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AEROSPACE ELECTRICAL SYSTEMSPAST, PRESENT, AND NEXT STEPS
November 28-30, 2016
ERIC J. KLINEEngineering Manager
Generators & Ram Air Turbines
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PAST: A BRIEF HISTORY OF ELECTRICAL SYSTEMS
1
Safran Electrical & Power / Confidential / November 2016 / Overview2
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AIRCRAFT ELECTRICAL POWER SYSTEMS BY ERA
• 1903 to 1913 – No electrical power (0 VDC)
• 1913 to 1920 – Battery only (6-12 VDC)
• 1920 to 1933 – External Generators and Battery (12-24 VDC)
• 1933 to 1945 – Internal Generators and Battery (28 VDC)
• 1945 to 1960 – 400 Hz AC, slip ring exciters (120 VAC, 400 Hz)
• 1960 to 1976 – CSD, Rotor diodes brushless (120 VAC, 400 Hz)
• 1976 to 1996 – IDG 400 Hz AC systems (120 VAC, 400 Hz)
• 1996 to today – CF, VF, VSCF (120 VAC, 360-800 Hz)
1903 1927 1945 1970 2005
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• 1903: Wright Flyer first flight
• Early aircraft had no electric power on board
• No lights, no radio, no entertainment system
• Engines did not require electric power; magnetos for spark ignition
• Control surfaces entirely mechanical
• Flights lasted seconds to minutes… and were dangerous
HISTORY OF AIRCRAFT ELECTRIC POWER: 1903-1913
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HISTORY OF AIRCRAFT ELECTRIC POWER: 1913-1920
• Aircraft began to require electricity for radios and lights
• 1913: first use of wireless telegraphy (morse code)
• 1915: first use of 2-way voice communication
• 1916: Marconi Radio Company started production of ground-to-air radio transmitter/receivers
• 6-12VDC power provided by batteries (charged on ground)
• Battery charge would last length of flight
• Technology advancement driven by WW I
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HISTORY OF AIRCRAFT ELECTRIC POWER: 1920-1933
• Innovations increase electrical load
• Battery ignition for engines, radios, lights
• Flights get longer, required generator to re-charge battery
• 12-24 VDC
• Technology fueled by inter-war air transport growth (tourism and air mail)
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HISTORY OF AIRCRAFT ELECTRIC POWER: 1920-1933
• 1921: US Army Air Corps bombing demo of USS Alabama.
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HISTORY OF AIRCRAFT ELECTRIC POWER: 1920-1933
• 1921: Ram Air Turbine (RAT) generator on MB-2
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HISTORY OF AIRCRAFT ELECTRIC POWER: 1920-1933
• 1921: RAT generator on Handley-Page W8B
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HISTORY OF AIRCRAFT ELECTRIC POWER: 1920-1933
• 1927: RAT generator on OX-5 Swallow
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HISTORY OF AIRCRAFT ELECTRIC POWER: 1920-1933
• 1930: RAT generators Handley-Page HP40
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HISTORY OF AIRCRAFT ELECTRIC POWER: 1933-1945
• Engine-mounted generators
• Electric starters
• Aerial Radar
• Required 600V power
• Used Motor-Generator sets to provide high-voltage
• Technology fueled by WW II
• 24-28 VDC batteries
• 120VAC: B-29 drives major changes to electrical system
• Transcontinental capability
• More electric actuators, higher power levels, longer cable runs
• Need for high voltage to reduce current requirements
• 3-phase, 120V, 400Hz AC architecture chosen as optimum
Douglas DC-1
B-17
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HISTORY OF AIRCRAFT ELECTRIC POWER: 1933-1945
• Converts 28 VDC to 600 VDC to drive radar loads
• Two machines built on one common shaft
• Lots of added weight just to convert voltage
Douglas DC-1
B-17
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HISTORY OF AIRCRAFT ELECTRIC POWER: 1933-1945
• 1945: B-29. First AC electrical system. Set standards still widely in use today.
• 3-phase, 120V, 400Hz AC
• 28 VDC for some loads
• Motor-gen set for high voltage radar load
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HISTORY OF AIRCRAFT ELECTRIC POWER: 1945-1960
• Innovations:
• 120V 3-phase AC implementation in large aircraft
• Sundstrand Constant Speed Drive (CSD)
• Technology driven by jet propulsion and Cold War
• Larger aircraft have two power busses: 28 VDC and 120V, 400 Hz AC constant frequency
• Mag-Amp and Carbon Pile voltage regulation
B-29 and B-36
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HISTORY OF AIRCRAFT ELECTRIC POWER: 1945-1960
Boeing 707
B-47
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• Innovations: oil cooling, hermetic semiconductors, HiperCo50, Kapton, Nomex
• Diodes allow first brushless machines with rotating rectifiers
• Rotating exciters create AC power that is rectified to excite main rotor stage
• Previosly, slip rings were used to excite main rotor stage
• First oil-spray cooled machines
• 2-3x increase in power density
• Technology is driven by the space race and Cold War - miniaturization
• Analog generator control units and voltage regulators
HISTORY OF AIRCRAFT ELECTRIC POWER: 1960-1975
Concord
F-111
KC-135
DC-10
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• Business dominated by Sundstrand (later United Technologies) due to CSD (constant
speed drive)
• 4-pole, 2-pole IDG’s
• Analog GCUs common
• First digital GCUs (generator control units)
• Some competition from VSCF for 400 Hz
• Westinghouse did initial 737 power system (late-1960s) with VSCF (variable speed, constant frequency)
• Relied on power electronics, but maturity level was not sufficient
• Boeing eventually replaced with Sundstrand CSD and CF (constant frequency) generators
HISTORY OF AIRCRAFT ELECTRIC POWER: 1975-1996
757
C-17
757
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• Rise of variable frequency (VF) systems: 360-800 Hz
• Diminishes monopoly of Hamilton-Sundstrand (United Technologies)
• Re-introduction of VSCF: more capable power electronics
• High voltage DC on military aircraft: 270VDC
• Still safety concerns on commercial aircraft, due to fault detection
• Brushless starter generator (BSG): commutation by power electronics instead of brushes
HISTORY OF AIRCRAFT ELECTRIC POWER: 1996-2016+
Global Express A380
787
VF systems:
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• Electric Start
• 100+ kVA brushless starter-generators for engine start and power generation
• Replaces pneumatic start from APU; ducting is heavy, bulky, and difficult to maintain
• Ventilation
• Engine bleed air replaced with electric blowers and compressors
• Increases efficiency and thrust of engines
• Can be reduced during takeoff an
• Actuation: gradual replacement of hydraulic equipment
• ETRAS: Electric Thrust Reverser Actuation System
• Electric-Mechanical and Electro-Hydraulic actuators
• Green Taxi
• APU powers motor on main landing gear wheels.
• 3% saving on total fuel burn; significant reduction in NOx, noise, and engine wear
• Electric Drive Train
• Helicoptor tail rotors, distributed propulsion for VTOL
MORE ELECTRIC AIRCRAFT: 2011+REDUCED WEIGHT, INCREASED EFFICIENCY
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This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran
SAFRAN AT A GLANCE
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Safran Electrical & Power / Confidential / November 2016 / Overview22
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SAFRAN AT A GLANCE
Safran Electrical & Power / Confidential / November 2016 / Overview23
AN INTERNATIONAL
HIGH-TECHNOLOGY
GROUP
€17.4 BILLION in sales*
€2.1 BILLION in R&D expenditures*,
equal to nearly 12% of
sales
Over 900
INITIAL
PATENTS filed in 2015
€2.4 BILLION in adjusted recurring
operating income*
*2015
This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran
SAFRAN CAPABILITIES FOR ELECTRIC PROPULSION
Safran Electrical & Power / Confidential / November 2016 / Overview24
Electrical & Power Systems
Formed in 2013 to address growing focus on aircraft electrification
Distribution, Generation, Starters, Motors, Wiring Systems, System Development
Includes former divisions of Goodrich, Lucas, Lear-Siegler, Jack & Heintz
Aircraft Engines (formerly Snecma)
Includes CFM JV with General Electric
CFM-56, LEAP, Silvercrest, components for GE90
Helicopter Engines (formerly Turbomeca)
Power Units (formerly Microturbo APUs)
Transmissions (formerly Hispano-Suiza)
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Safran Electrical & Power / Confidential / November 2016 / Overview25
SAFRAN ELECTRICAL & POWER
COPPER Bird electrical system test facility.
This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran
SAFRAN ELECTRICAL & POWER AT A GLANCE
Safran Electrical & Power / Confidential / November 2016 / Overview26
*EWIS: Electrical Wiring Interconnection Systems
(2015 figures)
A WORLD
LEADER IN
ELECTRICAL
SYSTEMS
N°1
WORLDWIDE
FOR EWIS*
and ventilation
systems
A WORLDWIDE
CUSTOMER
SERVICES
NETWORK
N°2
WORLDWIDE
FOR
ELECTRICAL
power generation
~ 14, 000
PEOPLE
IN 12
COUNTRIES
GLOBAL
ENGINEERING
SERVICES
and innovative data &
power interconnection
systems
Comprehensive
product portfolio
covering all on
board electrical
systems
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AN UNRIVALLED PRODUCT RANGE
27
GENERATION
> Variable and constant
frequency AC generators
> 2-Pole, high speed APU
generators
> 28VDC Brush and
Brushless DC Start
Generators
Safran Electrical & Power / Confidential / November 2016 / Overview
DISTRIBUTION
> AC and DC distribution
> Secondary AC and DC
Solid State Power
Controller (SSPC)
> Circuit breakers
> Contactors & Relays
ALTERNATE
POWER
> Auxiliary Power Unit
e-APU and MPG (Main
Power Generators)
> RAT (Ram Air Turbine)
product policy from
conventional deploy to
integrated solutions
WIRING
> EWIS processes and
Tools
> All-ATA interface
modeling & simulation
> One-Stop Shop for
configuration control
LOADS
ELECTRIFICATION> Green Taxiing (APU
Supplied) and e-Brake
> Electric Nacelle (eTRAS-
Electrical Thrust Reverser
Actuation System, VFN -
Variable Fan Nozzle, Anti-
Ice functions)
> Electric Engine Start
> Flight Controls EMA
(Electro Mechanical
Actuator)
> Variable frequency fans
INTEGRATION &
CERTIFICATION
> Complete nose-to-tail
electrical power systems
for any size of aircraft
> Integration of a complete
electrical power generation
and distribution system and
certification process
support
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SAFRANAIRCRAFT ENGINES
Day/month/year
Safran Electrical & Power / Confidential / November 2016 / Overview28
This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran
No. 1 engine
supplier worldwide for mainline commercial jets (over 100 seats)
CFM® –
Safran Electrical & Power / Confidential / November 2016 / Overview29
More than 550customers worldwide
Partnership extended
to 2040
Safran Aircraft Engines & GE, successful partners for over 40 years
50/50 joint companyAll activities are equally split: design,
development, production, sales and support.
This document and the information therein are the property of Safran. They must not be copied or communicated to a third party without the prior written authorization of Safran
CFM56, LEAP® – Combining the best technologies from Safran Aircraft Engines and GE
Safran Electrical & Power / Confidential / November 2016 / Overview30
CFM56-5BCFM56-7BOver 29,000 sold.
LEAP-1ALEAP-1BLEAP-1C15% reduction in CO2 emissions
More than 10,000engines ordered to date
A320
B737
A320NEO
B737MAX
C929
A330
B777
A380
CFM-6GE90GP7200GE’s main partner for large turbofans.
More than 29,000CFM56 enginesdelivered worldwide
GE90The most powerful
aero-engine in the world
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SAFRANHELICOPTER ENGINES
Day/month/year
Safran Electrical & Power / Confidential / November 2016 / Overview31
• Turboshaft engines
• Helicoptor and VTOL applications
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SAFRAN TRANSMISSION SYSTEMS: A WORLD LEADER IN MECHANICAL POWER TRANSMISSION SYSTEMS
Day/month/year
Safran Electrical & Power / Confidential / November 2016 / Overview32
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NEXT STEPS,STANDARDS,ANDCERTIFICATION
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Safran Electrical & Power / Confidential / November 2016 / Overview33
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ELECTRIC PROPULSION ARCHITECTURES
Safran Electrical & Power / Confidential / November 2016 / Overview34
Series
Parallel
All-Electric Battery powered (low energy density limits applications to short flights, unmanned vehicles)
Electricity provided by fuel cell; fuel cell TRL (technology readiness level) not currently sufficient.
Turbo-Electric Engine powered generator provides electric power to motorized propellers
Distributed propulsion where multiple engines are not practical (i.e. X-57 or VTOL applications)
Electric Drive Train Some portion of propulsion provided directly by engine
Distributed propulsion powered via electrical drive train
i.e. Helicoptor tail rotor
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STANDARDS, BEST PRACTICES, SAFETY
Safran Electrical & Power / Confidential / November 2016 / Overview35
Power Quality Standards
Exist to simplify system integration for airframers
But also “dumb down” envelope based on sometimes outdated limitations
New standards will be needed for advanced electrical systems
Best Practices for Aerospace Design: SAE ARP4754A
Safety: SAE ARP4761
Allowable catastrophic failure probability for a system: 10-9/flight hr
737 fleet hrs = 13,000 aircraft x 80,000 hr = 109 flight hrs
So a single system can never demonstrate high enough reliability
Plan for redundancy if you hope to certify
Why do RATs exist?
Because there are common fault modes for electrical system: i.e. fuel…
Gimli Glider 1982: 767 ran out of fuel. Glided 100+ miles using 20kW of RAT power for control.
18 incidents of RAT deployment for emergency use in past 30 years
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MODERN RAM AIR TURBINE
Safran Electrical & Power / Confidential / November 2016 / Overview36
Uses power in airstream to generate electrical or hydraulic power
Constant rotational speed via centrifugal governor
Power independent of main electrical or hydraulic system
Power independent of fuel system
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Thank you!
Safran Electrical & Power / Confidential / November 2016 / Overview37