Electrification of Aircraft and Vehicles Current Status and Future Trends Dr. Bulent Sarlioglu Associate Professor, University of Wisconsin-Madison Associate Director of WEMPEC [email protected] (608) 262 2703 WEMPEC Wisconsin Electric Machines and Power Electronics Consortium 1 My research is on innovative electric motors and power electronics. • Conventional and Novel Electric Machines • Power Electronics with SiC and GaN Devices Tesla Model 3 Electric Power Train with SiC Inverter 2 Efficient Motors and Drives Research Motor & Drive design Robotics Chuo Shinkansen (Maglev) Transportation Industrial Actuators Daily life Electric aircraft (Efan-X) Electric and Autonomous HVAC units vehicles Vacuum cleaners 3 University of Wisconsin-Madison • 2017 student enrollment: 43,820 • 2016-17 degrees awarded: 10,515 • 2017 research expenditure ranking (U.S.A.): 6th nd • 2 most for Federally Funded research 4 Wisconsin Electric Machines and Power Electronics Consortium (WEMPEC) • Innovative research for • 60 on-campus students 37 years – Power electronics • 70 off-campus students – Electric machines • Degrees granted: – Controls – 425 MS Degrees • 87 sponsoring companies – 160 PhD Degrees • 4 tenured faculty • More than 510 alumni • 2 tenure-track faculty 5 WEMPEC Faculty Prof. Tom Jahns Prof. Giri Venkataramanan Prof. Bulent Sarlioglu Prof. Dan Ludois Prof. Eric Severson 6 WEMPEC Faculty, cont’d Prof. Don Novotny Prof. Tom Lipo Prof. Bob Lasseter (Emeritus) (Emeritus) (Emeritus) 7 WEMPEC Sponsors ABB Inc., Drives and Power Products Division Harley-Davidson Motor Co. Nidec Motor Corp. ANSYS, Inc. HBM Test and Measurement Nissan Research Center Arnold Magnetic Technologies Hitachi, Ltd. Research Laboratory Oriental Motors BTG ASELSAN A.S. Huawei Technologies Co. LTD Oshkosh Corporation BAE Systems E&IS Infolytica Corporation Regal-Beloit Enabling Technologies Div Boeing Company John Deere Construction & Forestry Div. ResMed Motor Technologies BorgWarner PowerDrive Systems John Deere Electronic Solutions Rockwell Automation - Kinetix Division Carrier Corporation John Deere Moline Technical Innovation Rockwell Automation - Standard Drives CRRC Zhuzhou Institute Co., Ltd. Center Rolls-Royce Corp. N.A. Daikin Industries John Deere Power Systems S & C Electric Company Danfoss Power Electronics Johnson Controls, Inc.-York SAFRAN Delta Electronics, Inc. Johnson Electric Industrial Manufactory, Smart Wires, Inc. DRS Power & Control Technologies, Inc. Ltd. TECO-Westinghouse Motor Company dSPACE, Inc. JSOL Corporation, Engr. Technology Div. Teledyne LeCroy Eaton Corporation Research and Technology Kohler Company, Power Systems Div. Texas Instruments Motor Control Kilby Lab Eaton Industrial Controls Division L-3 Communications Electronic Devices TMEIC Fuchu, Japan Electro-Motive Diesel International Corp. L-3 Power Paragon, Inc. TMEIC Corporation Electronic Concepts, Inc. LEM USA, Inc. TMNA – Toyota Motor N.A. R&D Fiat Chrysler Automobiles Lenze Americas Toro Company Fisher & Paykel Appliance LG Electronics – Korea Trane Company Div. of Ingersoll Rand Flanders Electric LG Electronics – Troy, MI Triumph Aerospace Systems Ford Motor Company R&AE Magna Powertrain TRW Automotive GE Aviation - Electrical Power Magnetek Inc. UNICO, Inc. Div. of Regal Corp. GE Global Research Center Mathworks, Inc. UT Aerospace Systems Generac Power Systems Mercedes-Benz R&D, N.A. Inc. United Technologies Research Center GM Propulsion Systems Engineering Miller Electric Manufacturing Co. Wolong Electric Group Co., Ltd GM R & D – Warren Milwaukee Electric Tool Corporation Woodward GW Lisk Company, Inc Mitusbishi Electric Corporation Yaskawa Electric America Inc. MOOG, Inc. Moving Magnet Technologies, SA 8 University of Wisconsin - Madison http://wempec.wisc.edu 9 Electrification of Aircraft Current Status and Future Trends 10 Outline 1. Introduction and Motivations 2. Current Trends: power system, MES, etc. 3. Future Trends: e-taxi, e-propulsion 4. Enabling Technologies and Considerations 5. Conclusions 11 Potential Benefits of Electrification • Benefits of Electrification – Reduced fuel consumption – Reduced carbon emissions (highest priority) – Increased reliability 2.0 - 2.5% of total global annual CO2 emission Electrification can potentially enable reduced fuel consumption and provide means to meet various requirements, such as environmental concerns, etc. National Academies Press 2016 Commercial aircraft propulsion and energy systems research: reducing global carbon emissions https://nap.edu/catalog/23490/ commercial-aircraft-propulsion-and-energy-systems- research-reducing-global-carbon 12 Outline 1. Introduction and Motivations 2. Current state-of-the art 3. Future Trends: e-taxi, e-propulsion 4. Enabling Technologies and Considerations 5. Conclusions 13 More Electric Aircraft B787 A350 A380 Trend is to use more electrical power for various subsystems 14 Comparison of Most Recent Commercial Aircraft Designs Comparison of current MEA 15 All Electric Aircraft VoltAir 330LE Alice Transitioning into using all electric propulsion systems 16 Outline 1. Introduction and Motivations 2. Current state-of-the art 3. Future Trends: e-propulsion 4. Enabling Technologies and Considerations 5. Conclusions 17 Future Trends: Electric Propulsion • All Electric Propulsion (AEP) – Uses Battery and/or Fuel Cell • Hybrid Electric Propulsion (HEP) – Series – Parallel – Series/parallel • Turboelectric Propulsion (TEP) – Full – Partial 18 All Electric Propulsion (AEP) National Academies Press 2016 Commercial aircraft propulsion and energy systems research: reducing global carbon emissions https://nap.edu/catalog/23490/ commercial-aircraft-propulsion-and-energy-systems- research-reducing-global-carbon 19 Airbus E-FAN All Electric • Efan 2.0 with two seat trainer Airbus E-FAN • Weighs 500 kg • All electric using dual electric motors with total 60 kW (2 of 30kW) • : Lithium-ion 18650, with 207 Wh/kg per cel, total of 29 kWh • Efan 4.0 with four seats, touring aircraft • Engine used as range extender for Efan 4.0 www.airbusgroup.com All electric using dual electric motors with total 60 kW (2 of 30kW) 20 330 LE Siemens All-electric Siemens-330LE • Two passenger aircraft weighing approx. 1000 kg • Single electric motor producing 260 kW and weighing only 50 kg • 14 Li-Ion battery packs totaling 18.6 kWh. • Target of 100 passenger craft with 1000 km range by 2030. https://www.siemens.com 21 Hybrid Electric Propulsion (HEP) Batteries provide power to fans during one or more flight phases 22 Airbus E-FAN X Hybrid- electric propulsion • Collaboration among Airbus, Rolls-Royce, Siemens E-FAN X • Based on a 100-seat airplane • One gas turbine replaced by a 2 MW electric motor • Announced in November 2018, anticipate to fly in 2020 www.airbus.com 23 Future Trends: Hybrid- electric propulsion www.airbus.com 24 Turbo Electric Propulsion (TEP) No batteries are used in TEP. Partial topology uses both fan connected to turbo engine and individual fans run by motors National Academies Press 2016 Commercial aircraft propulsion and energy systems research: reducing global carbon emissions https://nap.edu/catalog/23490/ commercial-aircraft-propulsion-and-energy-systems- research-reducing-global-carbon 25 MW Class Motors Papathakis, K. V. https://ntrs.nasa.gov/search.jsp?R=20170009874 High power (MW class) machines are necessary for commercial aviation 26 Example: Series Hybrid Electric Propulsion Systems Architecture 27 NASA’s Turbo Electric Propulsion • Turboelectric Propulsion – NASA has proposed Turboelectric Distributed Propulsion (TeDP) – ~15 2-3 MW motors to propel machine from 2 massive engine/generator (~20 MW each) Maximize boundary layer Generator placed at the ingestion wing-tip for receiving undisturbed free-stream air 28 Future Trends: Distributed Propulsion Cape Air Cessna 402 NASA Rolls-Royce National Academies Press 2016 Commercial aircraft propulsion and energy systems research: reducing global carbon emissions https://nap.edu/catalog/23490/ commercial-aircraft-propulsion-and-energy-systems- research-reducing-global-carbon 29 Outline 1. Introduction and Motivations 2. Current Trends: power system, MES, etc. 3. Future Trends: e-taxi, e-propulsion 4. Enabling Technologies and Considerations 5. Conclusions 30 Enabling Technologies and Considerations State-of-the-art Current research targets Viable production target in 20 years Research goal is set to achieve ~9 kW/kg specific power in both motor and power electronics National Academies Press 2016 Commercial aircraft propulsion and energy systems research: reducing global carbon emissions https://nap.edu/catalog/23490/ commercial-aircraft-propulsion-and-energy-systems- research-reducing-global-carbon 31 Enabling Technologies and Considerations Specific power for electric motor and power electronics needs to be higher than ~ 2.2 kW/kg state-of-the-art National Academies Press 2016 Commercial aircraft propulsion and energy systems research: reducing global carbon emissions https://nap.edu/catalog/23490/ commercial-aircraft-propulsion-and-energy-systems- research-reducing-global-carbon 32 Needed Technologies • Electric Machines – Particularly high speed, high power density and fault tolerant machines – MW level – Larger Voltage • Power Electronics – High efficiency and high reliability – MW Level – Larger Voltage • Batteries – Replacement of APUs • Fuel Cells – Replacement of APUs 33 Electrification of Vehicles Current Status and Future Trends 34 Application of WBG-based Motor Drive l ~200 kW IPM machine replaces induction machine used in Roadster