nasa electric aircraft testbed (neat) · • univ. illinois motor superconducting turbo-electric...

National Aeronautics and Space Administration

www.nasa.gov

NASA Electric Aircraft Testbed (NEAT)Overview

Hybrid Gas-Electric Propulsion

November 28, 2016

Advanced Air Transport Technology Project

Advanced Air Vehicles Program

Boeing SUGAR Volt 2040

In-line Turbo/Electric

Airbus/RR E-Thrust 2036

Distributed

NASA AATT N+3 Concept

Boundary Layer Ingestion


www.nasa.govAdvanced Air Transport Technology Project


Executive Summary

2

As large airline companies compete to reduce emissions, fuel burn, noise, and maintenance costs, it is expected that more of their

aircraft systems will shift from using turbofan propulsion, pneumatic bleed power, and hydraulic actuation, to instead using

electrical motor propulsion, generator power, and electrical actuation. This requires new flight-weight and flight-efficient

powertrain components, fault tolerant power management, and electromagnetic interference mitigation technologies. And NEAT is

the first reconfigurable hybrid gas-electric propulsion testbed capable of supporting full-scale single-aisle electrified aircraft

powertrain technology including:

High fidelity turbo-generation and ducted fan transient emulation, Establishing baseline power quality and electromagnetic interference levels, Validating aircraft powertrain modeling tools Demonstrating single-aisle flight-weight powertrains Ground test research motors and inverters under flight altitude conditions at full power levels

Reduce single-aisle aircraft carbon use,

noise and emissions in US airspace




Extending Turbine Driven Propulsion to

Hybrid Gas-Electric Propulsion

Category Aircraft Bus Voltage Power Level

More Electric Boeing 787 540V 1.4MW

All Electric GA 1-2kV <1MW

Hybrid Gulfstream 1-2kV 2MW

Hybrid Boeing 737 2-4.5kV 22MW

Boeing

787

Gulfstream

150

Boeing

737


www.nasa.gov

Parallel Hybrid

FuelFan

TurbofanElectric Bus

MotorBattery

1 to Many

Fans

Electric BusMotor(s)

BatteryAll Electric

Turboelectric

Fuel

Turboshaft

Generator

Electric Bus

Distributed

Fans

Motor

Motor

Series Hybrid

Fuel

Turboshaft

Generator

Electric Bus

Battery

Distributed

Fans

Motor

Motor



NEAT supports all four basic configurations

Power to Propulsion Configurations


www.nasa.gov

Near Term Electrified Propulsion OptionsParallel - Motor with Engine Turboelectric – Motor Distributed


www.nasa.gov

Flight-Weight Powertrain Technology Paths

Ambient

Turbo-electric

• Turbo-generator

• GE MW Inverter

• NASA MW Motor

• Univ. Illinois Motor

Superconducting

Turbo-electric

• Turbo-generator

• Boeing MW

Inverter

• NASA MW SC

Motor

Ambient

Parallel Hybrid

• Podded Motor

• GE MW Rectifier

• OSU Motor


www.nasa.gov7

Distributed Propulsion Hybrid Electric System

Many Possible Architectures• Turboelectric

• Hybrid Electric

• Distributed Propulsive Power

• Tube & Wing or Blended Wing

Airbus E-Thrust distributed concept Example of a Distributed Concept in the NEAT Testbed




www.nasa.gov

STARC-ABL Turbo-Electric Configuration

8

13 MW

Turbine

Engine

1.4 MW

Generator

3 φ ACRectifier

DC

Circuit

Protection

Devices

13 MW

Turbine

Engine

1.4 MW

Generator

Rectifier

Inverter

Or

Rectifier

3 φ AC DC

Motor

2.6MWFan

3 φ ACDC

Fuel

Fuel

Thrust and Power

Rectifier 2

Generator 2

Rectifier 1

Generator 1

Fan

Motor

Inverter

Cables

BLI Thrust




Electric Aircraft Testbed Portfolio

RR/Singapore

GRC/Cleveland

GE/Dayton

AFRC/Palmdale

Capability List

PEGS 1MW CRC

NEAT HEIST

Max Power Level 3kW 1MW 24MW 200kW

Components Tested

Scaled Electric

Grid

Cryo Motor, Drives

Flight-Weight

Powertrain

Wing Integration,

Flight Controls

TRL Demo 3 4 6 7

Aircraft Size NA NA 150 PAX 2 PAX

Cryogenic No

500 gal. LH2

3000 gal. LH2,LN,LNG

No

Chiller No No Yes No

HVAC No No Yes No

Aerodynamic Loading

No No No Yes

Thermal No Yes Yes Yes

Control No No Yes Yes

Atmospheric Pressure

No No No No

TLC Operation YES NA Yes Yes

GRC/Cleveland




Research and Technology Overview

• Primary purpose of the testbed is to enable the high power ambient and

cryogenic flight-weight power system testing that is required for the

development of the following components to Technology Readiness Level 6:

• High voltage bus architecture –• Insulation, geometry, 600V up to 4500V

• High power MW Inverters, Rectifiers-• Commercial, In-House, NRAs

• High power MW Motors, Generators-• Commercial, In-house, NRAs

• System Communication –• Aircraft CAN, Ethernet, Fiber-optics

• System EMI Mitigation and Standards –• Shielding, DOD-160, MIL-STD-461

• System Fault Protection –• Fuse, Circuit Breaker, Current Limiter

• System Thermal Management –• Active/Passive, Ambient/Cryo, Distributed/Mixed

Gulfstream Iron-Bird




Facility Selection and Repurposing

Required Infrastructure & Con Ops Available

Aerial View




HTF OverviewHot Train and Chamber

Steam Ejector

Graphite Heater

5-story basement


www.nasa.gov

Recent HTF Refurbishments

13

Exterior Views – Paved lot, updated signage, new windows

Interior Views – Painted walls, HVAC, updated floor

Updated for Initial Tests in FY16


www.nasa.gov

Testbed Layout

~ 27’ x 88’

~ 20’ x 16’

Shop Area and Cabin Converted to Testbed

Office/Storage AreaAltitude Chamber

27’ x 100’

Testbed



Power Cooling Safety Expansion Altitude

Up to

48MW

MW Chillers

and LH2

Remotely

located

Wall

Extension

Up to

120,000 ft


www.nasa.gov

56 feet

15

Distributed Powertrain Installed



• Modular and Scalable

• Reconfigurable testbed

• 2+ MW powertrain systems

• Ambient and Cryogenic


www.nasa.gov

Notional Single-Aisle Powertrain Installed

16

• Modular and Scalable

• Reconfigurable testbed

• Parallel Hybrid and

Turbo-Electric

• MW powertrain systems

• Ambient and Cryogenic

• Atmospheric Testing

Turbo-Electric

Parallel Hybrid




NEAT Fundamental Architecture

Utilize electric motor pairs connected via shaft

Speed and Torque Control Mapping

Propulsor

Load




Incorporating Turbofan Physics

Utilize Speed & Torque Maps under TLC Conditions

ERJ-190 – 100 PAX

Modeling Plant and Control System




NEAT Modularity and Regeneration

19

1MW

Turbine

Simulator

900kW MW

Generator

3 φ ACRectifier

DC

Circuit

Protection

Devices

900kW

Generator

Rectifier

Inverter

Or

Rectifier

3 φ AC DC

200kW Battery

Simulator

DCDC

1MW

Turbine

Simulator

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Motor

125kWFan Simulator

3 φ ACDCDyno

125kW

Building Power

3 φ AC

System Under Test Validation FacilityValidation Facility

1 MW

Generator

1 MW

Generator

125kW 1MW 10MW 4X250kW

Bolted reconfigurable wing

Rib supported, light-weightRe-use Generated Power

Machine

Pair

Interfaces




Propulsor System:

Inboard motors/inverters/turbogenerator

COTS motor

COTS inverter

Ducted fan replaced by

regenerative motor load




Wing Generators and Tail-Cone Thrusters:

1MW up to 10MW

Turbo-generator replaced with

motor driven generator

Parker 250 kW Motor

John Deere PD400 Inverter

Drive Motors

Generator

Motors


www.nasa.gov 22

System Power Distribution Testing

Stability, Efficiency, Mass,

and Voltage OptimizationAdvanced Air Transport Technology Project





System Bus Communication Testing

23

Response, Bandwidth, Shielding,

Standards, and Topology


www.nasa.gov

System Thermal Management Testing

Active/passive Cooling, Insulation,

Mass, EfficiencyAdvanced Air Transport Technology Project



www.nasa.gov

Flight Altitude Compatibility Testing

25

STARC-ABL Tail-cone Motors Installed in Cabin

Paschen Curve, Corona

Discharge, EMI, EMC,

Flight Profile Stresses

Tailcone inserted in cabin for

motor/inverter flight environment testing

Cabin

Tail-cone

Top View

Side View




NEAT Scientific Development Path

Single-StringTwo-Bus Full Aircraft Flight-Weight




CF34 Flight Profile Validation Completed

27

Confirmed Flight Speed/Torque

Profile Gradients Achievable


www.nasa.gov

X-57 DC Bus Radiated EMI Results

Confirmed Relative DC Bus

Radiated EMI for MAXWELL


www.nasa.gov

FY17 Capability Updates

29

Relocate current tower near Pump Bldg.

Second Tower Expansion for 1650 KW. Towers will share cold basins. Allows staging

based on loading.

Pump Building to house CT pumps, NEAT closed loop cooling components and electrical/control interfaces in building.

Reactor Field for Stand-alone MW Testing

Transformer, Reactor Loading, Cooling Upgrade, STARC-ABL


www.nasa.gov

Conclusions

• The NASA Electric Aircraft Testbed is a key enabler

of flight-weight powertrain development.

• Its high power, remote location, large footprint,

conditioned atmosphere, cryogenic infrastructure,

atmospheric chamber, and extensibility make it a

unique testbed for full-scale aircraft powertrain

development.

• It addresses and fills a unique role not currently

available with existing test facilities.

• And when used in conjunction with the other

government, industrial, and academic facilities, it

provides an important next step in the path towards

electrification of future single-aisle aircraft.

30


www.nasa.gov

Questions? Thank you.

31Advanced Air Transport Technology Project



www.nasa.gov

References

32Advanced Air Transport Technology Project


• ARINC Specification 825 - The General Standardization of CAN for Airborne Use

• Michael Armstrong, Rolls-Royce North American Technologies Inc, Cryogenic Engineering Conference /

International Cryogenic Materials Conference, “Superconducting Turboelectric Distributed Aircraft Propulsion”,

July 1, 2015, Contract Number NNC13TA7T

• http://forums.pelicanparts.com/off-topic-discussions/679966-oye-solar-power-plant-good-vs-bad-2.html

• http://www.embraercommercialaviation.com/Pages/Ejets-190.aspx

• http://www.Janis.com/

• http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20140010471.pdf

• http://roadwarriorvoices.com/2015/06/15/airbus-unveils-nearly-silent-emissions-free-electric-plane-at-paris-air-show/

• Clarke, S.; Lin, Y., Kloesel K., Ginn, S. “Enabling Electric Propulsion for Flight: ”Hybrid electric aircraft research at

AFRC”, NASA Armstrong Flight Research Center, 14th AIAA Technology Conference, Tranformational Flight-

Electric Propulsion Development and Testing, Wed., June 18, 2014

• Armstrong, M. “Superconducting Turboelectric Distributed Aircraft Propulsion”, Rolls-Royce North American

Technologies, Inc., Cryogenic Engineering Conference, International Cryogenic Materials Conference, July 1, 2015

• Jansen, R., Brown, G., Felder, J., Kirsten, D. “Turboelectric Aircraft Drive Key Performance Parameters and

Functional Requirements”, AIAA Propulsion & Energy 2015, 27-29 Jul. 2015

• Choi, B., Morrison, C., Dever, T., Brown, G. “Propulsion Electric Grid Simulator (PEGS) for Future Turboelectric

Distributed Propulsion Aircraft”, 12th IECEC, July 28-30, 2014

• SAE-ARP-1870 (8/2012) Aerospace Systems Electrical Bonding and Grounding for Electromagnetic Compatibility

and Safety

• NASA-STD-4003A (2/2013) Electrical Bonding for NASA Launch Vehicles, Spacecraft, Payload

• NFPA 70 National Electric code, and NFPA 70E Standard for Electrical Safety in the Workplace

• NPR 7150 – Software Assurance

• DOE-160

• MIL-STD-461

http://forums.pelicanparts.com/off-topic-discussions/679966-oye-solar-power-plant-good-vs-bad-2.html

http://www.embraercommercialaviation.com/Pages/Ejets-190.aspx

http://www.janis.com/

http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20140010471.pdf

http://roadwarriorvoices.com/2015/06/15/airbus-unveils-nearly-silent-emissions-free-electric-plane-at-paris-air-show/

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