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Electric & Hybrid Aerospace Technology Symposium

Leveraging its pursuit of electric motor technology for motorsports applications, MTS has developed a portfolio of high-performance electric power systems that are uniquely suited for deployment in electric and hybrid aircraft.

In 2008, MTS successfully adapted highly optimized permanent magnet motor technology – originally developed for mechanical testing – for onboard Formula 1 energy recovery and later Formula E traction applications. Achieving this required dramatic increases in power density and efficiency and significant reductions in weight. As overcoming these same challenges is critical to achieving electric flight, continued adaptation and optimization of the MTS technology has yielded a portfolio of electric power solutions suitable for airborne applications.

Poised for Flight: High-performance Electric Power Systems

This portfolio comprises extremely power dense electric motor/generator units (machines) and compact, lightweight silicon carbide controls and electronics (inverters). Born of a harmonized development approach, MTS machines and inverters are engineered in conjunction to produce complete, tightly integrated systems capable of delivering optimal power density at the highest possible efficiency point. Potential aerospace applications for these systems include distributed propulsion, power generation, high-speed compressors and pumps, energy recovery and aerodynamic simulation.

To fully realize the power and efficiency of these systems for your electric or hybrid aircraft program, MTS has assembled a world-class team, combining unmatched electrical, mechanical, software and power electronics engineering talent with a trusted, reputable global supply chain partner. Visit with us in Köln at Stand EH2 and explore how MTS expertise and high-performance electric power systems can help your organization rise above the challenges of electric flight.

Optimized Permanent Magnet Motors » Extremely High Power Density » Compact & Lightweight » Tremendous Dynamic Response

Harmonized Machine/Inverter Development » Complete Solutions » Unmatched Systems Integration » Optimal Power Density & Efficiency

Innovative Silicon Carbide Inverters » Highly Compact & Lightweight

Motorsports Tested – Robust & Efficient » Formula 1 Racing – KERS, eTurbo » Formula E Racing – Traction

Proven Reliable Global Supply Partner » Rinehart Motion Systems LLC (RMS)

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M T S A E R O S P A C E S O L U T I O N S

MTS’ entry into electric and hybrid aircraft stems from more than a decade of achievements on the ground. It began with the pursuit of electric motor technology powerful enough to drive Formula 1 transmission test systems followed by the development of energy recovery systems for Formula 1 vehicles and traction motors and systems for Formula E vehicles. Success in these demanding motorsports environments is directly attributable to the extreme high power density and efficiency of MTS electric power systems– characteristics that even more critical for airborne vehicles.

MTS is a renowned innovator of mechanical test solutions. Among its myriad technology milestones is an electric, lab-based Transmission Test System capable of replicating the torque and acceleration of a high-performance Formula 1 engine. In the early stages of TTS development, a global search revealed that no vendor could provide an electric motor dynamic enough for this application, prompting an in-house R&D effort. After exploring the physics, MTS’ Victor Aronovich devised a highly optimized permanent magnet design capable of delivering the tremendous dynamic response required for this type of test.

From there, the MTS team further optimized and adapted Aronovich’s motors for deployment as onboard kinetic energy recovery systems for Formula 1 racecars. Meeting the demanding performance and compact physical requirements for that application launched the company on its current trajectory as a manufacturer of extremely power dense, low weight and efficient electric power systems. The harsh motorsports environment – extreme accelerations/decelerations, high temperatures, jarring shocks and vibrations – served to temper the technology, driving it to very high standards of robustness and reliability.

The rigors of Formula E racing, as well, served to propel MTS technology to new levels. Meeting Formula E requirements compelled an exploration into new ways to reduce costs and further optimize efficiency. This effort yielded an innovative silicon carbide inverter that is one third the size and weight of previous MTS units.

Electric Power Systems: Motorsports Origins

Formula 1 Transmission Test System (TTS)

Formula 1 Racecar: Energy Recovery (eTurbo & Electro-dynamic Braking)

Formula E Racecar: Traction

Electric Road Car: Traction

Electric Power Systems: Electric & Hybrid Aircraft Applications

Distributed Propulsion

The tremendous power density of MTS machines and the low weight and efficiency of its integrated systems make them the ideal solution for electric flight propulsion. In addition, MTS engineers have devised a highly compact, inverted motor design that integrates propeller and pitch control mechanism, eliminating the need for a gearbox. The resulting streamlined profile and lower weight of this package make it ideal for deployment throughout aerodynamically efficient, distributed power architectures.

High-speed Pumps & Compressors

Driving next-generation pumps and compressors for both hybrid and IC/turbine aircraft is another application of significant interest. Unlike the relatively massive, centralized pump and compressor schemes deployed today, the next generation will be smaller, lighter and distributed throughout the aircraft, affording far higher levels of control and operational efficiency. To achieve the weight and size reductions to make this distributed approach feasible, MTS engineers are leveraging ultra-high-speed machine technology developed originally for electric turbo compounding, or eTurbo, applications in Formula 1 racing.

Aerodynamic Simulation

One of the first non-motorsports applications for MTS electric power systems was replicating the aerodynamic effects of powered jet engines during wind tunnel testing of scale aircraft models. Compact, power dense MTS motors can provide the thrust required for these simulations far more accurately and efficiently than conventional, energy and infrastructure intensive air turbine powered simulators.

Power Generation

Low weight, high efficiency MTS systems are also well suited for onboard power generation. As aircraft transition from hybrid to fully electric - i.e., battery powered – there will applications for compact Internal Combustion (IC) motor/generator sets to power specific systems or localized zones. These types of applications are already the subject of considerable interest and exploration throughout the aerospace industry.

Energy Recovery

Developed for Formula 1 racing, MTS eTurbo systems recover heat energy from the exhaust of high-performance IC engines. To do this effectively, the machines must be capable of reaching tremendous rotational speeds, well in excess of 100 thousand RPM. This technology is directly applicable to conventional piston-driven and hybrid aircraft. Recovered IC motor heat energy could drive auxiliary electric motors and/or charge batteries, boosting overall efficiency and extending aircraft range of flight.

MTS Systems Corporation

Electric Power Systems eps-info@mts.com

ISO 9001 Certified QMS

Mechanical Test Solutions

Fully Integrated, Structural Test Solutions

Aircraft designs will have to evolve to contend with the physics of electric flight. Wings will exhibit different structural characteristics to accommodate distributed propulsion schemes and airframes will comprise new, lighter weight materials to a far greater degree than conventional aircraft. New structures, assemblies and components will have to undergo rigorous mechanical testing for determining fatigue life, strength, and of course safety. To address these needs, MTS offers decades of industry expertise and an unmatched portfolio of structural testing components, including:

» Test-accelerating AeroPro™ application software

» Synchronized FlexTest® controls and MTS FlexDAC™ 20 data acquisition

» Reliable SilentFlo™ hydraulic power and distribution

» Precision MTS DuraGlide™ test actuators, servovalves, load cells and manifolds

» Durable portal frames and load-bearing components

MTS and FlexTest are registered trademarks and AeroPro, MTS DuraGlide, MTS FlexDAC and SilentFlo are trademarks of MTS Systems Corporation in the United States. These marks may be protected in other countries. RTM no. 211177.

Products or company names other than trademarks of MTS Systems Corporation are used for identification purposes only and may be trademarks of their respective owners.

© 2017 MTS Systems Corporation. ElectricHybrid Germany backgrounder 11/17

To support the ongoing optimization, customization and manufacture of motorsports electric power systems, MTS has developed an array test benches for QA/QC and R&D applications. Used for simulating fully integrated machine/inverter operations and developing optimum control strategies for specific applications, these test benches are capable of rotational speeds of up to 150 thousand RPM – anywhere from 1 kilowatt to 1 megawatt of power. While engineered for MTS product development and production, they can also be manufactured for customers to help them achieve optimal performance from their own machine/inverter designs – whether for traction/propulsion, energy recovery (heat or kinetic), or other motor applications.

Photo courtesy NRC - Canada

Photo courtesy Gulfstream Aerospace

Photo courtesy Cessna Aircraft Company

Photo courtesy Airbus Military

Electric Power System QA/QC and R&D Test Benches