AV Expert Series Technical notes from energy innovators

Transcription

1 in Aerospace Applications CASE STUDY: AeroVironment Global Observer This technical note describes various applications of AeroVironment s (AV s) Power Cycling and Test Systems in the Aerospace industry, including development of electrical components and systems, durability testing and production testing. Table of Contents 1. Background: Electric Aircraft Systems and AV 2. Overview of Component Development and Testing 3. Energy Storage System Development 4. Power System Development 5. Summary 1

2 Background: Electronic Aircraft Systems and AV Commercial aircraft manufacturers are relying increasingly on electric power to: 1. Reduce emissions 2. Improve system efficiency and reduce fuel use 3. Increase reliability and redundancy 4. Improve performance Some of today s large commercial aircraft are approaching or exceeding 1 MW of on-board electrical power generation in order to meet these goals. Electric power and control systems replace inefficient pneumatic systems and are being used to power hydraulics, engine start and de-icing functions. Over the next five to ten years, commercial and military aircraft manufacturers will produce new planes with even greater electric production and usage to exceed current performance and economy targets. Potential upgrades include: 1. Electric actuated landing gear 2. Electric actuated flight controls 3. Peak power management 4. Emergency power 5. Electric propulsion AeroVironment s more than 25 years of hands-on experience developing electric aircraft systems makes it particularly well suited for meeting the needs of today s and tomorrow s aircraft market. AeroVironment s history in electric aircraft systems began with the Solar Challenger, the first solarpowered aircraft and continues today with a number of broadly-adopted small Unmanned Aircraft Systems, and the Global Observer High-Altitude, Long-Endurance (HALE) aircraft platform. A timeline of AV s innovations in large electric aircraft systems is shown below in Figure 1. Figure1. AeroVironment Timeline: Large Electric Aircraft Development 2

3 Overview of Component Development and Testing AV s engineers have continuously relied on the company s own to develop critical components and sub-systems for the Global Observer HALE aircraft, including (see Figure 2 below for a sampling of components): 1. Battery Pack 2. Motor controllers 3. Propulsion motors 4. APU Figure 2. Global Observer Major Electrical Components 3

4 AV Expert Series Technical notes from energy innovators Energy Storage System Development and Testing One of the key elements of the Global Observer powertrain is the energy storage system the battery pack used to provide critical functions, including: DC buss stabilization and management Peak power functions for climbing Emergency back-up power APU starting Since the battery pack is critical to all major functions of the aircraft, significant effort was allocated to the rigorous selection, testing and packaging of the cells. This was accomplished using AV s MT-30 and ABC-150 Power Cycling and Test System equipment. The equipment was used to screen the cells for capacity and impedance, and then to run them through a gauntlet of performance and environmental tests. The screened cells were then assembled into modules, and finally a full pack, including its intelligent Battery Management System (BMS). The fully-assembled pack, along with its BMS, underwent another battery of tests as shown below in Figure 3. Figure 3. Global Observer Battery Screening, Performance and End of Line Testing Processes 4

5 Power System Development and Testing Global Observer is a breakthrough high-altitude platform designed to stay aloft for days without refueling. This unique value proposition requires rigorous validation of the durability of the power generation system, including the alternator and rectifier. The Global Observer test rig used two ABC- 150 systems to test these components and recover the generated energy. A schematic and photo of the test rig is show below in Figures 4 and 5. Figure 4. Global Observer APU Test Rig Figure 5. Global Observer Major Electrical Components 5

6 Summary The commercial and military aircraft industry will continue its aggressive focus on electrification in order to maximize performance, reliability and efficiency all while reducing emissions. Power Cycling and Test Systems are critical to the development of new components and sub-systems to support this shift toward electrification. This Technical Note reviewed multiple applications of AeroVironment s Power Cycling and Test Systems in the development of the aircraft of the future. Call or us for a more in-depth look our systems experts provide detailed phone consultations and are standing by to discuss your individual development and testing needs. 6