-1/XC-2 was completed.

Total 110,000 hour Lead The Fleet Test since Mar.2006 ( av.22,000hr5 T-IDGs)was completed in Sept.2013.

P-1 first flight: Sept.2007,XC-2 first flight: Jan. 2010Since then good reliability has been proven.

T-IDG® Development Status

T-IDG onTrent 500 Engine


Time Elapse(sec)

Out

put

Freq

uenc

y(H

z)

MIL-STD-704E Frequency Allowable LimitsIDG Load

Output Frequency

Typical Test Results(1/2)

T-IDG Heat Rejection(@90kW Load)

150%(112.5kW) Step Load

Load

(kW

)

1000hr Endurance TestPer MIL-E-85583

Endured Traction Drive Parts

Power Roller

Disc


Typical Test Results(2/2）

Attitude Test30deg Nose Down

T-IDG

Drive Motor

Tilting Bed

T-IDGEMI Test

Oscillator

T-IDG

Drive Motor

Vibration Test

Cold Temperature/ Altitude Test

Altitude/Cold Temp Chamber

Drive Motor

Refrigerator

Inside the Chamber

Oil Cooler T-IDGFurnaceT-IDGDrive Motor

High Temperature Test


Technology Update

Optimization of CVT geometry

High stiffness structure

Hydraulic clamp control

Compact

High Responsiveness

Compact

High EfficiencyOptimization of control system

High Durability

High EfficiencyHigh Stability

High Responsiveness

High Durability

High EfficiencyOptimization of

oil flow and parts cooling

Extensive R&Ds have been conducted for the next generation T-IDG development.


Summary

Traction Drive IDG(T-IDG® ) has proved its high reliability and high efficiency on the P-1/XC-2 aircraft and in the 110,000 hour “Lead the Fleet Test”.

In parallel KHI has been improving the CVT technology to enhance its competitiveness.

The T-IDG® will meet the requirements for future MEAs.

t-idg technology overview - sunjet iithe idg(integrated drive generator) is an aircraft power...

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