Electrical Power Generation & Start Solutions for the Falcon 5X Program (ppt)

03/02/2015
OAI : oai:www.see.asso.fr:10638:12709
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Electrical Power Generation & Start Solutions for the Falcon 5X Program (ppt)

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application/pdf Electrical Power Generation & Start Solutions for the Falcon 5X Program (ppt) François Biais, Francis Delhasse, Pascal Thalin
application/pdf Electrical Power Generation & Start Solutions for the Falcon 5X Program François Biais, Francis Delhasse, Pascal Thalin

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www.thalesgroup.com This document is the property of Thales Group and may not be copied or communicated without written consent of Thales ThalesAvionicsElectricalSystems16/02/2015 MEA 2015 Toulouse Electrical Power Generation and Start Solution for the Falcon F5X Program F Biais F Delhasse P Thalin 2 /2 / This document is the property of Thales Group and may not be copied or communicated without written consent of ThalesThis document is the property of Thales Group and may not be copied or communicated without written consent of Thales Electrical Power Generation and Start Solution for F5X ThalesAvionicsElectricalSystems-ElectricalPowerGenerationandstartsolutionfortheF5Xprogram Content 1/ Background on electric start: DC to AC start 2/ F5X generation and start solution 3 /3 / This document is the property of Thales Group and may not be copied or communicated without written consent of ThalesThis document is the property of Thales Group and may not be copied or communicated without written consent of Thales Background on electric start ThalesAvionicsElectricalSystems-ElectricalPowerGenerationandstartsolutionfortheF5Xprogram Electric start by DC machines Electric start of engines is widely used, based on 28 Vdc starters or starter/generators: business jet engines - commuter aircraft engines - APU turbines 4 /4 / This document is the property of Thales Group and may not be copied or communicated without written consent of ThalesThis document is the property of Thales Group and may not be copied or communicated without written consent of Thales Background on electric start ThalesAvionicsElectricalSystems-ElectricalPowerGenerationandstartsolutionfortheF5Xprogram Introduction of Variable Frequency AC Generators Variable Frequency Generators directly driven by the engine Gearbox (constant speed drive removed) combined with Power converter performances Makes possible the replacement of the engine air start by brushless 3-stage AC generator start (operating as a synchronous motor supplied by a converter) 5 /5 / This document is the property of Thales Group and may not be copied or communicated without written consent of ThalesThis document is the property of Thales Group and may not be copied or communicated without written consent of Thales Background on electric start ThalesAvionicsElectricalSystems-ElectricalPowerGenerationandstartsolutionfortheF5Xprogram Thales demonstrations of electric start by brushless 3-stage AC generator Based on its experience on brushless 3-stage AC generators and “autosynchronous” motors and control Thales demonstrated back in 1995 the AC electric start by a brushless 3- stage generator 6 /6 / This document is the property of Thales Group and may not be copied or communicated without written consent of ThalesThis document is the property of Thales Group and may not be copied or communicated without written consent of Thales Background on electric start ThalesAvionicsElectricalSystems-ElectricalPowerGenerationandstartsolutionfortheF5Xprogram 1st demonstration of electric start by brushless 3-stage AC generator In 1995 an off-the-shelf air-cooled 115 VAC 30 kVA 12000 rpm generator was modified so as to operate in motor mode in low speed range (0 to idle): Exciter modified to operate as a transformer • Rotor position sensor introduced to enable autosynchronous control • Supply of the 3-phase main stator with flux weakening capability and the main exciter by a converter A turboprop engine was successfully started by this modified generator. ~ 7 /7 / This document is the property of Thales Group and may not be copied or communicated without written consent of ThalesThis document is the property of Thales Group and may not be copied or communicated without written consent of Thales Background on electric start ThalesAvionicsElectricalSystems-ElectricalPowerGenerationandstartsolutionfortheF5Xprogram Challenges for the brushless 3-stage starter-generator to operate in both starting and generating modes Exciter: The same exciter must be capable of operating in two different modes: In generating mode: is excited by GCU DC current, operates as a synchronous machine, and delivers the power to the main rotor from mechanical power In starting mode: is supplied by AC converter, provides full AC power to the exciter rotor through transformer effect Main stator: In generating mode: provides electric power meeting voltage standards constraints In motoring mode: provides torque within converter current constraints Cooling: Oil or air flow rate is reduced during starting sequence at low speed > challenge on rotating diodes 8 /8 / This document is the property of Thales Group and may not be copied or communicated without written consent of ThalesThis document is the property of Thales Group and may not be copied or communicated without written consent of Thales Background on electric start ThalesAvionicsElectricalSystems-ElectricalPowerGenerationandstartsolutionfortheF5Xprogram Development of a high power Starter Generator (MEGEVE) In 2005 an oil-cooled 200 kVA starter-generator demonstrator was developed by Thales: • Including “hybrid” exciter with both generating and starting functions • Including position sensor Generating and starting modes were validated Various starting control laws were incorporated and tested. 130 kW 9 /9 / This document is the property of Thales Group and may not be copied or communicated without written consent of ThalesThis document is the property of Thales Group and may not be copied or communicated without written consent of Thales Background on electric start ThalesAvionicsElectricalSystems-ElectricalPowerGenerationandstartsolutionfortheF5Xprogram Development of a high power Starter Generator (MEGEVE) • Starting sequences were tested • Thermal behavior during starting sequence was analyzed on the instrumented Starter generator (stator, and also rotor through tele-transmission) Temperature on stator winding, exciter winding and rotating diodes time (s) time (s) temperatures(°C) temperatures(°C) rotating diodes AC exciter DC exciter Main stator end turns and slots 10 /10 / This document is the property of Thales Group and may not be copied or communicated without written consent of ThalesThis document is the property of Thales Group and may not be copied or communicated without written consent of Thales Background on electric start ThalesAvionicsElectricalSystems-ElectricalPowerGenerationandstartsolutionfortheF5Xprogram Development of an embedded high power Permanent Magnet Starter Generator in Rolls Royce engine (POA program) A 150 kW (Gen) / 175 kW (Start) embedded Permanent magnet generator was developed and tested in a RR engine (on HP shaft). Integration challenge of a PM machine in harsh environment Starting and generating operation were validated Embedded stator immersed in cooling oil with ceramic sleeve separation Rotor on High pressure shaft 11 /11 / This document is the property of Thales Group and may not be copied or communicated without written consent of ThalesThis document is the property of Thales Group and may not be copied or communicated without written consent of Thales FALCON F5X Generation and start solution ThalesAvionicsElectricalSystems-ElectricalPowerGenerationandstartsolutionfortheF5Xprogram Challenges addressed during these advanced developments • Optimization of double operation of the exciter • Machine cooling during start phase • Optimization of kVA rating of main and auxiliary converter Complete generation and start solution TopStartTM proposed for the new Dassault Falcon F5X 12 /12 / This document is the property of Thales Group and may not be copied or communicated without written consent of ThalesThis document is the property of Thales Group and may not be copied or communicated without written consent of Thales FALCON F5X Generation and start solution ThalesAvionicsElectricalSystems-ElectricalPowerGenerationandstartsolutionfortheF5Xprogram Falcon F5X : Thales generation and start solution 2 x main Starter Generators 115 V, air cooled Start the Snecma Silvercrest engine 1 APU Starter Generator 115 V, air cooled Start the PW APU turbine 3 GCU 13 /13 / This document is the property of Thales Group and may not be copied or communicated without written consent of ThalesThis document is the property of Thales Group and may not be copied or communicated without written consent of Thales FALCON F5X Generation and start solution ThalesAvionicsElectricalSystems-ElectricalPowerGenerationandstartsolutionfortheF5Xprogram Falcon F5X : Thales generation and start solution 1 Start box Delivers AC power to the APU Starter/Generator from Battery through DC/DC boost converter Delivers AC power to the Main Starter/Generator from Ground Power Unit / Main Starter Generator /APU through rectifier Air cooled (-55°C to +70°C)