Search Results

This talk will present an overview of the newly published DO-326/ED-202 "Airworthiness Security Process Specification". Presenter Daniel P. Johnson, Honeywell

Fuel consumption in internal combustion engines and their associated CO2 emissions have become one of the major issues facing car manufacturers everyday for various reasons: the Kyoto protocol, the upcoming European regulation concerning CO2 emissions requiring emissions of less than 130g CO2/km before 2012, and customer demand. One of the most efficient solutions to reduce fuel consumption is to downsize the engine and increase its specific power and torque by using turbochargers. The engine and the turbocharger have to be chosen carefully and be finely tuned. It is essential to understand and characterise the turbocharger's behaviour precisely and on its whole operating range, especially at low engine speeds. The characteristics at low speed are not provided by manufacturers of turbochargers because compressor maps cannot be achieve on usual test bench.

Honeywell has developed a unique turbofan engine for application to the super mid-size business aviation market, the HTF7000. This paper will describe the design of this engine including aeromechanical design of its components. The unique design features of this engine will be described along with the technology growth path to keep the engine current. This paper will also describe several features which have been developed for this engine in response to new regulatory requirements. Some aspects of the engine to aircraft integration will also be described.

As on-highway heavy-duty diesel engine designs have evolved to meet tighter emission regulations, the crankcase environment for heavy-duty engine lubricants has become more challenging. The introduction of Exhaust Gas Recirculation (EGR) has allowed for significant reductions of exhaust emissions, but has led to increased oxidation and acid build-up in the lubricant. Engine lubricant quality is important to help ensure engine durability, engine performance, and reduce maintenance downtime. Increased acidity and oxidation accelerate the rate at which the lubricant quality is degraded and hence shorten its' useful life. This paper explores the use of a lube filter with a controlled additive release to maintain lubricant quality.

This paper presents a novel scheme for the start-up of prime movers in starter/generator systems, such as main engine and auxiliary power units (APUs) in aerospace applications. The paper discusses this novel technique in detail for providing single-phase excitation techniques to a start exciter in a starter/generator system to increase the torque per ampere and lower the excitation voltage requirement. Simulation results are provided comparing this novel scheme with a traditional method.

This paper studies the technical characteristics of a start system for aircraft engines. By using the latest improvements in power electronics and digital controls this system eliminates the conventional Air Turbine Starter (ATS) or DC starter by driving the generator installed on the engine as a motor to achieve the start. The presented start system enables a completely new architecture in today's modern and efficient aircraft using the More Electric Architecture (MEA), since bleed air is not required to start the main engines. The MEA increases the overall efficiency of the aircraft by electrically driving the Environmental Control System (ECS) and other major systems such as anti-ice, landing gear, hydraulics etc. This start system eliminates the ATS and its equipment (bleed valve, clutch) for the larger engines or the DC Starter, while providing a start where the engine is accelerated up to 80% idle speed vs. 50-60% provided by the previous Starter.

This paper focuses on advances in active power converter topologies for power quality solutions for More Electric Aircraft (MEA). Advancements in power electronics encompass many technologies including power semiconductors, microprocessors or digital signal processors (DSPs), and component packaging. Hence, active power electronic solutions are becoming more attractive from the perspective of weight, volume, performance and cost. A particular contribution that leads to these advancements is the feasibility of implementing the robust control topologies using faster processors. In this paper various active topologies are reviewed, but a particular emphasis is given to a novel control topology for an active filtering technique where an overall reduction of current harmonics of an aircraft power distribution system can be achieved at the system level rather than at the Line Replaceable Unit (LRU) level.

Commercial transport aircraft have adopted TCP/IP based onboard networking technology to integrate information interchange. This change along with the addition of a TCP/IP based air-ground data link will permit the aircraft network to establish links with ground networks and be integrated into the airline enterprise network. There are many challenging considerations when connecting a remote network to an enterprise network. These challenges are multiplied when that remote network is constantly in motion, both physically and in terms of its link to the ground network. An important consideration in any enterprise network is the element of security. AEEC has published ARINC Report 811: Commercial Aircraft Information Security Concepts of Operation and Process Framework [1] as a guide for the airlines as they consider how to deal with this new challenge.

Various government agencies such as EPA and CARB have established evaporative emission standards for light duty vehicles. To help the OEM's meet these emission standards for volatile organic compounds (VOC's), Honeywell has developed a hydrocarbon adsorber (HCA) approach to reduce hot soak emissions that escape through the air induction system. The HCA has a small footprint and is incorporated in the air filter housing while having a minimal impact on the air flow to the engine during normal operation. As required through EPA regulations it is permanently mounted to provide life of the vehicle durability. In this paper, the process for selecting the VOC adsorbent that functions within the parameters of the hot soak cycle and is regenerated under standard engine operation is discussed. An important part of this technology has been the development of a laboratory test that would simulate engine conditions and permit evaluation of various HCA prototypes.

Thermal management requirements for aerospace applications continue to grow while weight and volume allotments remain constant or shrink. Compact, high performance and lightweight heat transfer equipment is needed to meet these high heat flux removal requirements. Several innovative heat transfer enhancement techniques are being considered for development of thermal management components that will meet these challenging demands. Honeywell, under an AFRL funded program, is developing two new heat exchanger technologies; microchannel and advanced heat transfer surfaces to improve thermal management systems for a fuel-to-air heat exchanger. Heat transfer systems in military aircraft are increasingly using fuel as a heat sink. Heat transport loops containing several fuel-to-liquid heat exchangers are used to cool electronics, engine oil, hydraulic oil, and elements of the thermal management system.

This paper reviews the characteristics of a power line network as data communication medium and studies the challenges encountered when communicating over power wiring. This technology review has been done as part of feasibility study for using aircraft power-lines for data communication. Power-Line Communication is a term which describes the use of existing electrical lines to provide the medium for a high speed communications network. Power Line Communications is achieved by superimposing the voice or data signals onto the line carrier signal using an appropriate communication technology. Power Line Communications represent a potential simplicity for communications among different devices, because it does not need additional wires for connecting devices network together. Power line cables have been used as a communication medium for many years. However, because power line cables are not designed for communication, they pose major challenges for a modem designer.

This work deals with the modeling and analysis of a phasor-controlled Starter/Generator (S/G) electrical machine during starting either an aircraft Main Engine (ME) or Auxiliary Power Unit (APU). The model can be used to determine how much stator and exciter current is required to be supplied by a controlled power converter to the S/G to meet the start torque profile. In addition to modeling details and simulation results the paper presents a thorough analysis of the S/G machine, its environment and control.

Operational ranges of compressors are limited when running at low mass flow. In particular, large pressure fluctuations occur when reaching surge that can cause rapid deterioration of the bearing system and considerably increase the level of noise. In order to extent the operability of their turbochargers, Honeywell equipped its compressor housings with ported shrouds located at the inlet. The ported shroud has been demonstrated to allow a larger range of operability with minor negative impact on the compressor efficiency. In a collaborative work between Honeywell and the University of Cincinnati, a turbocharger bench facility was designed and tested. The size of the compressor was typical for a turbocharger used on diesel engines. The goal of the experimental study was to develop better understanding of the flow dynamic in the compressor housing that affects stall and surge for different operating conditions.

A passive gas removal device, i.e. gas trap is used in the Internal Thermal Control System (ITCS) of the International Space Station (ISS) to remove non-condensable gases to prevent the cavitation or air locking of the pump and malfunction of the pressure and flow sensors. Since the non-condensable gases are always ingested into the ITCS during the routine maintenance and/or replacement of components in the ITCS, it is necessary to have an efficient and reliable gas trap in the liquid coolant loop of the ITCS. To increase tolerance to particulate and microbial growth fouling, extend the operational life, reduce the cost and on-orbit maintenance, and decrease crew workload, an alternative gas trap composed of only one type of membrane is developed. This paper describes the efforts involved in this development, which include the design concept of the alternative gas trap, performance modeling, and the preliminary performance test of the alternative gas trap in the relevant environment.

This paper discusses the problem of designing electric machines (EM) for advanced electric generators (AEG) used in aerospace more electric architecture (MEA) that would be applicable to aircraft, spacecraft, and military ground vehicles. The AEG's are analyzed using aspects of Six Sigma theory that relate to critical-to-quality (CTQ) subjects. Using this approach, weight, volume, reliability, efficiency, and cost (CTQs) are addressed to develop a balance among them, resulting in an optimized power generation system. The influence of the machine power conditioners and system considerations are also discussed. As a part of the machine evaluation process, speeds, bearings, complexities, rotor mechanical and thermal limitations, torque pulsations, currents, and power densities are also considered. A methodology for electric machine selection is demonstrated. Examples of high-speed, high-performance machine applications are shown.

Surge is a phenomenon that limits the operational range of the compressor at low mass flow rates. The objective of this research is to study effective operational range for a ported shroud compressor. The size of the compressor is typical for a turbocharger used on diesel engines. To be able to extend the operational range, the surge characteristics have to be assessed. This is done by performing measurement of the flow at the inlet to the compressor wheel and pressure fluctuations at the inlet and outlet of the compressor housing. Detailed numerical computations of the flow in the entire compressor section under similar operating conditions have also been carried out. The experimental work includes Particle Imaging Velocimetry (PIV) measurements of the instantaneous and mean velocity field at the inlet. At surge, low frequency pulsations are detected that seem to result from back flow already observed in stall.

The Indirect Boundary Element Analysis is employed for developing a computational pass-by noise simulation capability. An inverse analysis algorithm is developed in order to generate the definition of the main noise sources in the numerical model. The individual source models are combined for developing a system model for pass-by noise simulation. The developed numerical techniques are validated through comparison between numerical results and test data for component level and system level analyses. Specifically, the source definition capability is validated by comparing the actual and the computationally reconstructed acoustic field for an engine intake manifold. The overall pass-by noise simulation capability is validated by computing the maximum overall sound pressure level for a vehicle under two separate driving conditions.

This paper examines why large aircraft engines are started the way they are today, and why that may all change in the not too distant future. Electric starting of aircraft engines and Auxiliary Power Units (APU) has been limited to 28 VDC battery systems, with starting power typically under 10 kW. Above this power level the very high battery currents, and resulting voltage drops, make the approach less and less practical. Large engines for commercial transports may require more than 100 kW to start so low voltage battery starting will not be an option.

The bleed air contamination monitor was developed at Honeywell to ensure that our products provide the highest quality bleed air to aircraft environmental control systems. The bleed air contamination monitor is currently for ground based applications only. It is being developed into an on board system for future applications. Current Aircraft Cabin Air Quality measurement techniques are very labor intensive and require days or even weeks of laboratory analysis to provide results. This is unacceptable from a manufacturing and service perspective. Development of a real time analyzer began in the early 1990s and has progressed to a point where a product is ready for introduction that not only provides real time information regarding engine air contamination, but is also easy for operators to use with a minimum amount of training.

In this work we have proposed an interesting clamping solution of V-band which has an important industrial impact by reducing the cost and assembly process as well compare to the traditional V-band. The design what we are focusing for is applied for all size of turbochargers which helps to connect the hot components such as manifold and turbine housing. The cost for V-band is mainly from T-bolt. It is made from special stainless steel which represents 50% of the total cost. In this work it is proposed a new V-band joint by changing bolt clamping status from tension to compression. From tension to compression we change the bolt material from high cost steel to low cost steel. The new total cost is reduced by 40%. The prototype is made and performed in static tests including anti-rotating torque test and salt spray test. The new joint meets the design requirements at static condition. Further work will focus on the dynamic qualification and at high temperature as well.