simulation helps designing more electric aircraft

1 © 2015 ANSYS, Inc. ANSYS Confidential

Simulation helps designing More Electric Aircraft

Laurent Bracq

ANSYS


Aircraft Energy Consumption Key aircraft components and functions

High Medium Low

Presence of electrical power

Energy consumption

Flight control and operations Avionics, cockpit displays, navigation systems …

Power generation management Engine & generator management, fuel supply …

Configuration management Actuation of landing gear, brakes, deicing …

Passenger confort Lights, galleys, IFE, connectivity …

Air pressurization and conditioning Cabin ventilation, pressure systems …


Aircraft electrical systems

Starter generators APU RAT

PEPDS SPDS Conversion Ventilation

Electrical braking system

Green taxiing system Reverser actuation system

Landing gear doors system

Power Generation

Distribution

Electrical Equipment

Wiring


More Electric Aircraft Motivation

→Removal of hydraulic system • reduced system weight • ease maintenance

→“Bleedless” engine • improved efficiency

Reduced operating costs

Reduced fuel burn

Reduced environmental impact

→Controllability • power on demand

→Reconfigurability • maintain functionality during faults

→Advanced diagnostics / prognostics • more intelligent maintenance • increased aircraft availability


Model-Based Systems Engineering (MBSE)

Detailed Design

Embedded Software, Electronics, Physics Hardware

Functional and Architectural Analysis

Modelling of functions and Architecture

Operational Analysis

Modelling of operational scenarios

Requirements Analysis

Manage textual requirements (Doors, Word, Excel…)

1

3

2

4


Detailed Design 3D Multiphysics

Software Engineering

ANSYS Solution for MBSE System

Validation

Sub-System Integ. & Verification

Component Integration & Verification

Requirements and Specifications

Sub-System Design

System Functional & Architectural Design

Mechanical Electrical Software

Detailed Design & Optimization

Systems Functional Engineering

0D Physical Modeling

Electromagnetics Thermal Mechanical

EMC / EMI


ANSYS Systems Solutions

SCADE System: Model-Based Systems Architectural and Functional Design Standards-based (SysML & Eclipse-based) System/Software Synchronisation

Simplorer: E/E systems simulation and virtual prototyping Adheres to physical laws 3D precision when needed Leader in power electronics and eletromechanical


ANSYS Simplorer

Unmatched Versatility for E/E Systems Simulation Standard modeling languages, mixed digital and analog solver

technology, and standard cosimulation interfaces for simulation of electrical, electronics and embedded software systems

Adheres to Physical Laws Behind every modeling component is a corresponding

conservation law that ensures real-world physics are being respected

Systems

Leader in power electronics simulation Rich modeling libraries and design automation designed especially for high-

performance power electronics and electromechanical simulation

3-D Precision When You Need It Cosimulation with 3-D solvers and reduced-order modeling (ROM) captures complex multi-physics interactions when

precise system verification is required


ANSYS SCADE System

Model-Based Systems Engineering Complete standards-based model-based systems

Engineering environment (SysML & Eclipse-based)

Functional and Architectural Design Supports industry and customer specific systems

engineering configurability (such as IMA) as well as model-based SE data management via open data

dictionary

System/Software Synchronization Enables modular system design and verification,

Automatic I/O definition synchronization , Interface Control Documents production

and Team Collaboration support


Aircraft Electrical Systems Library

• Complete set of blocks for modeling aircraft electrical power systems

• Over 70 models and examples

• Generators, converters, rectifiers, machines & drives, loads

• For a range of simulation studies:

• Power Quality

• System Stability

• Protection & Fusing


Explore & Optimize System Performance


ANSYS Solution for Power Systems

Power Distribution

(cable)

Power

Distribution -

fault protection, switchgear

Power Source

Power Conversion /

Inversion

Electrical Loads

Electro- Mechanical

Loads


ANSYS Simplorer System Design

PP := 6

ICA:

A

A

A

GAIN

A

A

A

GAIN

A

JPMSYNCIA

IB

IC

Torque JPMSYNCIA

IB

IC

Torque

D2D

ANSYS Maxwell 2D/3D FEA Analysis

HF/SI

HFSS, Q3D, SIWave

RLCG Parasitics

ANSYS

Mechanical Thermal/Stress

ANSYS CFD Thermal

Model order Reduction

Co-simulation

Field Solution

FE Model Generation

Optimetrics

LS-DSO

SCADE Suite Control Systems

Embedded Design

Push Back Excitations

PExprt Magnetics

RMxprt Machine Design



Close loop control, Full Details

• Complete Software Controller

• Complete description of electric drive

• With detailed IGBTs

• Machine

• Cooling system


IGBT device: Device Parameter Extraction

Infineon : eupec FZ600R12KE3

Simplorer Device Characterization Tool automatic parameter fitting from data sheet

0.00 1.00 2.00 3.00 4.00 5.00Vce.V [V]

0.00

200.00

400.00

600.00

800.00

1000.00

1200.00

Ic.I [A

]

x02_OutputOutput Char. @Tj=125c

Curve Info

Ic.ITR

Output Vce-Ic

Vg=17 15 11

9

Product Data sheet

Simplorer

Characterization Tool

Device Model


Equivalent Thermal Circuit Model （IGBT&Diode）

IGBT Diode

25℃

特性抽出ツール

0 650.0 125.0 250.0 375.0 500.0 0

70.00

10.00

20.00

30.00

40.00

50.00

60.00

E=f(Ic)

Eon

Eoff

I [A]

E

[mJ]

1k * igbt_... 1k * igbt_...

Eon = f... Eoff = f...

20.0 140.0 40.0 60.0 80.0 100.0 120.0 15.00

40.00

17.50

20.00

22.50

25.00

27.50

30.00

32.50

35.00

37.50

E=f(Tc)

Eon

Eoff

E

[mJ]

Tc [C]

IGBT device: Thermal Impedance Extraction

Characterization Tool

Infineon : eupec FZ600R12KE3

Product Data sheet

Simplorer

Simplorer Device Characterization Tool automatic parameter fitting from data sheet


EMI analysis by Q3D LRC extraction

Circuit Model ・DC or AC

Static

Circuit Model ・DC or AC

State Space Model ・Freq. Sweep

Dynamic

Equiv. Circuit

Project info.

R/L vs Freq.

DC Circuit Model

AC Circuit Model

State Space / IFFT Model

Q3D Simplorer

ANSYS Solution for RLC Extraction


ANSYS Solution for RLC Extraction Cable Design Toolkit

Bounds Noise

Surge Noise

Geometry: 2D with skew

0

0

0

0

0 0 0000

00

0

0

E1

E2

E3

TFR3P6WL1

R4

R5

R6

armor_A

core_A_A

core_B_A

core_C_A

sheathA_A

sheathB_A

sheathC_A

armor_B

core_A_B

core_B_B

core_C_B

sheathA_B

sheathB_B

sheathC_B

R7 R8 R9R10R11R12

R13

R14

S1 R16

M3 ~

BA

C

IM1

MASS_ROT1S2

S3

S4

Q3D Simplorer


ANSYS Solution for Electric Machines

Enter Design Parameters

and Evaluate Design

Tradeoffs

Sizing

Predict Design

Performances

Efficiency Optimization

Optimize Cooling,

Noise and Bearing Life

Thermal Vibration

Interactions with Power Electronics and Control

Drive Control System


Electric Machines Design Flow


and Evaluate Design

Tradeoffs

Sizing

Predict Design

Performances

Efficiency

Optimize Cooling,


Thermal Vibration



→ Optimal Motor Dimensions → Coil Arrangements → Machine Performance Metrics

→ Rapid Sizing of Motors/Generators → Parameterize any of the over 50 Inputs → 30%-40% Time Savings Compared to Traditional Method




and Evaluate Design

Tradeoffs

Efficiency Optimization

Predict Design

Performances

Efficiency

Optimize Cooling,


Thermal Vibration



→ Minimise Losses → Minimize Magnet Size → Reduce Cogging and Ripple Torque

→ Advanced Magnetic Material Modeling → 20% of Rare Earth Magnet Size Reduction → Automated Prediction of Efficiency Maps




and Evaluate Design

Tradeoffs

Thermal Vibration

Predict Design

Performances

Efficiency

Optimize Cooling,


Thermal Vibration



→ Optimize Cooling → Reduce Noise → Increase bearing life

→ 20% More Accurate Over Single Physics Approach → Reduce NVH Profile by 40% → Increase Bearing Life by 150%




and Evaluate Design

Tradeoffs


Predict Design

Performances

Efficiency

Optimize Cooling,


Thermal Vibration



→ Simulate Entire Drive System With Controls

→ Dynamic Performances

→ Integrated Circuit and 2D/3D Simulations → Reduce Late Stage Changes → Reduce Warranty Cost By 40%


Requirement

Req 23: On request, the valve should close in 500us

Functional simulation

500us 0

Pos

true

false t

Behavorial simulation (0D)

t

Pos

0 500us

Virtual Prototyping

t

Pos

500us

Prototypes and Testing

Pmax

500us t

Pos

High fidelity 3D Design

Electronics Design Embedded Software Design

Magnetics Thermal 0.20 0.40 0.60 0.80 1.00

Stroke (Normalized Distance)

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

Y1

TRW / Ansoft Force vs Stroke

Curve Info

ArmStepHeight1='0mm' ArmStepRad1='2

ArmStepHeight1='0.000130288001891299

500us

t

ANSYS Simulation for Actuators


ANSYS Simulation for Actuators

0

0

0

0 0

S

+

SM_TRB1

F

F_TRB2

MASS_TRB1

V0=0m_per_sec

S0=0.5mm

M=1gram

F

F_TRB1

Ide

al

STOP

LOWER_LIM=0.01mm

UPPER_LIM=0.195mm

F

F_mag

F

F_Plunger

F

F_spring

SPRING_TRB1

C=333

S+

S_TRB1

VALUE=0.185mm

E1

R1

T1

T2T3

T4

smpl_lift

cfd_force

S1

CTRL=S1

D1

Electromagnetics Fluid

0.00 2.50 5.00 7.50 10.00 12.50 15.00Time [ms]

0.00

100.00

200.00

300.00

400.00

500.00

Po

sitio

n [u

m]

0.00

0.01

0.02

0.03

0.04

0.05

0.06

Co

il C

urr

en

t [A

]

-20.00

-15.00

-10.00

-5.00

0.00

5.00

10.00

15.00

20.00

Plu

ng

er

Fo

rce

[n

ew

ton

]

02_CoSim_MAgnetic_CFDTransient Switching with CFD ANSOFT

Curve Info Y Axis

Current Current

Plunger Force Plunger Force

Position w. CFD Y3

Position w/o CFD Y3

System

Magnetic Flux Density vs Time Includes Magnetic Diffusion Coil Temperature

Deformation


ANSYS Solution for Batteries C

ELL

Elec

tro

chem

istr

y C

ELL

& M

OD

ULE

Th

erm

al

PA

CK

Th

erm

o-E

lect

ric

• Electrochemistry models, Geometry Soc, Voltage, Ohm losses, temp

• Data (Voc vs SoC, V under discharge) Equivalent Circuit Model

• Cooling, Cells connections Temperatures

Thermal Model

Thermo-electric Model

DATA

ROM

Assembly Mgt

3D 0D


ANSYS Solution for Batteries


ANSYS Solution for Cockpit

Structural & Fatigue & Explicit Thermal

Electrical

Acoustics

Software & System


ANSYS Solution for Direct Strike

Current flowing on cables, here at 1MHz

Plot PeakH vs. distance along the whole cable length for each frequency.

Transient Thermal

31 © 2015 ANSYS, Inc. ANSYS Confidential *BusinessWeek, FORTUNE

ANSYS Strengths

FOCUSED This is all we do. Leading product technologies in all physics areas Largest development team focused on simulation

CAPABLE 2,600+

75

40

employees

locations

countries

TRUSTED

FORTUNE 500 Industrials 96 of the top 100

ISO 9001 and NQA-1 certified

PROVEN Recognized as one of the world’s MOST INNOVATIVE AND FASTEST-GROWING COMPANIES*

INDEPENDENT Long-term financial stability

CAD agnostic


OEMs Airbus Boeing Embraer Bombardier Alenia COMAC IRKUT Tupolev Northrop Grumman Aerospace Systems Lockheed Martin Aerospace Systems General Atomics Bell Sikorsky Eurocopter Agusta Westland

NASA JAXA SpaceX Astrobotic Astrium SP Korolev Rocket and Space Corporation Ampac ISP NEC Toshiba Space Systems Orbital Sciences United Launch Alliance United Space Alliance

Engines GE Aviation Pratt and Whitney Honeywell Rolls Royce MTU Aero Engines ITP Snecma

Suppliers GE Aviation Honeywell UTC Aerospace Systems Safran GKN Meggitt Moog

Northrop Grumman Lockheed Martin Aerospace Systems Thales L-3 Rockwell Collins Raytheon Harris BAE Sagem General Dynamics Cobham Elbit Systems

US Army US Air Force US Navy US DOD DGA AWE DSTL DRDC Lockheed Martin Boeing Northrop Grumman General Dynamics JPL JHU APL Wyle Labs SAIC QinetiQ Raytheon DRS General Dynamics Textron

MBDA Aerojet Rafael Remington Sturm Ruger ATK Roketsan Ruag Diehl BGT

Top Aerospace and Defense Companies Rely on ANSYS Tools


ANSYS System Solutions @ Airbus

SCADE Suite & SCADE Display have been used in the following A380 systems:

Flight Warning System

Electrical Load Management System

Cockpit Display System

ATSU (Board / Ground communications)

Braking and Steering System

Flight Control System

Anti Icing System

FADEC (Engine Control)


ANSYS provides market-leading depth and breadth of capabilities in one discipline, while allowing for integrated simulation across all disciplines

Products Overview: Leaders in the Field


ANSYS solutions deliver value across a wide range of aerodynamic, aeroacoustic and multidisciplinary design optimization applications

Drag prediction workshop

Aeroelasticity prediction workshop

High lift prediction workshop

Aero-acoustics


ANSYS solutions deliver value across a wide range of aerostructural, composite material and aerothermal applications

Building block simulations from coupons to airframes

Impact (e.g. bird strike)

Optimization and multifunctional simulations for composites

Integrated aero-thermal-structural simulations

Lightning


ANSYS solutions deliver value across a wide range of aircraft systems applications

Environmental control systems

Avionics and Embedded code

- Control - Display - Requirements Management - Auto-generation of certified code

-ARINC 661 compliant -DO 178B Level A -DO 178C ready -Def Stan 00-56 -FACE Consortium

ANSYS solutions in place on: -Airbus (A318 Elite, A340, A380, A350, A320 Neo -Boeing (787, 747-8) -COMAC (C919) -Irkut-OAK MS 21 -Bombardier CRJ1000, C Series -Embraer Phenom 100/300 -Eurocopter AS350, EC 135/145/155/225 -Sikorsky S76D

Mechanical/Hydraulic systems

De-icing systems

Passenger safety

Mechantronics for the “More Electric Aircraft”

*Courtesy of Parker Aerospace

Batteries and power electronics