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Rolls-Royce
KTN Engage with…
PEMD and the Aerospace Gas Turbine
The informationin this document is proprietary and confidential to Rolls-Royceand is available to authorised recipients only – copying
and onward distribution is prohibited other than for the purpose for which it was made available.
Private | Not subject to Export Control| © 2020 Rolls-Royce
Graham Bruce – Electronics Specialist – Rolls-Royce Control Systems (graham.bruce@rolls-royce.com)
Mark Husband – Lead Engineer Electrical Systems and Technologies – Rolls-Royce Electrical
Jeff Hobday – Chief Product Engineer – Rolls-Royce Control Systems
14th May 2020

2
Who We Are
Defence Power Systems▪ Civil Aerospace
Rolls-Royce is one of
the world’s leading
industrial technology
companies, creating
power and propulsion
systems for use on land,
at sea and in the air.
Private | Not subject to Export Control | © 2020 Rolls-Royce
2

Business sensitivity classification | © 2018 Rolls-Royce
Business proprietary classification
Export Control classification
Electrification of
Aviation
There are two major
dynamics…
Evolutionary (incremental)
• More electric aircraft
• Electrical content increases e.g.
mechanical and hydraulic systems
• Understanding of electrical technology
becomes more important across the
industry
Revolutionary (disruptive)
• Electric and hybrid electric
aircraft/propulsion
• New airframe and /or transport concepts now
appearing
• Scope of supply will change
• New entrants will appear in the market
• Market could structurally change
3

A More-Electric Gas Turbine
4

5
The More Electric
UltraFan
5

6
The More Electric
UltraFan
6

7
The More Electric
UltraFan
7

8
The More Electric
UltraFan
8

9
The More Electric
UltraFan
9

10
The More Electric
UltraFan
10

Power Electronics
• The Solid State Gearbox
11

12
4 Key Functions
Solid-State Power
Control
Power Supply
Bus Provision
Motor & Actuator
Control
A Product Line
for a More-
Electric Gas
Turbine
12

13
Key Challenge is
power density
kW/kg
Year
1. Automotive claims are ~10-15 kW/kg
2. Gas Turbine constraints pull power
density down:
• Reliability
• Availability
• Environmental Challenge
• Thermal Constraints
• Power Quality
• Abnormal Operating Conditions
• Component Utilisation and De-rating
• EMC
3. Combination of:
• Appropriate system level design
• Optimised packaging and design with
• Good component utilisation
• Adoption of high performance technology
…will push power density up.
1
2
3
13

14
Reliability is a
real challenge
“Only when its as reliable as a gearbox shaft”
▪ Mechanical items
have an assumed
reliability of 1 x 10-6
failure per flying hour.
▪ No single point fault
can cause a loss of
thrust control.
▪ We have experience
of fault tolerant
electronics solution
with our EECs
▪ Significant challenge
to deliver this to
deliver a fault tolerant
electrical system
solution
Fault Tolerance is a key enabler…PEMD and the Aerospace Gas Turbine
14

15
Shock and
Vibration
▪ The vibration inputs
levels at the unit
mounting points are
nominally in the range
of 20G to 40G peak.
▪ Loads during fan-
blade off events can
be as high as a shock
load of 200G.
15

16
Thermal
Constraints
▪ Fan case mounted
unit sees air temp up
to 85°C
▪ Active cooling options
on engine are limited
▪ After engine shut-
down stored heat
‘soaks back’
▪ Extreme temperature
testing to -55°C.
▪ Deep thermal cycle
testing is needed to
prove out
components.
16

17
Where’s the
operational
benefit?
Max take off
sizing point
Normal
take off
Max
continuous
thrust
▪ We require a
significant
performance or
operability
improvement
▪ Can we make a pump
last longer?
17

18
E-Fuel
Demonstrator
Power Electronics
▪ Total Output Power of
72 kW
▪ Key metrics of:
▪ 9.16kW/L
▪ 8.7kW/kg
▪ 96.4% eff
▪ Fault-tolerant Unit
▪ 4 Segregated
Channels of Power
▪ ALM Cooling Gallery
preferentially cools to
the components that
need it most.
18

19
Component
Challenges
▪ Power Modules
▪ Capacitors
▪ PCB / Bus Bar
▪ Custom Magnetics
▪ I and V Meas.
▪ Connectors
▪ Heat Sink
▪ Casing
Also:
▪ Rapid Prototyping
▪ Environmental & EMC
Testing
19

20
Modular Design &
Automation
▪ Design once, use
many times
▪ Hardware is
implemented using
‘Common Circuit
Block’ approach
▪ Designed such that
automation can be
used to increase
repeatability
▪ Pushing the envelope
of Power on PCB to
leverage existing
knowledge, know-
how, and capability
20

Power Electronics for an Aerospace Gas Turbine
21
In Summary
PEMD. An essential ingredient in an amazing opportunity to shape the
future of aerospace:
Paced by technology at propulsion and platform level
Characterised by multiple markets
Enabled by an ecosystem
Significant challenges exist in deploying PEMD solutions on an aerospace
gas turbine that meet all key requirements:
Reliability and Availability
Environmental Ruggedness
Performance (kW/kg, kW/L, Efficiency)
PEMD solutions for incremental ‘more-electric’ and disruptive
opportunities will build upon existing aerospace experience and leverage
on-going developments in other sectors.
DER presents a significant opportunity for UK PEMD. We would like to
reach out to the supply chain…
21

Power Electronics for an Aerospace Gas Turbine

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