Approximate, Average, Dynamic Models of Uncontrolled Rectifiers for Aircraft Applications

To carry out stability and voltage regulation studies on more electric aircraft systems in which there is a preponderance of multi-pulse, rectifier-fed motor-drive equipment, average dynamic models of the rectifier converters are required. Existing methods are difficult to apply to anything other than single converters with a low pulse number. Therefore an efficient, compact method for deriving the approximate, linear, average model of 6- and 12-pulse rectifiers, based on the assumption of a small duration of the overlap angle is presented. The models are validated against detailed simulations and laboratory prototypes.

Interactions within heterogeneous systems of uncontrolled rectifiers for aircraft electrical power systems

There is an increase in the use of multi-pulse, rectifier-fed motor-drive equipment on board more-electric aircraft. Motor drives with feedback control appear as constant power loads to the rectifiers, which can cause instability of the DC filter capacitor voltage at the output of the rectifier. This problem can be exacerbated by interactions between rectifiers that share a common source impedance. In order that such a system can be analysed, there is a need for average, dynamic models of systems of rectifiers. In this study, an efficient, compact method for deriving the approximate, linear, large-signal, average models of two heterogeneous systems of rectifiers, which are fed from a common source impedance, is presented. The models give insight into significant interaction effects that occur between the converters, and that arise through the shared source impedance. First, a 6-pulse and doubly wound, transformer-fed, 12-pulse rectifier system is considered, followed by a 6-pulse and autotransformer-fed, 12-pulse rectifier system. The system models are validated against detailed simulations and laboratory prototypes, and key characteristics of the two system types are compared.

Modelling and simulation strategies for the electric systems of large passenger aircraft

The simulation of a power system such as the More Electric Aircraft is a complex problem. There are conflicting requirements of the simulation, for example in order to reduce simulation run-times, power ratings that need to be established over long periods of the flight can be calculated using a fairly coarse model, whereas power quality is established over relatively short periods with a detailed model. An important issue is to establish the requirements of the simulation work at an early stage. This paper describes the modelling and simulation strategy adopted for the UK TIMES project, which is looking into the optimisation of the More Electric Aircraft from a system level. Essentially four main requirements of the simulation work have been identified, resulting in four different types of simulation. Each of the simulations is described along with preliminary models and results.

Simulation and Evaluation of High-Voltage Power Systems for Civil Aircraft

A status report of the modelling and simulation work that is being undertaken as part of the TIMES (Totally Integrated More Electric Systems) project is presented. Dynamic power quality simulations have been used to asses the performance of the electrical system of a EMA based actuation system for an Airbus A330 size aircraft, for both low voltage 115 V, and high voltage 230 V three-phase AC systems. The high voltage system is shown to have benefits in terms of power quality and reduced size and weight of equipment.

Manufacturing and assembly automation by integrated metrology systems for aircraft wing fabrication

Discrepancies of materials, tools, and factory environments, as well as human intervention, make variation an integral part of the manufacturing process of any component. In particular, the assembly of large volume, aerospace parts is an area where significant levels of form and dimensional variation are encountered. Corrective actions can usually be taken to reduce the defects, when the sources and levels of variation are known. For the unknown dimensional and form variations, a tolerancing strategy is typically put in place in order to minimize the effects of production inconsistencies related to geometric dimensions. This generates a challenging problem for the automation of the corresponding manufacturing and assembly processes. Metrology is becoming a major contributor to being able to predict, in real time, the automated assembly problems related to the dimensional variation of parts and assemblies. This is done by continuously measuring dimensions and coordinate points, focusing on the product's key characteristics. In this paper, a number of metrology focused activities for large-volume aerospace products, including their implementation and application in the automation of manufacturing and assembly processes, are reviewed. This is done by using a case study approach within the assembly of large-volume aircraft wing structures.

IT support for managing aircraft spares in a closed-loop supply chain

This paper reports on the development of elements of an e-supply chain management system for managing maintenance, repair and overhaul (MRO) relationships in the aerospace industry. A standard systems development methodology has been followed to produce a process model (i.e. the AMSCR model); an information model (i.e. business rules) and a computerised information management capability (i.e. automated optimisation). The proof of concept for this web-based MRO supply chain system has been established through the collaboration with a sample of the different types of supply chain members. The proven benefit is a reduction in the stock-holding costs for the whole supply chain whilst also minimising non-flying time of the aircraft that the supply chain supports. This type of system is now vital in an industry that has continuously decreasing profit margins, which in turn means pressure to reduce servicing times and increase the interval between maintenance actions.

The properties of advanced alumimium alloy systems

2XXX and 7XXX series aluminium alloys have been the accepted materials for airframe construction for many decades. However, only minor improvements in properties have been possible by the development of these alloys since the early 1970's. The constant need to reduce weight in aircraft has therefore led to a resurgence in the research for higher performance aluminium alloys. The reason for this investigation was to evaluate possible alternatives for the existing conventional aluminium alloy 2014 for aircraft wheel applications. Three new technologies in alloy development were considered: a metal matrix composite, an aluminium-lithium alloy and a powder metallurgical alloy. The basic mechanical properties of these advanced materials have already been established to an extent, but their fatigue behaviour has yet to be fully understood. The purpose of this work was to investigate the fatigue properties of the materials concerned, in both air and an aerated 3.5% NaCl solution, and compare these properties to 2014-T6. As well as the basic mechanical properties, fatigue crack propagation data is presented for all of the materials concerned. Additionally, fatigue crack initiation data is presented for the aluminium-lithium alloy and 2014. The D.C. electrical potential method was used to monitor crack growth. Of the materials investigated, the most promising was the aluminium-lithium alloy. However, short transverse properties need to be increased and the commercial cost of the material needs to be decreased before it can be considered as a direct replacement for 2014 for aircraft structural applications. It was considered that the cost of the powder metallurgical alloy would limit its further use. The metal matrix composite material proved to be unsuitable for most ambient temperature applications

Aircraft rotable inventory optimisation: development of a new solution

Analysis of the use of ICT in the aerospace industry has prompted the detailed investigation of an inventory-planning problem. There is a special class of inventory, consisting of expensive repairable spares for use in support of aircraft operations. These items, called rotables, are not well served by conventional theory and systems for inventory management. The context of the problem, the aircraft maintenance industry sector, is described in order to convey some of its special characteristics in the context of operations management. A literature review is carried out to seek existing theory that can be applied to rotable inventory and to identify a potential gap into which newly developed theory could contribute. Current techniques for rotable planning are identified in industry and the literature: these methods are modelled and tested using inventory and operational data obtained in the field. In the expectation that current practice leaves much scope for improvement, several new models are proposed. These are developed and tested on the field data for comparison with current practice. The new models are revised following testing to give improved versions. The best model developed and tested here comprises a linear programming optimisation, which finds an optimal level of inventory for multiple test cases, reflecting changing operating conditions. The new model offers an inventory plan that is up to 40% less expensive than that determined by current practice, while maintaining required performance.

Simulation of power quality issues in more electric aircraft actuator supplies

To examine the detailed operation of the power distribution network in a future more electric aircraft that employs electric actuation systems, a Micro-Cap SPICE simulation is developed for one of the essential buses. Particular attention is paid to model accurately the most important effects that influence system power quality. Representative system and flight data are used to illustrate the operation of the simulation and to assess the power quality conditions within the network as the flight control surfaces are deployed. The results illustrate the importance of correct cable sizing to ensure stable operation of actuators during transient conditions.

Review of the application of flexible, measurement-assisted assembly technology in aircraft manufacturing

Aircraft assembly is the most important part of aircraft manufacturing. A large number of assembly fixtures must be used to ensure the assembly accuracy in the aircraft assembly process. Traditional fixed assembly fixture could not satisfy the change of the aircraft types, so the digital flexible assembly fixture was developed and was gradually applied in the aircraft assembly. Digital flexible assembly technology has also become one of the research directions in the field of aircraft manufacturing. The aircraft flexible assembly can be divided into three assembly stages that include component-level flexible assembly, large component-level flexible assembly, and large components alignment and joining. This article introduces the architecture of flexible assembly systems and the principles of three types of flexible assembly fixtures. The key technologies of the digital flexible assembly are also discussed. The digital metrology system provides the basis for the accurate digital flexible assembly. Aircraft flexible assembly systems mainly use laser tracking metrology systems and indoor Global Positioning System metrology systems. With the development of flexible assembly technology, the digital flexible assembly system will be widely used in current aircraft manufacturing.

A hybrid measurement systems analysis and uncertainty of measurement approach for industrial measurement in the light controlled factory

The uncertainty of measurements must be quantified and considered in order to prove conformance with specifications and make other meaningful comparisons based on measurements. While there is a consistent methodology for the evaluation and expression of uncertainty within the metrology community industry frequently uses the alternative Measurement Systems Analysis methodology. This paper sets out to clarify the differences between uncertainty evaluation and MSA and presents a novel hybrid methodology for industrial measurement which enables a correct evaluation of measurement uncertainty while utilising the practical tools of MSA. In particular the use of Gage R&R ANOVA and Attribute Gage studies within a wider uncertainty evaluation framework is described. This enables in-line measurement data to be used to establish repeatability and reproducibility, without time consuming repeatability studies being carried out, while maintaining a complete consideration of all sources of uncertainty and therefore enabling conformance to be proven with a stated level of confidence. Such a rigorous approach to product verification will become increasingly important in the era of the Light Controlled Factory with metrology acting as the driving force to achieve the right first time and highly automated manufacture of high value large scale products such as aircraft, spacecraft and renewable power generation structures.

Fuel level sensor based on polymer optical fiber Bragg gratings for aircraft applications

Safety in civil aviation is increasingly important due to the increase in flight routes and their more challenging nature. Like other important systems in aircraft, fuel level monitoring is always a technical challenge. The most frequently used level sensors in aircraft fuel systems are based on capacitive, ultrasonic and electric techniques, however they suffer from intrinsic safety concerns in explosive environments combined with issues relating to reliability and maintainability. In the last few years, optical fiber liquid level sensors (OFLLSs) have been reported to be safe and reliable and present many advantages for aircraft fuel measurement. Different OFLLSs have been developed, such as the pressure type, float type, optical radar type, TIR type and side-leaking type. Amongst these, many types of OFLLSs based on fiber gratings have been demonstrated. However, these sensors have not been commercialized because they exhibit some drawbacks: low sensitivity, limited range, long-term instability, or limited resolution. In addition, any sensors that involve direct interaction of the optical field with the fuel (either by launching light into the fuel tank or via the evanescent field of a fiber-guided mode) must be able to cope with the potential build up of contamination-often bacterial-on the optical surface. In this paper, a fuel level sensor based on microstructured polymer optical fiber Bragg gratings (mPOFBGs), including poly (methyl methacrylate) (PMMA) and TOPAS fibers, embedded in diaphragms is investigated in detail. The mPOFBGs are embedded in two different types of diaphragms and their performance is investigated with aviation fuel for the first time, in contrast to our previous works, where water was used. Our new system exhibits a high performance when compared with other previously published in the literature, making it a potentially useful tool for aircraft fuel monitoring.