A large number of concepts were considered, including mechanical actuation methods without a screw. Detailed analysis, modelling and simulation tasks have been undertaken to determine whether the PCM system meets the specification in terms of mass, size, dynamic performance, fault tolerance etc. within the challenging operating environment.
Key developments include fault tolerant electric drives, rotating electrical power transfer device, magnetically geared motor and development of lightweight mechanical actuation components.
The fault tolerant electrical drive uses silicon carbide technology to reduce losses and allow high operating temperatures. The fault tolerant, rotating, contactless power transfer uses high frequency methods of electromagnetic power transfer. Complex models and hardware have been built and tested.
A digital twin (a method of using a computer model to predict behaviour and lifetime of physical systems) has been created to support the design of the actuator. The digital twin is based on commercially available software that will be exploited through commercial sales..
The unique environment is challenging for designers, as the electronics must work at high rotational speed and the high forces generated need to be controlled to prevent damage.
An ultra-lightweight magnetically geared motor has been designed, built and tested and shows good performance. Both metallic and composite parts have been the subject of significant research efforts in order to provide a lightweight and reliable PCM.
The developed components have been tested under high vibration conditions to aerospace test standards.
A full-scale rotating PCM has been designed, manufactured. The novel PCM cwas tested on a bespoke test-rig designed to replicate the rotating environment of an open-rotor engine. Comparisons have been made between measured and predicted results. The PCM was tested over the most challenging parts of the duty cycle of the engine and the results show that the electro-mechanical magnetic PCM is capable of meeting the performance requirements of the open rotor engine with a total mass only 17% higher than the target. With further developments of the technologies, further mass saving is possible and the target is capable of being met.
The full impact of the project will be realised through further development, with application to new aircraft engines predicted to save 180 million tonnes of CO2 per year.
Project results have been disseminated in leading international conferences (IEEE) and through institutional publications and magazines all available through open access sites.
