Full electrical E-Fan aircraft for general aviation: Project Overview and main perspectives. Innovations and challenges

03/02/2015
OAI : oai:www.see.asso.fr:10638:12779
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Full electrical E-Fan aircraft for general aviation: Project Overview and main perspectives. Innovations and challenges

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application/pdf Full electrical E-Fan aircraft for general aviation: Project Overview and main perspectives. Innovations and challenges Emmanuel Joubert

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Title of presentation runs here on two lines / Arial Regular 30 pt Subtitel goes here / Arial Regular 20 pt VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France E-FAN The first purpose-built, electrically powered trainer aircraft AIRBUS Group – SAFRAN – ZODIAC 05/02/2015 - TOULOUSE VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France Agenda 26/02/2015 E-FAN: Development of an electrically-powered aircraft 2 History and Origin of the project E-Fan 2.0 objectives Partnership Requirements Challenges Electrical System Devices High Voltage Electrical System Skills Technical Challenges Electric Propulsion Challenges eFAN eIPS 2.0 Concept VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France The “E-FAN Family” concept 26/02/2015 E-FAN: Development of an electrically-powered aircraft 3 2017 World’s first fully electric four engine aerobatic plane First purpose-built electric powered training aircraft Industrialized version of E-FAN 1.0 => Electrization of a thermical plane => Flying test bed => Commercial version of a full-electrical training plane VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France E-FAN 2.0: Main objectives & challenges • 4 objectives: ▫ Competitive aircraft Response to a market need for ab-initio trainings Competitive price in Total Cost of Ownership (TCO) ▫ Certifiable aircraft: regulatory acceptance of electric propulsion ▫ Aircraft suitable for production: structuring of an industrial sector ▫ Acceptability of new learning methods by all the stakeholders (teachers, pilots, regulatory authorities) • 4 challenges: 26/02/2015 4 Avion Thermal Aircraft Project goals Weight <600 kg (LSA certification) <600 kg (LSA** certification) TCO 100 à 120 €/h Less than 90 €/h (low energy cost, minimizing immobilization with low maintenance) Autonomy 4 - 5 hours 1h + 15 min for security reasons Availability 10 hours / day scheduled maintenance every 50h 5 hours / day (quick charge in 45 min) Yearly scheduled maintenance*** * Restricted certificate of airworthiness ** Light Sport Aircraft *** Based on the use of 300 hours per year E-FAN: Development of an electrically-powered aircraft VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France Towards production 26/02/2015 E-FAN: Development of an electrically-powered aircraft 5 E-FAN 1.0 Flying Demonstrator Design Pré- Industrialization E-FAN 2.0 June 2011 July 2014 2017 100% electrical engine 2 seats side-by- side Fixed gear Initial training Battery management system E-FAN 2.0 E-FAN 1.0 PSPC Creation of VoltAir, 100% Airbus Group Subsidiaries VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France E-FAN 2.0: Partners 26/02/2015 E-FAN: Development of an electrically-powered aircraft 66 Consortium of 10 partners for industrial production • 6 industrial partners: Airbus Group (with Daher- Socata as key subcontractor), Zodiac Aerospace, Safran, ACS, Evtronic, Serma Technologies; • 4 research organizations / schools: CEA Tech, ENAC, ENSAM, ISAE, INSA. VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France ASTM 2840 26 February 2015 Presentation Title runs here (go to Header & Footer to edit this text) 7 This specification provides designers and manufacturers of electric propulsion for light sport aircraft design references and criteria to use in designing and manufacturing EPUs • This specification covers minimum requirements for the design and manufacture of Electric Propulsion Units (EPU) for light sport aircraft, VFR use. The EPU shall as a minimum consist of the electric motor, associated controllers, disconnects and wiring, an Energy Storage Device (ESD) such as a battery or capacitor, or both, and EPU monitoring gauges and meters. Optional onboard charging devices, in-flight charging devices or other technology may be included. • § 5 : Data requirement : data recorder & storing, drawings, reference, M&P, operating manuel, maintenance manuel • § 6 : Design Criteria : Material, Fire, Crash, vibration, SW • § 7 : Qualification tests : durability, endurance, reliability (for each component of EPU and for the EPU system) • § 8 : Manufacturing Requirements Applicable to Airbus Group, SAFRAN, ZODIAC VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France Example of Top Level Requirement TLR Regulatory requirements 6 Operating environment and limitations 7 Mission capability and performance 9 Physical characteristics 9 Cabin & comfort 8 Ergonomy/HMI 10 Safety 3 Reliability 7 Availability 1 Maintainability 5 Service life and utilization characteristics 5 Total Cost of Ownership (TCO) 10 Rescue and emergency equipment 1 Commercial options 2 26/02/2015 Regulatory : - MTOW = 600 kg (LSA) - Vs ≤ 83 km/h - Load Factor : Positive limit load factor : +4 g Negative limit load factor : -2 g - The system shall be designed for flight in heavy rain - Rate of climb at VY shall exceed 95 m/min (312 fpm) Market - Operating temperatures : ISA -30 to ISA +25 - Autonomy 1 hour + 15 min reserve - Nb Rotation : 6 per day - Average yearly utilization : 300 FH/year - Cabin size : fit with EU and US market - Heating system to ensure a cabin temperature of 15°C under an OAT of -10°C - Transition between thermal and electrical easy - No more than 30 min to remove or install Line Replaceable Units (LRU) - No additional calendar scheduled maintenance, except those mandated by A/C manufacturers VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France E-FAN 2.0 : Main innovations & challenges 26/02/2015 E-FAN: Development of an electrically-powered aircraft 9 Area of work E-FAN 1.0 demonstrator Project innovations Challenges Energy storage Energy density: 100 Wh/kg 130 kg of Li-Ion batteries Energy delivered: 13 kWh Energy density > 200 Wh/kg 200 kg max of Li-Ion batteries Typical energy: 40 kWh Mechanical integration / Packaging Electrochemistry and Materials Intelligent energy management / Safety Recharge Slow recharge in about 2h Quick recharge in 45 min Heating / cooling batteries Preservation durability / safety Engine specification Electric motor and fan ducted Optimization of the propulsion system (efficiency, cooling, acoustic) Cooling and electromagnetism management Internal aerodynamics Noise control and management High energy density (approx. 5kW/kg on the pack) VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France E-FAN 2.0 : Main innovations & challenges 26/02/2015 E-FAN: Development of an electrically-powered aircraft 10 Area of work E-FAN 1.0 demonstrator Project innovations Challenges Taxiing Remote engine with transmission to the wheel New system to integrate into a fixed gear Design / Integration motor/wheel Robustness and reliability under conditions of use IHM / Avionics Customization of a classic dashboard Modern cockpit compatible with the training demands and the transition to a thermal plane Ability to simplify the management of electric propulsion and autonomy Weight Current weight: 650 kg (incl. 130 kg of batteries) Weight to reach: 600 kg incl. 200 kg of batteries (reduction of 120 kg) Batteries mass: 200 kg max Lighter engines, structure and system Aircraft system No redundancy or system reconfiguration Combine the high requirements of reliability and security with high mass and cost constraints Complex system in a constrained environment VoltAir SAS au capital de 4 000 000 €, 803 675 628 R.C.S. BORDEAUX , Siège social : 25, rue Marcel Issartier, BP20005, 33702 Mérignac Cedex, France ZODIACAEROSPACEWP 26/02/2015 E-FAN:Developmentofanelectrically-poweredaircraft 11 ©ZodiacAeroElectric.Allrightsreserved.Confidentialandproprietarydocument. ZODIAC AIRCRAFT SYSTEMS Zodiac Aero Electric - 12 ZODIAC AEROSPACE PACKAGEZODIAC AEROSPACE PACKAGE 1. Energy Storage Device (ESD): Including cells, Battery Management System , Continuous load evaluation , packaging & assembly Activities: Design, protoptype assembly , testing in flight and on ground for the battery charger functton Suppor AGI for the certification activities 2. High voltage electrical system : High voltage distribution system (270 VDC & 350VDC) Activities: Design, protoptype assembly and testing Suppor AGI for the certification activities Competencies to develop : Acquire a global understanding of a full electrical A/C - (support the trade off s leaded by AGI/Socata) Acquire a first experience in hpw certified a a full electrical A/C Develop a battery system integreting COTS cells ©ZodiacAeroElectric.Allrightsreserved.Confidentialandproprietarydocument. ZODIAC AIRCRAFT SYSTEMS Zodiac Aero Electric - 13 CHALLENGESCHALLENGES Energy Storage Device : 1. Worldwide benchmark and selection of the Cells 2. Performances des cellules disponibles à ce jour (densité d’énergie) 3. Safety 4. Accuracy of the continuous load evaluation 5. Mechanical Integration directly in the wing box : High voltage electrical distribution system 1. HVDC level 2. HVDC integration (EMI, Safey , short circuit protection) VoltAir SAS au capital de 4 000 000 €, 803 675 628 R.C.S. BORDEAUX , Siège social : 25, rue Marcel Issartier, BP20005, 33702 Mérignac Cedex, France 26/02/2015 E-FAN:Developmentofanelectrically-poweredaircraft 14 VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France - 15 PROPULSION CHALLENGESPROPULSION CHALLENGES Electrical Motor Mass and Performance Integration Cooling Power Electronics Mass and Performances Integration Cooling Ducted Fan Mass and Aero Dynamic Performances Integration Speed Nacelle Mass and Aero Dynamic Performances Integration VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France - 16 eFAN eIPS 2.0 ConcepteFAN eIPS 2.0 Concept Reliable, Cost Improved Solution Low Drag Nacelle Advanced Aircooled Integrated Electronics and Electrical Motor 2 Synchronous Brushless Electrical Motors High Efficiency Distributed Power Electronics High Aerodynamic Efficiency Fan Easy Maintenance Project Management Electrical Motor Power Electronics FAN and Aerodynamics Nacelle Integration and Assembly Title of presentation runs here on two lines / Arial Regular 30 pt Subtitel goes here / Arial Regular 20 pt VoltAirSASaucapitalde4000000€,803675628R.C.S.BORDEAUX,Siègesocial:25,rueMarcelIssartier,BP20005,33702 MérignacCedex,France Thanks for your attention AIRBUS Group : emmanuel.joubert@airbus.com SAFRAN : christophe.claisse@safran.com ZODIAC : Thierry.RougeCarrassat@zodiacaerospace.com