1. F. Grauer, H. Pfoertner MTU Aero Engines AVT128 Oct. 6th / 7th Prague
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. Motivation for research on Micro System Technology (MST)
Contents
Introduction
Motivation for research on Micro System Technology (MST)
Objectives for future application of MST
Challenges
MTU activities
Dr. F. Grauer, MTPG

3. MTU as supplier of subsystems of commercial engines
Introduction
MTU as supplier of subsystems of commercial engines
MTU‘s activities related to subsystems (modules)
PW2000 CF6,JT8D
GP7000
PW4000 Growth
PW2000, V2500,
JT8D, PW300/500
PW6000, 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. overall propulsion system/ system integration capability
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
EJ200 / RB199 / MTR390 / TP400-D6
RB199
EJ200 MTR390 RB199
TP400-D6
EJ200
EJ200
RB199
MTR390
TP400-D6
EJ200
RB199
TP400-D6
MTR390
EJ200
MTR390
RB199
TP400-D6
EJ200
RB199
Design/development
Fan/LP
compressor
IP / HP
compressor
combustor
HP /IP / LP
turbine
afterburner
casing
Production
control systems
AK, Jan. 2004/28
Dr. F. Grauer, MTPG

5. MTU Compressor Technology
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. MTU Turbine Technology
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. Advances in Smart Compressor Technology
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. Electronics & Controls
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
1990
1995
2000
2005
Dr. F. Grauer, MTPG

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

14. 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
Vibration
Emissions
Leakage
Differential mon. inlet / exhaust
Harness
Model based diagnosis and prognosis
Attempt:
On-board performance model
Monitoring of FOD
Vibration monitoring
Harness monitoring
Smart Tagging
……..
Dr. F. Grauer, MTPG

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

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