16.10.2003 Dr. F. Grauer, MTPG 1

F. Grauer, H. Pfoertner

MTU Aero Engines

AVT128Oct. 6th / 7th

Prague

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

16.10.2003 Dr. F. Grauer, MTPG 2

Contents

• Introduction

• Motivation for research on Micro System Technology (MST)

• Objectives for future application of MST

• Challenges

• MTU activities

16.10.2003 Dr. F. Grauer, MTPG 3

MTU‘s activities related to subsystems (modules)

casings

Design/developmentProduction

JT8DLP

compressor

Engine testing andother sub-tasks

PW4000 GrowthPW2000, V2500,JT8D, PW300/500PW6000, GP7000

PW2000CF6,JT8D

GP7000PW6000HP

compressor

PW4084 / PW2000PW300 / PW500

HPturb.LP turbine

MTU as supplier of subsystems of commercial engines

AK, Jan. 2004/25

Introduction

16.10.2003 Dr. F. Grauer, MTPG 4

MTU‘s activities related to engine systems integration (modules)

casing

overall propulsion system/ system integration capability

EJ200MTR390RB199TP400-D6

Design/developmentProduction

IP / HPcompressor

combustor

EJ200 RB199

RB199

thrust reverser

HP /IP / LP turbine

afterburner

EJ200 MTR390EJ200 RB199TP400-D6

EJ200 MTR390 RB199TP400-D6

EJ200 / RB199 / MTR390 / TP400-D6

MTU is the German military engine systems integrator

Fan/LPcompressor

control systems

EJ200 RB199MTR390TP400-D6

AK, Jan. 2004/28

Introduction

16.10.2003 Dr. F. Grauer, MTPG 5

Highly loaded, affordable 6-stage HPC with Pressure Highly loaded, affordable 6-stage HPC with Pressure Ratio 12Ratio 12

Advanced 3D airfoil designAdvanced 3D airfoil design High efficiency provides minimum fuel burnHigh efficiency provides minimum fuel burn the product for the PW6000 enginethe product for the PW6000 engine

Highly loaded, affordable 6-stage HPC with Pressure Highly loaded, affordable 6-stage HPC with Pressure Ratio 12Ratio 12

Advanced 3D airfoil designAdvanced 3D airfoil design High efficiency provides minimum fuel burnHigh efficiency provides minimum fuel burn the product for the PW6000 enginethe product for the PW6000 engine

MTU Compressor Technology

Introduction

16.10.2003 Dr. F. Grauer, MTPG 6

Test Program of 5-stage Aero-RigTest Program of 5-stage Aero-Rig „ „Clocking“ of all statorsClocking“ of all stators Outstanding Aerodynamics: Outstanding Aerodynamics: Validation of unsteady aero toolsValidation of unsteady aero tools Engine Tests in progressEngine Tests in progress

Test Program of 5-stage Aero-RigTest Program of 5-stage Aero-Rig „ „Clocking“ of all statorsClocking“ of all stators Outstanding Aerodynamics: Outstanding Aerodynamics: Validation of unsteady aero toolsValidation of unsteady aero tools Engine Tests in progressEngine Tests in progress

MTU Turbine Technology

Introduction

16.10.2003 Dr. F. Grauer, MTPG 7

Intelligent Control for additional degrees of freedom in „Smart Intelligent Control for additional degrees of freedom in „Smart Compressor Design“:Compressor Design“: Active Surge DetectionActive Surge Detection Active Vibration ControlActive Vibration Control Active Clearance ControlActive Clearance Control

Intelligent Control for additional degrees of freedom in „Smart Intelligent Control for additional degrees of freedom in „Smart Compressor Design“:Compressor Design“: Active Surge DetectionActive Surge Detection Active Vibration ControlActive Vibration Control Active Clearance ControlActive Clearance Control

Demonstrator Engine Demonstrator Engine Extended stable Operating Range by ASCExtended stable Operating Range by ASC

„Active Surge Control“„Active Surge Control“

* ASC: Active Surge Control

Advances in Smart Compressor Technology

Introduction

16.10.2003 Dr. F. Grauer, MTPG 8

1990 20001995x 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

16.10.2003 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

16.10.2003 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

16.10.2003 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 controlUsing MEMS and smart materials

Attempt:• active surge control • active vibration control • active clearance controlUsing MEMS and smart materials

Smart Compressor

Objectives for future applications of MST

16.10.2003 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. 1994

Variable Guide Vanes

Surge Control: Actuation

Objectives for future applications of MST

16.10.2003 Dr. F. Grauer, MTPG 13

Dürr, Herold-Schmidt, Ihler „Schwingungsdämpfung mit adaptiven Werkstoffen in Turbinen - Teilprojekt Piezoaktive Strukturen“ FT4/WK-2000-016

Vibration Control: Actuation

Objectives for future applications of MST

16.10.2003 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

16.10.2003 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

16.10.2003 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

16.10.2003 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

16.10.2003 Dr. F. Grauer, MTPG 18

• DaimlerChrysler Cooperation on MST

• 6. EU Framework: ADVACT

• AVT128

MTU activities

MTU activities

16.10.2003 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