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16.10.2003 Dr. F. Grauer, MTPG 1 F. Grauer, H. Pfoertner MTU Aero Engines AVT128 Oct. 6th / 7th Prague Micro system technology in future engine applications.

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Presentation on theme: "16.10.2003 Dr. F. Grauer, MTPG 1 F. Grauer, H. Pfoertner MTU Aero Engines AVT128 Oct. 6th / 7th Prague Micro system technology in future engine applications."— Presentation transcript:

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

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

3 Dr. F. Grauer, MTPG 3 MTUs activities related to subsystems (modules) casings Design/development Production JT8D LP compressor Engine testing and other sub-tasks PW4000 Growth PW2000, V2500, JT8D, PW300/500 PW6000, GP7000 PW2000 CF6,JT8D GP7000 PW6000 HP compresso r PW4084 / PW2000 PW300 / PW500 HP turb. LP turbine MTU as supplier of subsystems of commercial engines AK, Jan. 2004/25 Introduction

4 Dr. F. Grauer, MTPG 4 MTUs activities related to engine systems integration (modules) casing overall propulsion system/ system integration capability EJ200 MTR390 RB199 TP400-D6 Design/development Production IP / HP compressor combustor EJ200 RB199 thrust reverser HP /IP / LP turbine afterburner EJ200MTR390EJ200 RB199 TP400-D6 EJ200 MTR390 RB199 TP400-D6 EJ200 / RB199 / MTR390 / TP400-D6 MTU is the German military engine systems integrator Fan/LP compressor control systems EJ200 RB199 MTR390 TP400-D6 AK, Jan. 2004/28 Introduction

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

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

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

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

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

10 Dr. F. Grauer, MTPG 10 Motivation 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 Motivation for research on MST

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

12 Dr. F. Grauer, MTPG 12 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 Variable Guide Vanes Surge Control: Actuation Objectives for future applications of MST

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

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

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

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

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

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

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


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