ENGINEERING MATTERS, INC Electric Machine Throws Aircraft...

ENGINEERING MATTERS, INC.w

.engineeri ngmatt ers .com

Electric Machine Throws Aircraft Overboard

David Cope Christopher CorcoranRichard Fontana

Engineering Matters,Inc.

375 Elliot St.Newton, MA 02464617-965-8974dcope@engineeringmatters.com

1. Purpose• 1.1. Aircraft Carriers

– New Design CVNX-1• 1.2. Possible ground-based applications

– Short-field take-off

2. Navy Goals• 2.1. Manning reduction: 30%• 2.2. Life Cycle Cost reduction: 20%• 2.3. Size and Weight reduction: 50% • 2.4. Operational Avail. increase: 20%• 2.5 Increased Performance: 25%

Electric Machines for Aircraft Arrestor

• Reduced manning & maintenance– Low maintenance electric motor– Self-diagnostics

• Reduced system mass & volume • Increased performance

– Greater launching aircraft energy, speed and mass

– Reduced peak-to-mean force ratio on aircraft

Navy Needs:EMALS Attributes - 1

NavyNeeds

EMALS Attributes EMALS Functions/Features

Survivability: Rapid aircraftlaunch time

Intelligent automated control of launchoperation: rapid shuttle return and realtime individual adjustment

“Dark ship” launchoperations

Integral energy storage

Sustainability: Lower manning Automated operationsLower maintenance Self-diagnostic controls, redundant

power electronics, simplified motor.Higher reliability Graceful degradation through

redundancy and simplicityMobility: Reduced WOD

requirementsIncreased energy capability

Reduced systemweight and volume

High power and energy densityelectromagnetic machines

Navy Needs:EMALS Attributes - 2

NavyNeeds

EMALS Attributes EMALS Functions/Features

Affordability: Restricted launchdistance

Efficient deck usage;Higher energy capability

Reduced airframestresses

Controlled launch profile

Reduced peak-to-meanforce

Closed-loop control

Eliminate hazardousmaterials

Hydraulic oil not used

DesignFlexibility:

Installation flexibility Possible athwartshipinstallation

Performance: Reduced airframe stressRestricted launchdistance

High bandwidth force controlAdvanced high level control

3. History• 3.1.Circa late 1940’s

– 3.1.1. Westinghouse’s “Electropult”

– 3.1.2. Failed technically & economically

3. Brief History (cont.) • 3.2. 1984

– 3.2.1. Solicitation– 3.2.2. (Kaman selected: cost & sched.

overrun?)

3. Brief History (cont.)• 3.3. 1987

– 3.3.1. New solicitation: $700k and MANY CDRLs

– 3.3.2. Kaman, GA, and PSA rec’d initial contracts

– 3.3.3. Kaman downselected and produced over-budget, over-sched. non-compliant ~1/4 scale model

3. Brief History (cont.)• Kaman EMALS Device

– Linear synchronous motor– Bipolar transistor-controlled– Met static force requirement– Did NOT meet acceleration requirement– Kaman sez the requirements were changed

midstream

Kaman’s EMALS Device

3. Brief History (cont.)• 3.4. 1995 Navy paper:

http://www.lakehurst.navy.mil/ieeere%7E1.htm - indicated EMALS success

• 3.5. 1997 (August)– 3.5.1. Industry briefing– 3.5.2. No solicitation

3. Brief History (cont.)• 3.6. 1999 CVNX-1

– 3.6.1. Industry briefing– 3.6.2. Draft RFP out (sans Sections L & M)– 3.6.3. Solicitation to come (RSN)

4. EMALS Schedule• 4.1. Three Phases: PDRR, EMD,

ProductionID Task Name1 EMALS Program

2 EMALS PDRR #1

3 EMALS PDRR #2

4 EMALS Downselect

5 EMALS EMD

6 EMALS Production

H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H2 H1 H21999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011

4.2. EMALS PDRR• 4.2.1. Two PDRR contracts• 4.2.2. FY00-03• 4.2.3. $60M ea.

EMALS 2nd & 3rd Phases• 4.3 EMALS EMD

– 4.3.1. Single downselect– 4.3.2. FY04-09– 4.3.3. ~$160M

• 4.4 EMALS Production– 4.4.1. FY08-10– 4.4.2. ~$25M x 4

5. Industrial Base• 5.1.Prime bidders

for the Navy Advanced Linear Motor (Suspected):

• 5.2.Other potential prime bidders

Engineering Matters, Inc.SPD, Electric BoatOak Ridge (multiple)General Atomics, Foster-Miller,

Newport NewsWestinghouseUniversity of TexasPRT SystemsMagnemotionAnalexMcMullen, Premier rides,

Kaman Electromagnetics

5. Industrial Base (cont.)• 5.3 EMALS Bidders

– Lockheed, Kaman– Northrup-Grumman,

Westinghouse– General Atomics,

Boeing Downey, Boeing St. Louis, Maxwell Labs, Univ. of Texas, BWXT, Foster-Miller

• 5.4 EMALS Bidders– SAIC, Power

Superconductor Applications (?)

6. Present System• 6.1. Prime Power supplied by ship’s

propulsion power• 6.2. Steam, Open-loop• 6.3. Two parallel slotted cylinders

– 6.3.1. 21” diameter– 6.3.2. 101 m long

• 6.4. Immediately below flight deck

6. Present System (cont.)• 6.5 Volume: 1133 m3

• 6.6. Weight: 486 metric tons• 6.7. Maintenance intensive• 6.8. Inefficient 4-6%• 6.9. Low availability• 6.10. Maximum energy: 95 MJ = 70

Million ft-lbs.

6. Present System (cont.)

7. EMALS Physics• 7.1. Masses: 1000 lb – 50,000 lb (500

kg – 23,000 kg)• 7.2. Velocity: 55 kts -200 kts (28-103

m/sec)• 7.3. Energy: up to 90 Million ft-lbs

(120 MJ)• 7.4. Power: up to 120 MW (assuming 2

sec launch)

8. EMALS Engineering• 8.1. Ship Interface (Prime Power, etc.)• 8.2. Energy Storage Subsystem• 8.3. Power Conditioning Subsystem• 8.4. Launcher Subsystem• 8.5. Control Subsystem

9. Energy Storage Subsystem• 9.1. Energy stored ~ 200 MJ (60%

extraction)• 9.2. Discharge time ~ 2 seconds• 9.3. Re-charge time ~ 42 seconds (~5

9. Energy Storage Subsystem (cont.)

• 9.4.Technologies– 9.4.1. Flywheel– 9.4.2. SMES– 9.4.3. Battery– 9.4.4. Capacitor– 9.4.5. Fuel Cell

10. Power Conditioning Subsystem

• 10.1. Switching Device– 10.1.1. SCR– 10.1.2. GTO– 10.1.3. IGBT– 10.1.4. MCT– 10.1.5. PEBB-

friendly

10. Power Conditioning Subsystem (cont.)

• 10.2. Power Architecture– 10.2.1. Converter/Chopper/Inverter– 10.2.2. VSI or CSI

11. Launcher Subsystem

11. Launcher Subsystem• 11.1. Launchbar: Aircraft Connection

11. Launcher Subsystem (cont.)• 11.2. Launcher

Functions– 11.2.1. Motoring– 11.2.2. Braking– 11.2.3. Retraction

(return to breach)

0 5 10 15 20 25 30 35 40 45

Time, sec

11. Launcher Subsystem (cont.)• 11.3. Machine

Configuration– 11.3.1. Single

Shuttle, Rigid Rail– 11.3.2. Dual Shuttle,

Rigid Rail– 11.3.3. Staggered Dual

Shuttle, Rigid Rail– 11.3.4. Articulated

11. Launcher Subsystem (end)• 11.4. Machine

Type– 11.4.1. Induction– 11.4.2. Permanent

Magnet– 11.4.3. Synchronous– 11.4.4. (DC Brush)

12. Control Subsystem• 12.1. Peak-to-Mean acceleration: 1.05

– Could feedback on distance, velocity, or acceleration

• 12.2. Sensing A/C mass/type• 12.3. Interface w/ ships control

subsystem

Electromagnetic Aircraft Launcher System Summary

• EMALS provides many advantages (reduced manning, maintenance, mass; increase reliability, performance, etc.).

• The Navy is actively and reluctantly pursuing this option.

• System design can be improved by innovative and intelligent applications of well-known technologies.

Electric Machine Types Advantages and Disadvantages

Machine Type Advantages DisadvantagesInductionMachine

• Rugged• Low maintenance

• High reactive power (with traditionalelectronics)

Reluctance • Rugged• Low maintenance

• High reactive power• Complicated power electronics• High acoustic noise

SynchronousPermanentMagnet

• No field excitationnecessary

• Low reactive power

• Permanent field (field always ON)• Lower shear force capability• Environmental sensitivity of pm

materialsSynchronousXfrmr-coupled

• Low reactive powerControllable BEMF

• Very heavy rotor• Fragile electronics on rotor

SynchronousSuperconducting

• Low reactive power• High field

• Unproven availability• High maintenance

Eddy CurrentBrake

• Simple• Rugged

• Unable to retract shuttle• No energy generation• Cannot bring aircraft to complete stop

Two Fundamental Launcher Configurations

• Slot-in-deck:– FOD, reliability are concerns – Slot length = runout plus shuttle length

• Hole-in-deck:– Covered pass-throughs– Sheaves can provide Purchase Ratio

Electric Aircraft Launcher• Revolutionary aircraft launcher system• Electric motors below the flight deck• Total machine rating: 120 MJ (90 million

foot-pounds)

Linear Induction Machine Components

ENGINEERING MATTERS, INC Electric Machine Throws Aircraft...

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