16.10.2003 Dr. F. Grauer, MTPG 1 F. Grauer, H. Pfoertner MTU Aero Engines AVT128 Oct. 6th / 7th...
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Transcript of 16.10.2003 Dr. F. Grauer, MTPG 1 F. Grauer, H. Pfoertner MTU Aero Engines AVT128 Oct. 6th / 7th...
16.10.2003 Dr. F. Grauer, MTPG 1
F. Grauer, H. Pfoertner
MTU Aero Engines
AVT128Oct. 6th / 7th
Prague
Micro system technology in future engine applications – objectives and next steps
16.10.2003 Dr. F. Grauer, MTPG 2
Contents
• Introduction
• Motivation for research on Micro System Technology (MST)
• Objectives for future application of MST
• Challenges
• MTU activities
16.10.2003 Dr. F. Grauer, MTPG 3
MTU‘s activities related to subsystems (modules)
casings
Design/developmentProduction
JT8DLP
compressor
Engine testing andother sub-tasks
PW4000 GrowthPW2000, V2500,JT8D, PW300/500PW6000, GP7000
PW2000CF6,JT8D
GP7000PW6000HP
compressor
PW4084 / PW2000PW300 / PW500
HPturb.LP turbine
MTU as supplier of subsystems of commercial engines
AK, Jan. 2004/25
Introduction
16.10.2003 Dr. F. Grauer, MTPG 4
MTU‘s activities related to engine systems integration (modules)
casing
overall propulsion system/ system integration capability
EJ200MTR390RB199TP400-D6
Design/developmentProduction
IP / HPcompressor
combustor
EJ200 RB199
RB199
thrust reverser
HP /IP / LP turbine
afterburner
EJ200 MTR390EJ200 RB199TP400-D6
EJ200 MTR390 RB199TP400-D6
EJ200 / RB199 / MTR390 / TP400-D6
MTU is the German military engine systems integrator
Fan/LPcompressor
control systems
EJ200 RB199MTR390TP400-D6
AK, Jan. 2004/28
Introduction
16.10.2003 Dr. F. Grauer, MTPG 5
Highly loaded, affordable 6-stage HPC with Pressure Highly loaded, affordable 6-stage HPC with Pressure Ratio 12Ratio 12
Advanced 3D airfoil designAdvanced 3D airfoil design High efficiency provides minimum fuel burnHigh efficiency provides minimum fuel burn the product for the PW6000 enginethe product for the PW6000 engine
Highly loaded, affordable 6-stage HPC with Pressure Highly loaded, affordable 6-stage HPC with Pressure Ratio 12Ratio 12
Advanced 3D airfoil designAdvanced 3D airfoil design High efficiency provides minimum fuel burnHigh efficiency provides minimum fuel burn the product for the PW6000 enginethe product for the PW6000 engine
MTU Compressor Technology
Introduction
16.10.2003 Dr. F. Grauer, MTPG 6
Test Program of 5-stage Aero-RigTest Program of 5-stage Aero-Rig „ „Clocking“ of all statorsClocking“ of all stators Outstanding Aerodynamics: Outstanding Aerodynamics: Validation of unsteady aero toolsValidation of unsteady aero tools Engine Tests in progressEngine Tests in progress
Test Program of 5-stage Aero-RigTest Program of 5-stage Aero-Rig „ „Clocking“ of all statorsClocking“ of all stators Outstanding Aerodynamics: Outstanding Aerodynamics: Validation of unsteady aero toolsValidation of unsteady aero tools Engine Tests in progressEngine Tests in progress
MTU Turbine Technology
Introduction
16.10.2003 Dr. F. Grauer, MTPG 7
Intelligent Control for additional degrees of freedom in „Smart Intelligent Control for additional degrees of freedom in „Smart Compressor Design“:Compressor Design“: Active Surge DetectionActive Surge Detection Active Vibration ControlActive Vibration Control Active Clearance ControlActive Clearance Control
Intelligent Control for additional degrees of freedom in „Smart Intelligent Control for additional degrees of freedom in „Smart Compressor Design“:Compressor Design“: Active Surge DetectionActive Surge Detection Active Vibration ControlActive Vibration Control Active Clearance ControlActive Clearance Control
Demonstrator Engine Demonstrator Engine Extended stable Operating Range by ASCExtended stable Operating Range by ASC
„Active Surge Control“„Active Surge Control“
* ASC: Active Surge Control
Advances in Smart Compressor Technology
Introduction
16.10.2003 Dr. F. Grauer, MTPG 8
1990 20001995x 1
x 4
x 8
Increase in Controller Functions (Basis RB 199 DECU)
EJ200 C2 DECU
EJ200 DECMU
EJ 200 C1 DECU
2005
Status
• Most advanced European Control System
• increasing electronics in future Engines
Objectives
• Increase in Functionality / Flexibility
• Reduction of Development Costs by 50%
• Monitoring / Diagnosis / Prognosis
• Improvement of Engine Components and the whole Propulsion System by smart controls
Electronics & Controls
Introduction
16.10.2003 Dr. F. Grauer, MTPG 9
Motivation
• Advanced Control Concepts require additional information (Sensors) and new ways of actuation
• New Monitoring Concepts require extended instrumentation
• Miniaturization enables action immediately at the source
• Microsystems Technology enables highly redundant systems
• Sensor induced flow distortion can be neglected
• Potential for significant cost reduction compared to present systems
Motivation for research on MST
16.10.2003 Dr. F. Grauer, MTPG 10
Motivation
• First applications in aviation known
• Many Engine Manufacturers are engaged (but no tangible applications realized yet)
• Environmental conditions extremely difficult for MEMS Applications
• Maturity for Engine applications seems to need long time
Motivation for research on MST
16.10.2003 Dr. F. Grauer, MTPG 11
Active Surge Control
Active Vibration Control
Active Clearance Control
Objectives:• Increase in Efficiency by better use of
design space in aerodynamics • Surge Margin• Blade Vibration
• Increase in efficiency by reduced clearances
• Reduction in cost and weight by reduced number of parts
Attempt:• active surge control • active vibration control • active clearance controlUsing MEMS and smart materials
Attempt:• active surge control • active vibration control • active clearance controlUsing MEMS and smart materials
Smart Compressor
Objectives for future applications of MST
16.10.2003 Dr. F. Grauer, MTPG 12
Spakovszky et al. „Rotating Stall Control in a High-Speed Stage with Inlet Distortion,Part I - Radial Distortion“ ASME 98-GT-264
Constant / modulated air injection
Haynes et al.: „Active Stabilization of Rotating Stall in a Three-Stage Axial Compressor“ Trans. Of the ASME, Vol.116, Apr. 1994
Variable Guide Vanes
Surge Control: Actuation
Objectives for future applications of MST
16.10.2003 Dr. F. Grauer, MTPG 13
Dürr, Herold-Schmidt, Ihler „Schwingungsdämpfung mit adaptiven Werkstoffen in Turbinen - Teilprojekt Piezoaktive Strukturen“ FT4/WK-2000-016
Vibration Control: Actuation
Objectives for future applications of MST
16.10.2003 Dr. F. Grauer, MTPG 14
Vibration
Emissions
Leakage
Differential mon. inlet / exhaust
Harness
Model based diagnosis and prognosis
Objectives:• Better exploitation of remaining parts life
• Maintenance on demand
• Extension of maintenance rate
• Support of Fly-by-hour concepts
Attempt:• On-board performance model• Monitoring of FOD• Vibration monitoring• Harness monitoring• Smart Tagging• ……..
Attempt:• On-board performance model• Monitoring of FOD• Vibration monitoring• Harness monitoring• Smart Tagging• ……..
Monitoring
Objectives for future applications of MST
16.10.2003 Dr. F. Grauer, MTPG 15
Temperatures in commercial engines
Fan & Booster(< 200ºC)
Fan & Booster(< 200ºC)
HP Compressor(< 700ºC)
HP Compressor(< 700ºC)
HP Turbine(< 1300ºC)
HP Turbine(< 1300ºC)
LP Turbine(< 1000ºC)
LP Turbine(< 1000ºC)
Challenges
16.10.2003 Dr. F. Grauer, MTPG 16
• Bird strike
• Foreign object damage (FOD)
• Ingestion of • Ice• Sand und dust• Water
• Humidity
• Icing
Environmental conditions
Damaged Fan Blade
Deposition on Compressor Rotor
Deposition of sand on an
compressor shaft
Challenges
16.10.2003 Dr. F. Grauer, MTPG 17
• System aspects / new approaches
• MST in “save” environment / locally distributed• Stepwise approaches• Integration into existing system: Pipes, Valves, Fluidic actuation
• Safety
• reliable fault detection• redundancy
• Benefits compared to “conventional” approaches
• Active vs. passive systems• Reliability
• Un-paralleled demands on packaging
Questions to solve
Challenges
16.10.2003 Dr. F. Grauer, MTPG 18
• DaimlerChrysler Cooperation on MST
• 6. EU Framework: ADVACT
• AVT128
MTU activities
MTU activities
16.10.2003 Dr. F. Grauer, MTPG 19
• System aspects / new approaches
• MST in “isolated” environment• Stepwise approaches• Integration into existing system: Pipes, Valves, Fluidic actuation
• Safety
• reliable fault detection• redundancy
• Benefits compared to “conventional” approaches
• Active vs. passive systems• Reliability
• Un-paralleled demands on packaging
Questions to solve
Challenges