Type of Awards: SBIR Phase I with IEDC and Phase II Contract Numbers: FA8650-07-M-2781and FA8650-08-C-2859 Agency: U.S. Air Force Research Laboratory Status: On Going Periods: 4/2/07 to 1/2/08 and 4/2/08 to 8/11/11 Principal Investigator: B. P. Loop Abstract: The primary objective of the proposed work is to investigate design techniques to improve torque density, power density, and efficiency in wound-rotor synchronous machines. The underlying principle of the proposed design technique is to alter the flux paths in the machine to increase torque production. This will be achieved through optimally altering the stator tooth geometry, rotor tooth geometry, and magnetic material properties. The design process is automated by an evolutionary optimization algorithm that employs a finite element analysis program as an objective function evaluation engine. Finite element modeling in the Phase I effort showed a potential increase of 12.2% in average torque production for the F18E/F generator. In the proposed Phase II effort, prototype machines will be built based on the designs obtained in the Phase I. Hardware validation of the approach will be performed with the help of GE Aviation. In order to investigate optimization of machines at high-speeds, additional research will be carried out to enhance the finite element modeling capabilities. These enhancements include saturation, eddy current effects, and skew. Finally, extensive statistical analysis of the performance of the genetic optimization procedure will be carried out to improve the design technique. The result will be a commercially viable machine design software package that could be adopted by government agencies and...
Read MoreTransient Electrical Power Response Enhancement for Turbine Drive Generators
Type of Awards: SBIR Phase I with IEDC and Phase II Contract Numbers: N00014-07-M-0328 and FA8650-08-C-2943 Agency: U.S. Air Force Research Laboratory and U.S. Office of Naval Research Status: On Going Periods: 5/4/07 to 3/9/08 and 07/30/08 to 11/30/10 Principal Investigator: J. R. Wells Abstract: Airborne electrical power requirements are increasing significantly to support Intelligence, Surveillance, and Reconnaissance (ISR) sensors, electronic attack suites, and directed energy weapons for military applications. When the electric generator is directly coupled to the propulsion engine, relatively large electric torque transients are often introduced with dynamics faster than previously handled by the engine control system. These transients may have serious implications with regard to stall margins, mechanical stress, speed regulation, and available thrust. To address challenges posed by such transients, this work is developing and demonstrationg novel architectures and system control strategies to maximize transient turbine engine performance utilizing modeling, simulation, and analysis (MS&A). A high-mach missile system is chosen as the prototype for optimization process demonstration and likely candidate for initial technology insertion. This work will expand upon the Phase I efforts through refined modeling and expanded optimization...
Read MoreF-35 Three-Bearing Swivel Nozzle (3BSN) Door Actuator
Type of Awards: SBIR Phase I with IEDC Contract Numbers: N68335-08-C-0060 Agency: U.S. Naval Air Systems Command Status: On Going Periods: 12/11/07 to 5/30/09 Principal Investigator: J. R. Wells Abstract: The lowered cost of maintenance, lowered weight, and reduced installation complexity of smart electric actuators continues to justify the transition from hydraulic actuation to EMAs/EHAs. This SBIR proposal will extend the advantages of EMA technology into high-temperature, high-vibration applications with a first commercialization target being the JSF F35 Lightning II aircraft platform. During the SBIR Phase I research, PCKA will collaborate with NAVAIR and Lockheed Martin to establish the actuator requirements. Once the requirements are defined, PCKA will identify suitable actuator architectures for the application and then optimize the design in terms of weight, reliability, maintainability, manufacturability, and cost. Key design constraints will be the thermal and vibration environment which may necessitate the use of specific motor technologies, high-temperature wire insulation, lubrication, and electronics. In Phase II, PCKA will fabricate a prototype of the optimal design and perform qualification tests including EMI/EMC, vibration, shock, and altitude. If successful, developed technologies will ultimately transition to DoD programs under a Phase III...
Read MoreDynamic Thermal Management System Modeling of a More Electric Aircraft
K. McCarthy, E. A. Walters, A. Heltzel, PC Krause and Associates, Inc; R. Elangovan, G. Roe, W. Vannice, Boeing; C. Schemm, Lockheed Martin; J. Dalton, Avetec; S. Iden, P. Lamm, C. Miller, U.S. Air Force Research Laboratory; A. Susainathan, U.S. Air Force Aeronautical Systems Center Advancements in electrical, mechanical, and structural design onboard modern more electric aircraft have added significant stress to the thermal management systems (TMS). A thermal management system level analysis tool has been created in MATLAB/Simulink to facilitate rapid system analysis and optimization to meet the growing demands of modern aircraft. It is anticipated that the tracking of thermal energy through numerical integration will lead to more accurate predictions of worst case TMS sizing conditions. In addition, the nonproprietary nature of the tool affords users the ability to modify component models and integrate advanced conceptual designs that can be evaluated over multiple missions to determine the impact at a system level. 2008 SAE Power Systems Conference, November 11-13 2008, Bellevue, WA. Paper...
Read MoreTools for Health Management of Aircraft Power Systems
T. Baudendistel, PC Krause and Associates, Inc; Steve Pekarek, Mario Rotea, Purdue University;E. A. Walters, Steve Peecher, Hao Huang, Smiths Aerospace; Sean A. Field, Nathan E. Kumbar, H. Huang, Naval Air Systems Command In this presentation, a pair of recently developed hardware and software tools for the prognostics and health-monitoring of electric generators, motors, power electronic components, and electric power systems will be presented. The first tool is a vibration sensor that is low cost, durable. This sensor has been used to detect torque-ripple-induced vibration created by electric machines. It provides a convenient means to detect faults of both electrical and mechanical components of electric drive systems and also facilitates feedback-based control to mitigate the vibration source through control of the excitation to a machine. The second tool is a thermal-observer based health monitor. This tool effectively predicts the thermal behavior of stator, rotor, and winding structures based upon input from a minimal number of thermocouples and stator current sensors. It is shown that through coupling of these two tools, a comprehensive prognostic and health management system (PHM) for aircraft generators and associated electrical systems can be developed. Using this multi-physics approach it is possible to effectively detect component degradation and aid in prediction of time-to-failure as well as provide information to feedback-based strategies for operation of generator electrical systems under component degradation or failure. This will improve the warfighting capabilities by extending the life of the generator electrical system. 2nd Annual Propulsion-Safety and Affordable Readiness Conference, March 2007, San Diego, CA. Contact information:...
Read MoreAdvanced Tools for Aircraft Power and Propulsion Simulation and Analysis
T. Baudendistel, M. Corbett, E. A. Walters, K. Miller, J. Williams, J. Wells, S. Pekarek, M. Rotea, S. Field, , S. Peecher, N. Kumbar, M. Wolff, J. Dalton, P. Lamm It will be shown that through coupling a set of multi-physics tools in a sensor suite, a comprehensive prognostics and health management system (PHM) for aircraft generators and associated electrical systems can be developed. Specifically, using DHS, component and system-level simulations, using Hardware-In-The-Loop (HIL), of aircraft generator systems under nominal and failure modes can be performed efficiently. Using the simulation results obtained, the vibration sensor, unique monitoring concepts and advanced signal conditioning are coupled to establish an approach that can effectively detect component degradation and predict time-to-failure, and to develop feedback-based strategies for operation of generator electrical systems under component degradation or failure. In addition, as aircraft power demands continue to increase with the increase in electrical subsystems. These subsystems directly affect the behavior of the power and propulsion systems and can no longer be neglected in system analyses. The performance of the whole aircraft must also be considered with the combined interactions between the power and propulsion systems. The larger loading demands placed on the power and propulsion subsystems result in thrust, speed, and altitude transients that affect the whole aircraft. This results in different operating parameters for the engine. The complex models designed to integrate new capabilities have a high computational cost. This paper investigates the possibility of using a hardware-in-the-loop (HIL) analysis with real time integration of the aircraft/propulsion system. Using this method, a significant reduction in computational runtime is observed, and the airframe/turbine engine model is usable in a HIL environment. This also allows for a more complete analysis of the interactions between engine loading and aircraft performance by including some real hardware components. The dynamic interactions between aircraft subsystems highlight the need for system-level modeling using a combination of high-fidelity computer models and hardware in a real-time environment. Hence, maintaining the war fighting capabilities by extending the life of the aircraft electrical systems. IAPG Mechanical Workgroup, May 2007, Alexandria, VA. Contact information:...
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