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NASA NTRS2015

An Overview of 2014 SBIR Phase 1 and Phase 2 Air-Breathing Propulsion

NASA's Small Business Innovation Research (SBIR) program focuses on technological innovation by investing in development of innovative concepts and technologies to help NASA mission directorates address critical research needs for Agency programs. This report highlights nine of the innovative SBIR 2014 Phase I and Phase II projects that emphasize one of NASA Glenn Research Center's six core competencies-Air-Breathing Propulsion. The technologies cover a wide spectrum of applications such as development of X-ray computed tomography (CT) imaging method for the measurement of complex 3D ice shapes, phased array techniques for low signal-to-noise ratio wind tunnels, compact kinetic mechanisms for petroleum-derived and alternative aviation fuels, and hybrid electric propulsion systems for a multirotor aircraft. Each featured technology describes an innovation, technical objective, and highlights NASA commercial and industrial applications. This report provides as an opportunity for NASA engineers, researchers, and program managers to learn how NASA SBIR technologies could help their programs and projects, and lead to collaborations and partnerships between the small SBIR companies and NASA that would benefit both.

phased array technique for wind tunnels↗

NASA NTRSDate not supplied

Motor Configuration Selection for A New Technical Challenge to Develop A 5 MW Cryogenic Motor and Drive

Due to aviation’s appreciable and growing share of humanity’s impact on our environment and estimates that CO2emissions only account for 34% of aviation’s total effective radiative forcing [1], there is a need to reach beyond climate goals that focus only on CO2emissions, such as the US Aviation Climate Action Plan’s [3] goal to reach net-zero carbon emissions by 2050.There is motivation to develop technology that pushes toward future large transport aircraft with net zero climate impact that are highly electrified (i.e., have higher power electrical propulsion system components). This paper describes a new, 6-year technical challenge to address this need by developing a 5 MW superconducting motor and cryogenic drive. Section 1 will detail the motivation for this work. Section 2 will describe the technical challenge and the selected specifications for the motor. Section 3 will present the results of a motor configuration trade study and the down selection of one configuration to develop a detailed design for. The technical challenge focuses on the design of a5 MW superconducting motor and cryogenic drive and demonstration of it at a 2+ MW scale to achieve TRL 3. Both fully superconducting (superconducting stator and rotor) and fully cryogenic (superconducting rotor and cryogenic stator) machine configurations will be explored. An emphasis will be placed on addressing the key tall poles for high power superconducting machines. Further details will be included in the full paper. The requirements and goals of the motor will be detailed. The rated speed (2,000 to 3,000 rpm) is defined to be appropriate for directly driving multi-MW fans or propellers. A range of rated speed is permitted because the motor is not designed for a specific aircraft and to provide design flexibility if AC losses in the stator winding are found to be a significant constraint (i.e., a lower speed can be selected to reduce electrical frequency). Relatively conservative requirements for efficiency (99%) and specific power (20 kW/kg) are defined, because TRL advancement and pushing toward flight readiness is emphasized over performance optimization. However, more aggressive efficiency and specific power goals are specified (99.9% and 40 kW/kg). The 3rd section will present the results of a motor configuration trade study. The study started with a qualitative assessment of sixteen motor configurations based on geometric, mechanical, thermal, and electromagnetic criteria. This assessment has been completed with three evaluators scoring all nine criteria. A configuration down select was made by prioritizing the sixteen configurations into four tiers based on each configuration’s total score and consideration of manufacturability, complexity, and support hardware (e.g., rotary vacuum seals, bearings). Configurations in priority A and B will be further evaluated through quantitative assessments, whereas those in priority C will only be further evaluated if time permits and priority D will not be further evaluated. Eight of the sixteen configurations were down selected for quantitative assessment, which will include analytical calculations and low-to moderate-fidelity finite element analysis to produce a preliminary Pareto front of efficiency versus specific power for each configuration. This assessment emphasizes the calculation of AC losses in the stator winding and an exploration of thermal management approaches to remove that heat and maintain cryogenic temperature. The final paper will include a description of each motor configuration that was considered. The quantitative assessments are underway, and an assessment of one configuration is complete for multiple stator conductor options. The remaining assessments are scheduled to be completed by late March so that the final down select to one configuration can be included in this paper.

Net Zero↗

NASA NTRSDate not supplied

Electrical Energy Storage Design Space Exploration for a Hybrid-Electric Six-Passenger Quadrotor

Hybrid-electric architectures are a promising means to achieve clean and efficient aircraft propulsion needed for small, short-range electric vertical takeoff and landing class vehicles. This paper explores the design space for a six-passenger quadrotor hybrid-electric propulsion system and shows that hybrid architectures that are more efficient than engine-only architectures can be built with near-term battery technology (approximately 150 Wh/kg at the pack level). Data obtained shows that hybrid-electric propulsion systems can achieve 37 percent block fuel reduction and 35 percent total energy cost savings over a 120 nautical mile mission compared to conventional turboshaft architectures. This work suggests that hybrids are likely the most efficient architectures that can be produced in the near term for this class of vehicle and motivates further development in this area.

parallel hybrid electric aircraft↗

NASA NTRS2005

Liquid-Hydrogen-Cooled 450-hp Electric Motor Test Stand Being Developed

With growing concerns about global warming, there is a need to develop pollution-free aircraft. One approach is to use hydrogen-fueled airc raft that use fuel cells or turbogenerators to produce electric power to drive the electric motors that turn the aircraft#s propulsive fan s. Hydrogen fuel would be carried as a liquid, stored at its boiling point of 20.5 K (-422.5 ?F). Conventional electric motors, however, are too heavy to use on an aircraft. We need to develop high-power, lig htweight electric motors (high-powerdensity motors).

Kascak, Albert F.↗

NASA NTRS2016

Aircraft Electric/Hybrid-Electric Power and Propulsion Workshop Perspective of the V/STOL Aircraft Systems Tech Committee

This presentation will be given at the AIAA Electric Hybrid-Electric Power Propulsion Workshop on July 29, 2016. The workshop is being held so the AIAA can determine how it can support the introduction of electric aircraft into the aerospace industry. This presentation will address the needs of the community within the industry that advocates the use of powered-lift as important new technologies for future aircraft and air transportation systems. As the current chairman of the VSTOL Aircraft Systems Technical Committee, I will be presenting generalized descriptions of the past research in developing powered-lift and generalized observations on how electric and hybrid-electric propulsion may provide advances in the powered-lift field.

V/STOL↗

NASA NTRS2022

Specific Power and Efficiency Projections of Electric Machines and Circuit Protection Exploration for Aircraft Applications

The purpose of this paper is to generate specific power and efficiency projections through the year 2050 for electric machines for aircraft applications. A general literature review was performed to identify the types of electric machines that are commonly used and which types have the biggest potential for future aircraft applications due to their high specific power and efficiency. A database with historical data was built to include parameters such as weight [kg], rated power [kW], specific power [kW/kg], RPM, efficiency, year, motor cooling type, application type and motor type to allow for trend identification and accurate projections. Once the data was gathered, multiple curve fits on the historical data were generated and extrapolated to produce the projections for specific power according to conservative, nominal and aggressive projection scenarios. A different process was followed for the efficiency projections due to the scattered nature of the data. A state of the art (SoA) value for efficiency was identified through literature review and was used to create the conservative, nominal and aggressive projections for the time frames of 2030, 2040, and 2050. The efficiency and the specific power projections of EMs for 2050 are 0.989 and 50kW/kg respectively. This paper will also be examining circuit protection as it is an additional component of electric powertrains.

electric machines↗

NASA NTRSDate not supplied

Hybrid Electric Aircraft with Unlike Engine Degradation

Control solutions are applied to uneven engine performance degradation on a conceptual twin-engine transport-class aircraft. Such degradation can lead to asymmetric thrust, which requires rudder trim to maintain desired aircraft heading. This will increase drag and fuel consumption. With the introduction of hybrid-electric aircraft powertrains, new solutions to unwanted asymmetric thrust can be derived. Four control strategies are demonstrated on the power and propulsion system of such an aircraft. Compared with existing strategies, the methodology proposed in this paper controls electromechanical actuators coupled to engine shafts and balances the thrust produced by both engines potentially leading to a decrease in fuel burn. The engine represented in this study is NASA’s conceptual dual-shaft Advanced Geared Turbofan 30,000 lbf thrust class engine. The conceptual engine is hybridized with electric machines attached to both shafts. Simulation results are presented with various levels of degradation. The control strategies are compared based on fuel burn, thrust symmetry, and estimated system weight.

control↗

NASA NTRSDate not supplied

Hybrid Electric Aircraft with Unlike Engine Degradation

control↗

NASA NTRSDate not supplied

Electrical Energy Storage Design Space Exploration for a Hybrid-Electric Six Passenger Quadrotor

Hybrid-electric architectures are a promising means to achieve clean and efficient aircraft propulsion needed for small, short-range electric vertical takeoff and landing (eVTOL) class vehicles. This paper explores the design space for a six-passenger quadrotor hybrid-electric propulsion system and shows that hybrid architectures that are more efficient than engine-only architectures can be built with near-term battery technology (~150 Wh/kg at the pack level). Data obtained shows that hybrid-electric propulsion systems can achieve 28 percent block fuel reduction and 27 percent total energy cost savings over a 120 nautical mile (nmi) mission compared to conventional turboshaft architectures. This work suggests that hybrids are likely the most efficient architectures that can be produced in the near term for this class of vehicle and motivates further development in this area.

Hybrid-electric↗

NASA NTRSDate not supplied

Preliminary Assessment of a Distributed Electric Propulsion System for the SUSAN Electrofan

The SUSAN Electrofan is a new hybrid electric large regional jet aircraft concept being studied by NASA that leverages advanced propulsion system technologies such as distributed electric propulsion (DEP) and boundary-layer ingestion (BLI) to reduce fuel consumption and emissions. In order to evaluate the individual benefits of these technologies toward the SUSAN Electrofan’s wing-mounted propulsion systems, three configurations are proposed. The first consists of two underwing pylon-mounted podded propulsors and serves as a baseline, while the second features an underwing pylon-mounted DEP concept with 16 ducted fans in a mail-slot nacelle. The third and final configuration mounts the mail-slot nacelle directly onto the pressure side of the wing to also take advantage of BLI. This paper presents preliminary investigations into the design and performance of the first two propulsion system configurations. This begins with an initial propulsor and mail-slot design where the aeropropulsive design space is explored, and adverse effects are addressed through iterative geometry modifications. The propulsion system configurations are then installed onto a wing–body model to account for integration effects and assess the relative aerodynamic and shaft power performance of each concept. Results indicate the potential benefits of DEP, which come from significant reductions in total drag, provided by operation at much lower propulsor fan pressure ratios.

ARMD↗

NASA NTRS2015

Architecture, Voltage, and Components for a Turboelectric Distributed Propulsion Electric Grid (AVC-TeDP)

The purpose of this effort was to advance the selection, characterization, and modeling of a propulsion electric grid for a Turboelectric Distributed Propulsion (TeDP) system for transport aircraft. The TeDP aircraft would constitute a miniature electric grid with 50 MW or more of total power, two or more generators, redundant transmission lines, and multiple electric motors driving propulsion fans. The study proposed power system architectures, investigated electromechanical and solid state circuit breakers, estimated the impact of the system voltage on system mass, and recommended DC bus voltage range. The study assumed an all cryogenic power system. Detailed assumptions within the study include hybrid circuit breakers, a two cryogen system, and supercritical cyrogens. A dynamic model was developed to investigate control and parameter selection.

power↗

NASA NTRS2010

NASA Puffin Electric Tailsitter VTOL Concept

Electric propulsion offers dramatic new vehicle mission capabilities, not possible with turbine or reciprocating engines; including high reliability and efficiency, low engine weight and maintenance, low cooling drag and volume required, very low noise and vibration, and zero emissions. The only penalizing characteristic of electric propulsion is the current energy storage technology level, which is set to triple over the next 5-10 years through huge new investments in this field. Most importantly, electric propulsion offers incredible new degrees of freedom in aircraft system integration to achieve unprecedented levels of aerodynamic, propulsive, control, and structural synergistic coupling. A unique characteristic of electric propulsion is that the technology is nearly scale-free, permitting small motors to be parallelized for fail-safe redundancy, or distributed across the airframe for tightly coupled interdisciplinary functionality without significant impacts in motor-controller efficiency or specific weight. Maximizing the potential benefit of electric propulsion is dependent on applying this technology to synergistic mission concepts. The vehicle missions with the most benefit include those which constrain environmental impact (or limit noise, exhaust, or emission signatures) are short range, or where large differences exist in the propulsion system sizing between takeoff and cruise conditions. Electric propulsion offers the following unique capabilities that other propulsion systems can t provide for short range Vertical Takeoff and Landing (VTOL) aircraft; elimination of engine noise and emissions, drastic reduction in engine cooling and radiated heat, drastic reduction in vehicle vibration levels, drastic improvement in reliability and operating costs, variable speed output at full power, for improved cruise efficiency at low tip-speed, elimination of high/hot sizing penalty, and reduction of engine-out penalties.

Moore, Mark D.↗

NASA NTRS2004

High Power Density Motors

With the growing concerns of global warming, the need for pollution-free vehicles is ever increasing. Pollution-free flight is one of NASA's goals for the 21" Century. , One method of approaching that goal is hydrogen-fueled aircraft that use fuel cells or turbo- generators to develop electric power that can drive electric motors that turn the aircraft's propulsive fans or propellers. Hydrogen fuel would likely be carried as a liquid, stored in tanks at its boiling point of 20.5 K (-422.5 F). Conventional electric motors, however, are far too heavy (for a given horsepower) to use on aircraft. Fortunately the liquid hydrogen fuel can provide essentially free refrigeration that can be used to cool the windings of motors before the hydrogen is used for fuel. Either High Temperature Superconductors (HTS) or high purity metals such as copper or aluminum may be used in the motor windings. Superconductors have essentially zero electrical resistance to steady current. The electrical resistance of high purity aluminum or copper near liquid hydrogen temperature can be l/lOO* or less of the room temperature resistance. These conductors could provide higher motor efficiency than normal room-temperature motors achieve. But much more importantly, these conductors can carry ten to a hundred times more current than copper conductors do in normal motors operating at room temperature. This is a consequence of the low electrical resistance and of good heat transfer coefficients in boiling LH2. Thus the conductors can produce higher magnetic field strengths and consequently higher motor torque and power. Designs, analysis and actual cryogenic motor tests show that such cryogenic motors could produce three or more times as much power per unit weight as turbine engines can, whereas conventional motors produce only 1/5 as much power per weight as turbine engines. This summer work has been done with Litz wire to maximize the current density. The current is limited by the amount of heat it generates. By increasing the heat transfer out of the wire, the wires can carry a larger current and therefore produce more force. This was done by increasing the surface area of the wire to allow more coolant to flow over it. Litz wire was used because it can carry high frequency current. It also can be deformed into configurations that would increase the surface area. The best configuration was determined by heat transfer and force plots that were generated using Maxwell 2D. Future work will be done by testing and measuring the thrust force produced by the wires in a magnetic field.

Kascak, Daniel J.↗

NASA NTRSDate not supplied

NASA’s Quiet Electric ENgines (QUEEN): Summary of the QUEEN V2 Test

A liquid-cooled electric ducted fan system was designed, built, and tested at the NASA Glenn Research Center. Main components of the system include a Commercial-Off- the-Shelf (COTS) fan and motor, and a custom-designed heat exchanger integrated into the fan duct. Fan speed, thrust, and cooling system thermal performance was measured in this static ground test of the propulsor. This propulsor prototype is one of NASA’s Quiet Electric ENgines (QUEENs) and is designated the ‘QUEEN V2.’ The Quiet Electric Engines are being developed for the 25% scale model of the Subsonic Aft Engine (SUSAN) Flight Research Vehicle and are intended to explore the potential of distributed electric propulsion for regional single-aisle aircraft. This test demonstrated the functionality of the QUEEN V2, quantified the thrust produced by the electrofan, and characterized the electrical and thermal performance of the system. Lessons learned will be used to guide development of future QUEEN prototypes.

Aerodynamics↗

NASA NTRSDate not supplied

Validation of the NASA Electrical Power System – Sizing and Analysis Tool (EPS-SAT)

The electrification of aircraft propulsion systems has opened the design space for engineers by allowing for unique and highly specialized propulsion system and vehicle designs. NASA developed the Electrical Power System – Sizing and Analysis Tool (EPS-SAT) to conduct high-level trade studies and sensitivity studies on the various propulsion system designs that can be implemented in electrified aircraft. The results of these studies would be used to better direct investment dollars and determine strengths and weaknesses of propulsion system designs. In this paper, the results of the EPS-SAT tool were validated with hardware data extracted from the NASA Revolutionary Vertical Lift Technology (RVLT) Advanced Reconfigurable Electric Aircraft Lab (AREAL). Updated performance maps were added to the EPS-SAT library so that high-fidelity results could be calculated.

Patrick A. Hanlon↗

NASA NTRSDate not supplied

NASA’s Quiet Electric ENgines (QUEEN): Summary of the QUEEN V2 Test

Aeronautics-General↗

NASA NTRS2016

Turboelectric Aircraft Drive Key Performance Parameters and Functional Requirements

The purpose of this paper is to propose specific power and efficiency as the key performance parameters for a turboelectric aircraft power system and investigate their impact on the overall aircraft. Key functional requirements are identified that impact the power system design. Breguet range equations for a base aircraft and a turboelectric aircraft are found. The benefits and costs that may result from the turboelectric system are enumerated. A break-even analysis is conducted to find the minimum allowable electric drive specific power and efficiency that can preserve the range, initial weight, operating empty weight, and payload weight of the base aircraft.

aircraft configurations↗

NASA NTRS2016

Optimizing Power Density and Efficiency of a Double-Halbach Array Permanent-Magnet Ironless Axial-Flux Motor

NASA Glenn Research Center is investigating hybrid electric and turboelectric propulsion concepts for future aircraft to reduce fuel burn, emissions, and noise. Systems studies show that the weight and efficiency of the electric system components need to be improved for this concept to be feasible. This effort aims to identify design parameters that affect power density and efficiency for a double-Halbach array permanent-magnet ironless axial flux motor configuration. These parameters include both geometrical and higher-order parameters, including pole count, rotor speed, current density, and geometries of the magnets, windings, and air gap.

electric propulsion↗