Electrical Starter / Generator disconnect system

Final Report Summary - STAGEDIS (Electrical Starter / Generator disconnect system)

Executive Summary:
This project, named as StaGeDiS (electrical Starter / Generator Disconnect System) and developed by the consortium CT-Ingenieros and Indra Systemas, has answered the topic-call of the “JTI-CS-2013-03-SGO-02-052” which is inside of the call16 of the FP7 of the European Commission
The StaGeDiS project has established a new conceptual designs for a dual-use over a starter/generator disconnect system.
In the scope of new generation aircrafts where it is required higher level of electrical power and leading to an increase in weight and volume of the electrical machines, it is important to compensate this increase of weight and volume by optimization of the aircraft systems. So, the generator shall be able to operate as an electric starter also, eliminating the need of pneumatic starter over the combustion engines (main engines and APU).
But in any case, due to safety reasons, the starter/generator requires a disconnection system to protect the machines and engine gearbox in case of a mechanical failure in one of them, especially in over the main engines, due to the catastrophic effect if all engines are damaged.
Most of current aircraft main engines are fitted with electrical generator and pneumatic starter. And the current safety disconnect system between generator and engine gearbox, where available, are mechanical fuses and/or clutching devices designed to transmit torque only in one rotating direction.
The electrical machine proposed in this CfP replaces the separated starter and generator machines by only one starter/generator (S/G) device which is able to work in two operational modes:
- Mode 1: starter to start the aircraft engine,
- Mode 2: generator to give electrical energy to the aircraft.
This feature requires a disconnection system able to transmit torque in both rotating directions of the S/G shaft.
So, this disconnection system expected for this kind of new electrical machines shall be able to separate mechanically the gearbox from the starter/generator with the electrical machine operating whether as starter or generator according to initial requirements. Moreover, according to aeronautic requirement, the expected new disconnection devices shall comply with at least the same levels of performances, weight, dimensions, integration, safety, robustness, reliability, maintainability and operability that the current and legacy disconnection systems, and if possible to improve all or some of these requirements.
Along the project, different technologies and architectures have been studied, evaluated and compared in order to define a proper disconnection system. Criteria of compactness, weight reduction and conformity with harsh aeronautic engine environment were also taking into account, as very important part of these studies to ensure and maximize the compliance with those previous requirements.
And at the end of the project a deep compatibility study was performed to confirm these compliances under studies and simulations and also a preparation of a required test campaign was done to ensure its future verification under a potential prototype.

Project Context and Objectives:
Both companies building the Consortium had experience in aeronautic system engineering. CT-Ingenieros working as consulter for several aircraft systems as APU, Bleed and hydraulic systems. And other hand, Indra has a vast experience in the design and manufacturing of aeronautic equipment's and systems, as electrical/electronic as mechanical ones.
Moreover, both companies have also a vast experience in other mechanical applications over ground and sea transports.
Then, due to this aeronautic experience (aeronautical requirements, current limitation and problems in this kind of system, potential improvements,...) due also to their global mechanical knowledge and finally, as not less important, due to the good previous relationship between both companies, it was decide to bet about this proposal, in order to find a challenge device capable to answer all these necessities.
To note that previously to the presentation of this project proposal, the consortium did a preliminary review of the state of the art over this kind of systems, in order to propose some first approach ideas of solutions for this proposal, to achieve the objectives requested for this project.
Once, that the project proposal was ranked by the independent experts committee, the project, was started and developed under an structure of eight work-packages. Six work packets were defined for technical aspects (RTD) in a sequential way, and two additional ones, were developed in parallel and along the project to cover the activities of dissemination & exploitation and the activities of coordination & project management.
So, a short description of the activities done under each of these WPs were:
- First work package
This first working period was based in the analysis of the system requirements in order to further define the applicable technologies for the potential solutions.
It was very important in this first period to identify the existence of any preliminary show-stopper in the requirements. The resulted requirement specification of the analysis were reviewed, agreed and consolidated, in order to be used as input for the following working periods of the project.

- Second work package
The purpose of this working period was to define the potential solutions for the starter-generator disconnect system taking into account the requirements analyzed in the previous period.
A deep State Of the Art analysis (SoA) was done, as key aspect for the success of this period and the project in general. Existing mechanisms and active patents applicable to the potential solution were identified and analyzed. After this analysis, a certain number of potential solutions were outlined for the subsequent working periods. In a first moment, three potential solutions were pre-selected.

- Third work package

Once the requirements were consolidated and these several possible solutions defined, the different criteria of selection were defined according to aerospace industry TRL methodology.
Moreover, during this phase, it was noted other opportunities not taken into account previously, so, two additional solutions were identified, treated and included in the criteria and pre-selection list.

- Fourth work package
The Preliminary Design Review (PDR) was divided in two main blocks: a technical analysis of the candidate solutions, and the subsequent down-selection. One of the five topologies proposed was selected as the design for the development, and a second was designed as backup solution to be used in case a show-stopper raised during the development of the main candidate solution.

- Fifth work package
The selected design progressed through the Critical Design Review level (CDR). The conceptual design of the selected solution was developed to its final system design, equivalent to a readiness level of TRL3.
The system was dimensioned to fulfill the consolidated requirements. And when the detail design was available, several studies were performed to demonstrate the compatibility of the resulting design with mechanical, electrical, thermal and fluidic environment, leading in same case to several loops od adjustments in the design to optimize the final design and get the maximum compatibility level.

- Sixth work package
Following to the resulting system design, it was defined a verification and qualification tests plan to be applied in the future over a real prototype, including, functional and environmental applicable requirements, tests setup, tests sequence and tests procedures. As commented before, Project Management and Dissemination & Exploitation activities were performed in parallel to the technical development activities along the entire project timeline. So additionally to these technical WPs, two other transversal WPs were performed along the project.
- Seventh work package
This WP was used to plan and report the dissemination and exploitation derivate activities from this project.

- Eighth work package
This final WP was used to cover the activities of project management and consortium coordination over this project. To note that coordination activities not only included internal coordination of teams and partners of the consortium but also relationships and communication with the Topic Manager and with the CSJU.
At the end of the project, all these project information has been reported for its validation and acceptance.

Project Results:
As a result of the work done during the project, the main expected results in the development for the new disconnect device were:
• An innovative disconnect system solution that fulfills all the requirements specified.
• A design that minimizes the risk of uncommanded disconnections and avoids accidental reconnections.
• A system compatible mechanical and environmentally.
• A system capable to operate in both directions of torque transmission.

And at the end of the project, the Consortium can confirm that all these objectives has been achieved and validated over the proposed solution and final design developed, as it can been confirmed through all the documents and deliverables performed by the Consortium and reviewed by the Topic Manager.

Potential Impact:
Although some scientific and technological objectives and results has been commented jus before, some additional results and impact that have been achieved through this project and that are put in advance by the current proposed design are:
• Disconnection System with the capability to operate with different torque transmission directions and that makes the system suitable for forthcoming More Electrical (MEA) & Full Electrical Aircraft (FEA) architectures.
• Applicable in future MEA & FEA architectures for electric generators connected to power-plants, both propulsive and non-propulsive.
• Use as connection / disconnection system over bidirectional electrical machines, as starter / Generators.
• Improvement of the reliability and robustness against the current systems.
• Improvement of the aircraft operability by capability to perform system tests in advance to a failure. And also better accessibility and re-engagement of the system.
• Possibility to use this solution in an integrated equipment or isolated or remote application.
• Consolidation of the Consortium build by CT-Ingenieros and INDRA to perform additional project and apply the concept and lesson learnt over potential opportunities, and get synergies between both companies.
• To propose alternative to the current disconnection devices, and not only over new topologies with S/G but also in legacy architectures with generators only. It is important also to comment that most of the legacy solutions are based in American Patents, and this could be an alternative over the current monopoly in some of these solutions.
• Finally to comment that this solution could be applied to other markets, as general industry and ground transport if not applied yet. Perhaps similar solution could be already applied in these other markets, but the current solution presented in this project could improve aspect over the ones potentially available in other markets, due to the restricted and harsh requirements in this aeronautical application (reduction of weigh and volume, lifetime and robustness, working performances under 32500rpm,...)
It is important to highlight again that all these points has been achieved at the end of the StaGeDiS project, and the idea is to get additional funding to develop a real prototype and to test it and in parallel to explore the possibility to apply this solution/concept over some projects and/or applications.

Moreover, this Project will allow to work with a simple system instead of to use old solution that are under patent and most of the time under EEUU companies control.

The dissemination activities were done based in the "General data" of this project in order to comply with the rules of IP-rights and protection of the knowledge. In future dissemination these same principles will be kept, although the general information about the Stagedis will be updated with the results obtained up to the end of the project.

The activities are done along the development time of this project by both companies of the consortium, CT-Ingenieros and Indra.

>Dissemination activities developed by CT-Ingenieros:
____________________________________________

Along the project, and as part of the dissemination plan, CT Ingenieros has attend to commercial fairs all the world around, we have released marketing materials (i.e. web site and commercial presentations), we have participated in oral presentations to customers and we are in the way to request continuation of the project and modification for other application over other project lines.

Website Publication
From the beginning of the project after KoM, the consortium agreed to perform internal webs to promote internally this project and with target to use this same website for later external dissemination.

Commercial fairs
All along the project, representatives of CT Ingenieros have traveled around the world to attend different fairs. Due to company structure, these representatives are not always from the same department of the project but their dissemination activities include all main projects of CT company portfolio, and also the Stagedis project has been presented.
The fairs CT attended in the last months were: Airtech Munich ’15, XPonential New Orleans ’16, ILA Berlin Airshow ’16, Farnborough Airshow ’16, Tokyo Airshow’16.

Marketing materials and customer presentations.
According to our commercial activities with different customers, CT has a portfolio of documents that are updated with the latest activities, in order to show customers the projects. In line with this aim, and with updated commercial presentations, we visited possible new customers: OHB, General Dynamics, Airbus Military USA, Strata.
Moreover, CT has a continuous commercial activity with their nearest customers, mainly Airbus Operations, Airbus Defense & Space and Airbus Helicopters at Getafe facilities (Madrid-Spain).

Conferences for educational aspects.
Additionally to the commercial activities, for a company as CT-Ingenieros, where engineering is the core of its activity (engineering and consulting more than manufacturing) the continuous source of "talents" is very important. And also due to the continuous company growth, CT-Ingenieros usually visit the different universities and expose its company and projects for promotion and at the same time that get contact with the future employees.

Other dissemination activities scheduled.
Moreover, other dissemination activities has been performed by CT-Ingenieros, as:
o Assistance at national industrial forums.
o Assistance to European H2020 forums as in Spain and Brussels.
o Contact for publication in same aeronautic and industrial newspaper, for example "AIRE newspaper", although the publication of the Stagedis project is even pending.

>Dissemination activities developed by INDRA:
______________________________________

Although some times, the dissemination was done in a general Indra airborne systems R&T frame and with presentation of the company, several of the Indra R&T project were also presented, and including the Stagedis project. Hereafter it will be presented the concrete actions only for the Stagedis project.

Website Publication
From the beginning of the project after KoM, the consortium agreed to perform internal webs to promote internally this project and with target to use this same website for later external dissemination. That website is available as in English as in Spanish. Other dissemination information's were available in English or Spanish depending of the actors and on the target audience.

Industrial forums
INDRA is member of several industrial organizations and also has a big activity of participation in Industrial forums as at national level as at international level.
- For example Indra is member of the TEDAE organization (Asociación Española de Empresas Tecnológicas de Defensa, Aeronáutica y Espacio), and being TEDAE part of other international associations as OCAR. And in the different commission of Aeronautic, Defence, Security and Space, Indra always is open to discuss and comment with different companies about R&T projects and potential future collaborations.
- Indra usually take part in the H2020 and CleanSky forums, as national as international. For example the Indra Stagedis team participated in last CS2 presentation and industrial forum in Seville on September 15th 2015.

Scientific conferences and forums.
Indra usually participate in a lot of national and international forums and share its R&T projects and status with the scientific community. But the assistance and presentations depend of the different departments and teams.
For example, not specific scientific presentation about the Sagedis has been done along the project time, but art of the team working in the Stagedis has participated in some scientific event and has commented also about the Stagedis but without Official presentation.

Conferences for educational aspects.
Indra has participated in several educational activities. Indra has participate in most of the national student employ faire at company level, but also some specific activities has been performed at Airborne system R&T department level. Some of these actions are showed hereafter:
- Indra participate in last "Annual Meeting" of the CEI in the "PolytechnicUniversity of Madrid" on July 22nd 2016.
- Indra Airborne System R&T department has also performed two conferences in a secondary educational center, with the objective to present the capabilities of a closer company as Indra as for students that can to continue with high-level studies for some other that want to specialize as technician. Moreover, the presentation included the R&T strategy in the European Union and the opportunities that there are in a lot of application fields and as for big companies as for smaller one, with additional help for enterprising students.
- Moreover, to comment that two students working partially in Indra under a previous funded scholarship as participate in the simulations activities of the
Stagedis projects.
- Indra Airborne System R&T department participated in the SINASA Seminaries (seminary de Aviónica y sistemas de navegación) of the Universidad of Sevilla on April 27th and 28th 2016. Indra was invited to perform a presentation and the intention was present the advance of the project, but finally it was not possible to perform the presentation and only participation without presentation was performed. To note that in 2015, Indra performed a presentation of other previous R&T project.
- Also to comment that some other conferences were scheduled for 2015 and 2016 but finally it was not possible due to agenda problems between Indra and the selected centers.

Other dissemination activities scheduled.
Additionally to the internal website publication, some alert news has been included in the external indra website, including promoting information and link for the internal website.
http://www.indracompany.com/en
http://www.indracompany.com/en/node

Moreover, other publication activities in aeronautic and industrial newspapers and magazines were scheduled, although not performed up to the moment, and it is possible that this action cannot be completed before of the project finalization.

From Exploitation point of view, the consortium have several plans about this.
- To ask for a new Project to develop a physical prototype and to tests the unit.
- To perform modification over the current solution to improve even more the robustness and weight, as already identified in deliverable D5.1
- To perform system customization to apply this solution to other aeronautical applications.
- To see potential applications on other sectors beyond aeronautic applications.

List of Websites:
The URL’s of the websites of both CT Ingenieros and INDRA are the following:

- http://www.ctingenieros.es/index.php/evento/ct-lidera-el-proyecto-stagedis/105
- http://www.ctingenieros.es/index.php/evento/ct-leads-stagedis-project/110?idioma_id=3
- http://www.indracompany.com/es/indra/stagedis-desconexion-arrancadorgenerador
- http://www.indracompany.com/en/indra/stagedis-startergenerator-disconnect-system

Final Report Summary - STAGEDIS (Electrical Starter / Generator disconnect system)

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