Session: 01-13 Thermal Management and Aero-engine Oil Systems I

Paper Number: 121348

121348 - A New Experimental Capability for Electric and Hybrid-Electric Propulsion and Thermal Management Research: The Surrey Aerothermal Test Facility (SATF) 

Electric and hybrid-electric propulsion show promise as part of the decarbonization solution for sustainable aviation. Challenges associated with power density and cooling limitations have emerged, along with opportunities and challenges in the integration of airframe and propulsion unit. Over recent years, research and development activities at the University of Surrey have been focussed upon design and evaluation of promising electric propulsion concepts, which balance aerodynamic, structural and thermal management requirements. To support this research, a variety of low-cost but highly effective experimental test techniques have been developed, together with the evolution of modular experimental test setup which can incorporate a range of test articles, for the purpose of aero-thermal performance evaluation and provision of test data for model validation. This new, flexible, Surrey Aerothermal Test Facility (SATF) is described in full, and results are presented from a series of tests of a modular Electric Ducted Fan (EDF). 

The facility allows an EDF to be evaluated over a representative operating cycle, incorporating steady state and transient effects. Off-the-shelf, low-cost electric motors and motor speed controllers can be used in combination with 60kW programmable power supplies to drive systems of appreciable power density. An initial calibration sequence is conducted to map the relationship between Pulse-Width Modulation (PWM) and RPM, which then allows subsequent programmable control using LabVIEW. Continuous health monitoring of model characteristics by LabVIEW, such as vibration and temperature, allows for safe operation and automatic shutdown in the event of excessive aero-structural vibration, blade failure, thermal overload etc.   

To demonstrate the capabilities of this new facility, results are presented using an in-house, bespoke, modular Electric Ducted Fan rig. This rig allows alternative motor, fan, stator, inlet, nozzle and cooling options to be evaluated, including use of low-cost 3D-print manufacturing options. For example, alternative fan and stator blade geometries, which have been designed at Surrey using the MULTALL-OPEN turbomachinery design software, have been rapidly and cost-effectively tested.  

The facility builds on the strong record of the EnFlo Laboratory at Surrey for development of low-cost, high-quality sensors, in combination with adoption of highly automated, testing approaches. Synchronised time trace data, obtained from a wide variety of sensors monitoring internal/external flow/pressures, surface/air temperature, vibration characteristics, as well as overall forces, allows trade-off analysis of transient aerodynamic and thermal cooling performance.  

Direct measurements using embedded microphones have been used to directly measure the RPM via blade passing, additionally allowing investigation of fan vibration, as subsequently used in the QinetiQ/Boeing/Surrey UK EMPAS project. Intrusive and non-intrusive measurement techniques have been used to produce efflux velocity contours and validate thrust measurements using mass flow integration. IR sensors have been used to measure surface temperature variations on an electric motor, providing evidence of thermal soak-back. Heat flux sensors allow for the monitoring of thermal components and derivation of local heat transfer coefficients. 

Presenting Author: Alishaan Hussain University Of Surrey

Presenting Author Biography: Currently studying for a PhD, within the Centre of Aerodynamics and Environmental Flow at The University of Surrey. Previously completed an MEng in aerospace engineering at The University of Surrey.

Authors:

Alishaan Hussain University Of Surrey
John Doherty University of Surrey
Michael Pekris University of Surrey
John Chew University of Surrey
Paul Hayden University of Surrey