ENGINEERING MATTERS, INC Electric Machine Throws Aircraft...
Transcript of ENGINEERING MATTERS, INC Electric Machine Throws Aircraft...
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ENGINEERING MATTERS, INC.w
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Electric Machine Throws Aircraft Overboard
David Cope Christopher CorcoranRichard Fontana
Engineering Matters,Inc.
375 Elliot St.Newton, MA [email protected]
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ENGINEERING MATTERS, INC.w
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1. Purpose• 1.1. Aircraft Carriers
– New Design CVNX-1• 1.2. Possible ground-based applications
– Short-field take-off
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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%
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ENGINEERING MATTERS, INC.w
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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
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ENGINEERING MATTERS, INC.w
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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
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ENGINEERING MATTERS, INC.w
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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
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3. History• 3.1.Circa late 1940’s
– 3.1.1. Westinghouse’s “Electropult”
– 3.1.2. Failed technically & economically
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3. Brief History (cont.) • 3.2. 1984
– 3.2.1. Solicitation– 3.2.2. (Kaman selected: cost & sched.
overrun?)
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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
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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
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ENGINEERING MATTERS, INC.w
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Kaman’s EMALS Device
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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
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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)
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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
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4.2. EMALS PDRR• 4.2.1. Two PDRR contracts• 4.2.2. FY00-03• 4.2.3. $60M ea.
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ENGINEERING MATTERS, INC.w
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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
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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
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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 (?)
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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
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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.
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6. Present System (cont.)
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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)
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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
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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
MW)
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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
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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
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10. Power Conditioning Subsystem (cont.)
• 10.2. Power Architecture– 10.2.1. Converter/Chopper/Inverter– 10.2.2. VSI or CSI
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11. Launcher Subsystem
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11. Launcher Subsystem• 11.1. Launchbar: Aircraft Connection
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11. Launcher Subsystem (cont.)• 11.2. Launcher
Functions– 11.2.1. Motoring– 11.2.2. Braking– 11.2.3. Retraction
(return to breach)
-50
0
50
100
0 5 10 15 20 25 30 35 40 45
Time, sec
Pow
er, M
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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
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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)
N
N
S S
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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
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ENGINEERING MATTERS, INC.w
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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.
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ENGINEERING MATTERS, INC.w
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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
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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
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Electric Aircraft Launcher• Revolutionary aircraft launcher system• Electric motors below the flight deck• Total machine rating: 120 MJ (90 million
foot-pounds)
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Linear Induction Machine Components