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Micro system technology in future engine applications – objectives and next steps

Micro system technology in future engine applications – objectives and next steps. F. Grauer, H. Pfoertner MTU Aero Engines AVT128 Oct. 6th / 7th Prague. Contents Introduction Motivation for research on Micro System Technology (MST) Objectives for future application of MST

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Micro system technology in future engine applications – objectives and next steps

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  1. Micro system technology in future engine applications – objectives and next steps F. Grauer, H. Pfoertner MTU Aero Engines AVT128 Oct. 6th / 7th Prague Dr. F. Grauer, MTPG

  2. Contents • Introduction • Motivation for research on Micro System Technology (MST) • Objectives for future application of MST • Challenges • MTU activities Dr. F. Grauer, MTPG

  3. Introduction MTU as supplier of subsystems of commercial engines MTU‘s activities related to subsystems (modules) PW4000 Growth PW2000, V2500, JT8D, PW300/500 PW6000, GP7000 PW2000CF6,JT8D GP7000 JT8D LP compressor PW6000 HP compressor HP turb. LP turbine Design/development Engine testing and other sub-tasks Production casings PW4084 / PW2000 PW300 / PW500 AK, Jan. 2004/25 Dr. F. Grauer, MTPG

  4. Introduction MTU is the German military engine systems integrator MTU‘s activities related to engine systems integration (modules) overall propulsion system/ system integration capability thrust reverser RB199 EJ200 / RB199 / MTR390 / TP400-D6 EJ200MTR390RB199 TP400-D6 EJ200 EJ200 RB199 MTR390 TP400-D6 EJ200 RB199 TP400-D6 MTR390 EJ200 MTR390 RB199 TP400-D6 EJ200 RB199 casing Design/development Fan/LP compressor IP / HP compressor combustor HP /IP / LP turbine afterburner Production control systems AK, Jan. 2004/28 Dr. F. Grauer, MTPG

  5. Introduction MTU Compressor Technology • Highly loaded, affordable 6-stage HPC with Pressure Ratio 12 • Advanced 3D airfoil design • High efficiency provides minimum fuel burn • the product for the PW6000 engine Dr. F. Grauer, MTPG

  6. Introduction MTU Turbine Technology  Test Program of 5-stage Aero-Rig  „Clocking“ of all stators  Outstanding Aerodynamics:  Validation of unsteady aero tools  Engine Tests in progress Dr. F. Grauer, MTPG

  7. Introduction Advances in Smart Compressor Technology Demonstrator Engine Extended stable Operating Range by ASC „Active Surge Control“ • Intelligent Control for additional degrees of freedom in „Smart Compressor Design“: • Active Surge Detection • Active Vibration Control • Active Clearance Control * ASC: Active Surge Control Dr. F. Grauer, MTPG

  8. Introduction Electronics & Controls Increase in Controller Functions (Basis RB 199 DECU) • 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 x 8 EJ200 DECMU EJ 200 C1 DECU x 4 EJ200 C2 DECU x 1 1995 2000 2005 1990 Dr. F. Grauer, MTPG

  9. Motivation for research on MST 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 Dr. F. Grauer, MTPG

  10. Motivation for research on MST Motivation • First applications in aviationknown • 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 Dr. F. Grauer, MTPG

  11. Objectives for future applications of MST Smart Compressor • 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 Active Surge Control Active Clearance Control • Attempt: • active surge control • active vibration control • active clearance control • Using MEMS and smart materials Active Vibration Control Dr. F. Grauer, MTPG

  12. Variable Guide Vanes Constant / modulated air injection Spakovszky et al. „Rotating Stall Control in a High-Speed Stage with Inlet Distortion,Part I - Radial Distortion“ ASME 98-GT-264 Haynes et al.: „Active Stabilization of Rotating Stall in a Three-Stage Axial Compressor“ Trans. Of the ASME, Vol.116, Apr. 1994 Objectives for future applications of MST Surge Control: Actuation Dr. F. Grauer, MTPG

  13. Objectives for future applications of MST Vibration Control: Actuation Dürr, Herold-Schmidt, Ihler „Schwingungsdämpfung mit adaptiven Werkstoffen in Turbinen - Teilprojekt Piezoaktive Strukturen“ FT4/WK-2000-016 Dr. F. Grauer, MTPG

  14. Leakage Harness Differential mon. inlet / exhaust Emissions Model based diagnosis and prognosis Vibration Objectives for future applications of MST Monitoring • 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 • …….. Dr. F. Grauer, MTPG

  15. Challenges Temperatures in commercial engines HP Turbine (< 1300ºC) Fan & Booster (< 200ºC) LP Turbine (< 1000ºC) HP Compressor (< 700ºC) Dr. F. Grauer, MTPG

  16. Deposition on Compressor Rotor Damaged Fan Blade Deposition of sand on an compressor shaft Challenges Environmental conditions • Bird strike • Foreign object damage (FOD) • Ingestion of • Ice • Sand und dust • Water • Humidity • Icing Dr. F. Grauer, MTPG

  17. Challenges Questions to solve • 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 Dr. F. Grauer, MTPG

  18. MTU activities MTU activities • DaimlerChrysler Cooperation on MST • 6. EU Framework: ADVACT • AVT128 Dr. F. Grauer, MTPG

  19. Challenges Questions to solve • 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 Dr. F. Grauer, MTPG

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