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- hydrogen (4)
- solar sail (4)
- MASCOT (3)
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The Dry-Low-NOx (DLN) Micromix combustion technology has been developed originally as a low emission alternative for industrial gas turbine combustors fueled with hydrogen. Currently the ongoing research process targets flexible fuel operation with hydrogen and syngas fuel.
The non-premixed combustion process features jet-in-crossflow-mixing of fuel and oxidizer and combustion through multiple miniaturized flames. The miniaturization of the flames leads to a significant reduction of NOx emissions due to the very short residence time of reactants in the flame.
The paper presents the results of a numerical and experimental combustor test campaign. It is conducted as part of an integration study for a dual-fuel (H2 and H2/CO 90/10 Vol.%) Micromix combustion chamber prototype for application under full scale, pressurized gas turbine conditions in the auxiliary power unit Honeywell Garrett GTCP 36-300.
In the presented experimental studies, the integration-optimized dual-fuel Micromix combustor geometry is tested at atmospheric pressure over a range of gas turbine operating conditions with hydrogen and syngas fuel. The experimental investigations are supported by numerical combustion and flow simulations. For validation, the results of experimental exhaust gas analyses are applied.
Despite the significantly differing fuel characteristics between pure hydrogen and hydrogen-rich syngas the evaluated dual-fuel Micromix prototype shows a significant low NOx performance and high combustion efficiency. The combustor features an increased energy density that benefits manufacturing complexity and costs.
The paper presents an overview of the past and present of low-emission combustor research with hydrogen-rich fuels at Aachen University of Applied Sciences. In 1990, AcUAS started developing the Dry-Low-NOx Micromix combustion technology. Micromix reduces NOx emissions using jet-in-crossflow mixing of multiple miniaturized fuel jets and combustor air with an inherent safety against flashback. At first, pure hydrogen as fuel was investigated with lab-scale applications. Later, Micromix prototypes were developed for the use in an industrial gas turbine Honeywell/Garrett GTCP-36-300, proving low NOx characteristics during real gas turbine operation, accompanied by the successful definition of safety laws and control system modifications. Further, the Micromix was optimized for the use in annular and can combustors as well as for fuel-flexibility with hydrogen-methane-mixtures and hydrogen-rich syngas qualities by means of extensive experimental and numerical simulations. In 2020, the latest Micromix application will be demonstrated in a commercial 2 MW-class gas turbine can-combustor with full-scale engine operation. The paper discusses the advances in Micromix research over the last three decades.
The feasibility study presents results of a hydrogen combustor integration for a Medium-Range aircraft engine using the Dry-Low-NOₓ Micromix combustion principle. Based on a simplified Airbus A320-type flight mission, a thermodynamic performance model of a kerosene and a hydrogen-powered V2530-A5 engine is used to derive the thermodynamic combustor boundary conditions. A new combustor design using the Dry-Low NOx Micromix principle is investigated by slice model CFD simulations of a single Micromix injector for design and off-design operation of the engine. Combustion characteristics show typical Micromix flame shapes and good combustion efficiencies for all flight mission operating points. Nitric oxide emissions are significant below ICAO CAEP/8 limits. For comparison of the Emission Index (EI) for NOₓ emissions between kerosene and hydrogen operation, an energy (kerosene) equivalent Emission Index is used.
A full 15° sector model CFD simulation of the combustion chamber with multiple Micromix injectors including inflow homogenization and dilution and cooling air flows investigates the combustor integration effects, resulting NOₓ emission and radial temperature distributions at the combustor outlet. The results show that the integration of a Micromix hydrogen combustor in actual aircraft engines is feasible and offers, besides CO₂ free combustion, a significant reduction of NOₓ emissions compared to kerosene operation.
The utilisation of vehicle-oriented gasoline in general aviation is very desirable for both ecological and economical reasons, as well as for general considerations of availability. As of today vehicle fuels may be used if the respective engine and cell are certified for such an operation. For older planes a supplementary technical certificate is provided for gasoline mixtures with less than 1 % v/v ethanol only, though. Larger admixtures of ethanol may lead to sudden engine malfunction and should be considered as considerable security risks. Major problems are caused by the partially ethanol non-withstanding materials, a necessarily changed stochiometric adjustment of the engine for varying ethanol shares and the tendency for phase separation in the presence of absorbed water. The concepts of the flexible fuel vehicles are only partially applicable in the view of air security.
Numerical Study on Increased Energy Density for the DLN Micromix Hydrogen Combustion Principle
(2014)
Development and Testing of a Low NOx Micromix Combustion Chamber for an Industrial Gas Turbine
(2015)
For more than a decade up to now there is an ongoing interest in small gas turbines downsized to micro-scale. With their high energy density they offer a great potential as a substitute for today’s unwieldy accumulators, found in a variety of applications like laptops, small tools etc. But micro-scale gas turbines could not only be used for generating electricity, they could also produce thrust for powering small unmanned aerial vehicles (UAVs) or similar devices. Beneath all the great design challenges with the rotating parts of the turbomachinery at this small scale, another crucial item is in fact the combustion chamber needed for a safe and reliable operation. With the so called regular micromix burning principle for hydrogen successfully downscaled in an initial combustion chamber prototype of 10 kW energy output, this paper describes a new design attempt aimed at the integration possibilities in a μ-scale gas turbine. For manufacturing the combustion chamber completely out of stainless steel components, a recuperative wall cooling was introduced to keep the temperatures in an acceptable range. Also a new way of an integrated ignition was developed. The detailed description of the prototype’s design is followed by an in depth report about the test results. The experimental investigations comprise a set of mass flow variations, coupled with a variation of the equivalence ratio for each mass flow at different inlet temperatures and pressures. With the data obtained by an exhaust gas analysis, a full characterisation concerning combustion efficiency and stability of the prototype chamber is possible. Furthermore the data show a full compliance with the expected operating requirements of the designated μ-scale gas turbine.
Prolonged operations close to small solar system bodies require a sophisticated control logic to minimize propellant mass and maximize operational efficiency. A control logic based on Discrete Mechanics and Optimal Control (DMOC) is proposed and applied to both conventionally propelled and solar sail spacecraft operating at an arbitrarily shaped asteroid in the class of Itokawa. As an example, stand-off inertial hovering is considered, recently identified as a challenging part of the Marco Polo mission. The approach is easily extended to stand-off orbits. We show that DMOC is applicable to spacecraft control at small objects, in particular with regard to the fact that the changes in gravity are exploited by the algorithm to optimally control the spacecraft position. Furthermore, we provide some remarks on promising developments.
This paper primarily presents an aerodynamic CFD analysis of a winged spaceplane geometry based on the Japanese Space Walker proposal. StarCCM was used to calculate aerodynamic coefficients for a typical space flight trajectory including super-, trans- and subsonic Mach numbers and two angles of attack. Since the solution of the RANS equations in such supersonic flight regimes is still computationally expensive, inviscid Euler simulations can principally lead to a significant reduction in computational effort. The impact on accuracy of aerodynamic properties is further analysed by comparing both methods for different flight regimes up to a Mach number of 4.
Physical interaction with small solar system bodies (SSSB) is the next step in planetary science, planetary in-situ resource utilization (ISRU), and planetary defense (PD). It requires a broader understanding of the surface properties of the target objects, with particular interest focused on those near Earth. Knowledge of composition, multi-scale surface structure, thermal response, and interior structure is required to design, validate and operate missions addressing these three fields. The current level of understanding is occasionally simplified into the phrase, ”If you’ve seen one asteroid, you’ve seen one asteroid”, meaning that the in-situ characterization of SSSBs has yet to cross the threshold towards a robust and stable scheme of classification. This would enable generic features in spacecraft design, particularly for ISRU and science missions. Currently, it is necessary to characterize any potential target object sufficiently by a dedicated pre-cursor mission to design the mission which then interacts with the object in a complex fashion. To open up strategic approaches, much broader in-depth characterization of potential target objects would be highly desirable. In SSSB science missions, MASCOT-like nano-landers and instrument carriers which integrate at the instrument level to their mothership have met interest. By its size, MASCOT is compatible with small interplanetary missions. The DLR-ESTEC Gossamer Roadmap Science Working Groups‘ studies identified Multiple Near-Earth asteroid (NEA) Rendezvous (MNR) as one of the space science missions only feasible with solar sail propulsion. The Solar Polar Orbiter (SPO) study showed the ability to access any inclination, theDisplaced-L1 (DL1) mission operates close to Earth, where objects of interest to PD and for ISRU reside. Other studies outline the unique capability of solar sails to provide access to all SSSB, at least within the orbit of Jupiter, and significant progress has been made to explore the performance envelope of near-term solar sails for MNR. However, it is difficult for
sailcraft to interact physically with a SSSB. We expand and extend the philosophy of the recently qualified DLR Gossamer solar sail deployment technology using efficient multiple sub-spacecraft integration to also include landers for one-way in-situ investigations and sample-return missions by synergetic integration and operation of sail and lander. The MASCOT design concept and its characteristic features have created an ideal counterpart for thisand has already been adapted to the needs of the AIM spacecraft, former part of the NASA-ESA AIDA missionDesigning the 69th International Astronautical Congress (IAC), Bremen, Germany, 1-5 October 2018. IAC-18-F1.2.3 Page 2 of 17 combined spacecraft for piggy-back launch accommodation enables low-cost massively parallel access to the NEA population.
Physical interaction with small solar system bodies (SSSB) is key for in-situ resource utilization (ISRU). The design of mining missions requires good understanding of SSSB properties, including composition, surface and interior structure, and thermal environment. But as the saying goes "If you've seen one asteroid, you've seen one Asteroid": Although some patterns may begin to appear, a stable and reliable scheme of SSSB classification still has to be evolved. Identified commonalities would enable generic ISRU technology and spacecraft design approaches with a high degree of re-use. Strategic approaches require much broader in-depth characterization of the SSSB populations of interest to the ISRU community. The DLR-ESTEC GOSSAMER Roadmap Science Working Groups identified target-flexible Multiple Near-Earth asteroid (NEA) Rendezvous (MNR) as one of the missions only feasible with solar sail propulsion, showed the ability to access any inclination and a wide range of heliocentric distances as well as continuous operation close to Earth's orbit where low delta-v objects reside.
Asteroid mining has the potential to greatly reduce the cost of in-space manufacturing, production of propellant for space transportation and consumables for crewed spacecraft, compared to launching the required resources from Earth’s deep gravity well. This paper discusses the top-level mission architecture and trajectory design for these resource-return missions, comparing high-thrust trajectories with continuous low-thrust solar-sail trajectories. This work focuses on maximizing the economic Net Present Value, which takes the time-cost of finance into account and therefore balances the returned resource mass and mission duration. The different propulsion methods will then be compared in terms of maximum economic return, sets of attainable target asteroids, and mission flexibility. This paper provides one more step towards making commercial asteroid mining an economically viable reality by integrating trajectory design, propulsion technology and economic modelling.
In parallel to the evolution of the Planetary Defense Conference, the exploration of small solar system bodies has advanced from fast fly-bys on the sidelines of missions to the planets to the implementation of dedicated sample-return and in-situ analysis missions. Spacecraft of all sizes have landed, touch-and-go sampled, been gently beached, or impacted at hypervelocity on asteroid and comet surfaces. More have flown by close enough to image their surfaces in detail or sample their immediate environment, often as part of an extended or re-purposed mission. And finally, full-scale planetary defense experiment missions are in the making. Highly efficient low-thrust propulsion is increasingly applied beyond commercial use also in mainstream and flagship science missions, in combination with gravity assist propulsion. Another development in the same years is the growth of small spacecraft solutions, not in size but in numbers and individual capabilities. The on-going NASA OSIRIS-REx and JAXA HAYABUSA2 missions exemplify the trend as well as the upcoming NEA SCOUT mission or the landers MINERVA-II and MASCOT recently deployed on Ryugu. We outline likely as well as possible and efficient routes of continuation of all these developments towards a propellant-less and highly efficient class of spacecraft for small solar system body exploration: small spacecraft solar sails designed for carefree handling and equipped with carried landers and application modules, for all asteroid user communities –planetary science, planetary defence, and in-situ resource utilization. This projection builds on the experience gained in the development of deployable membrane structures leading up to the successful ground deployment test of a (20 m)² solar sail at DLR Cologne and in the 20 years since. It draws on the background of extensive trajectory optimization studies, the qualified technology of the DLR GOSSAMER-1 deployment demonstrator, and the MASCOT asteroid lander. These enable ‘now-term’ as well as near-term hardware solutions, and thus responsive fast-paced development. Mission types directly applicable to planetary defense include: single and Multiple NEA Rendezvous ((M)NR) for mitigation precursor, target monitoring and deflection follow-up tasks; sail-propelled head-on retrograde kinetic impactors (RKI) for mitigation; and deployable membrane based methods to modify the asteroid’s properties or interact with it. The DLR-ESTEC GOSSAMER Roadmap initiated studies of missions uniquely feasible with solar sails such as Displaced L1 (DL1) space weather advance warning and monitoring and Solar Polar Orbiter (SPO) delivery which demonstrate the capability of near-term solar sails to achieve NEA rendezvous in any kind of orbit, from Earth-coorbital to extremely inclined and even retrograde orbits. For those mission types using separable payloads, such as SPO, (M)NR and RKI, design concepts can be derived from the separable Boom Sail Deployment Units characteristic of DLR GOSSAMER solar sail technology, nanolanders like MASCOT, or microlanders like the JAXA-DLR Jupiter Trojan Asteroid Lander for the OKEANOS mission which can shuttle from the sail to the asteroids visited and enable multiple NEA sample-return missions. These are an ideal match for solar sails in micro-spacecraft format whose launch configurations are compatible with ESPA and ASAP secondary payload platforms.
20 years after the successful ground deployment test of a (20 m) 2 solar sail at DLR Cologne, and in the light of the upcoming U.S. NEAscout mission, we provide an overview of the progress made since in our mission and hardware design studies as well as the hardware built in the course of our solar sail technology development. We outline the most likely and most efficient routes to develop solar sails for useful missions in science and applications, based on our developed `now-term' and near-term hardware as well as the many practical and managerial lessons learned from the DLR-ESTEC Gossamer Roadmap. Mission types directly applicable to planetary defense include single and Multiple NEA Rendezvous ((M)NR) for precursor, monitoring and follow-up scenarios as well as sail-propelled head-on retrograde kinetic impactors (RKI) for mitigation. Other mission types such as the Displaced L1 (DL1) space weather advance warning and monitoring or Solar Polar Orbiter (SPO) types demonstrate the capability of near-term solar sails to achieve asteroid rendezvous in any kind of orbit, from Earth-coorbital to extremely inclined and even retrograde orbits. Some of these mission types such as SPO, (M)NR and RKI include separable payloads. For one-way access to the asteroid surface, nanolanders like MASCOT are an ideal match for solar sails in micro-spacecraft format, i.e. in launch configurations compatible with ESPA and ASAP secondary payload platforms. Larger landers similar to the JAXA-DLR study of a Jupiter Trojan asteroid lander for the OKEANOS mission can shuttle from the sail to the asteroids visited and enable multiple NEA sample-return missions. The high impact velocities and re-try capability achieved by the RKI mission type on a final orbit identical to the target asteroid's but retrograde to its motion enables small spacecraft size impactors to carry sufficient kinetic energy for deflection.
Following the successful PHILAE landing with ESA's ROSETTA probe and the launch of the MINERVA rovers and the Mobile Asteroid Surface Scout, MASCOT, aboard the JAXA space probe, HAYABUSA2, to asteroid (162173) Ryugu, small landers have found increasing interest. Integrated at the instrument level in their mothership they support small solar system body studies. With efficient capabilities, resource-friendly design and inherent robustness they are an attractive exploration mission element. We discuss advantages and constraints of small sub-spacecraft, focusing on emerging areas of activity such as asteroid diversity studies, planetary defence, and asteroid mining, on the background of our projects PHILAE, MASCOT, MASCOT2, the JAXA-DLR Solar Power Sail Lander Design Study, and others. The GOSSAMER-1 solar sail deployment concept also involves independent separable sub-spacecraft operating synchronized to deploy the sail. Small spacecraft require big changes in the way we do things and occasionally a little more effort than would be anticipated based on a traditional large spacecraft approach. In a Constraints-Driven Engineering environment we apply Concurrent Design and Engineering (CD/CE), Concurrent Assembly, Integration and Verification (CAIV) and Model-Based Systems Engineering (MBSE). Near-term solar sails will likely be small spacecraft which we expect to harmonize well with nano-scale separable instrument payload packages.
Following the recent successful landings and occasional re-awakenings of PHILAE, the lander carried aboard ROSETTA to comet 67P/Churyumov-Gerasimenko, and the launch of the Mobile Asteroid Surface Scout, MASCOT, aboard the HAYABUSA2 space probe to asteroid (162173) Ryugu we present an overview of the characteristics and peculiarities of small spacecraft missions to small solar system bodies (SSSB). Their main purpose is planetary science which is transitioning from a ‘pure’ science of observation of the distant to one also supporting in-situ applications relevant for life on Earth. Here we focus on missions at the interface of SSSB science and planetary defence applications. We provide a brief overview of small spacecraft SSSB missions and on this background present recent missions, projects and related studies at the German Aerospace Center, DLR, that contribute to the worldwide planetary defence community. These range from Earth orbit technology demonstrators to active science missions in interplanetary space. We provide a summary of experience from recently flown missions with DLR participation as well as a number of studies. These include PHILAE, the lander of ESA’s ROSETTA comet rendezvous mission now on the surface of comet 67P/Churyumov-Gerasimenko, and the Mobile Asteroid Surface Scout, MASCOT, now in cruise to the ~1 km diameter C-type near-Earth asteroid (162173) Ryugu aboard the Japanese sample-return probe HAYABUSA2. We introduce the differences between the conventional methods employed in the design, integration and testing of large spacecraft and the new approaches developed by small spacecraft projects. We expect that the practical experience that can be gained from projects on extremely compressed timelines or with high-intensity operation phases on a newly explored small solar system body can contribute significantly to the study, preparation and realization of future planetary defence related missions. One is AIDA (Asteroid Impact & Deflection Assessment), a joint effort of ESA, JHU/APL, NASA, OCA and DLR, combining JHU/APL’s DART (Double Asteroid Redirection Test) and ESA’s AIM (Asteroid Impact Monitor) spacecraft in a mission towards near-Earth binary asteroid system (65803) Didymos. DLR is currently applying MASCOT heritage and lessons learned to the design of MASCOT2, a lander for the AIM mission to support a bistatic low frequency radar experiment with PHILAE/ROSETTA CONSERT heritage to explore the inner structure of Didymoon which is the designated impact target for DART.
For now, the Planetary Defense Conference Exercise 2021's incoming fictitious(!), asteroid, 2021 PDC, seems headed for impact on October 20th, 2021, exactly 6 months after its discovery. Today (April 26th, 2021), the impact probability is 5%, in a steep rise from 1 in 2500 upon discovery six days ago. We all know how these things end. Or do we? Unless somebody kicked off another headline-grabbing media scare or wants to keep civil defense very idle very soon, chances are that it will hit (note: this is an exercise!). Taking stock, it is barely 6 months to impact, a steadily rising likelihood that it will actually happen, and a huge uncertainty of possible impact energies: First estimates range from 1.2 MtTNT to 13 GtTNT, and this is not even the worst-worst case: a 700 m diameter massive NiFe asteroid (covered by a thin veneer of Ryugu-black rubble to match size and brightness), would come in at 70 GtTNT. In down to Earth terms, this could be all between smashing fireworks over some remote area of the globe and a 7.5 km crater downtown somewhere. Considering the deliberate and sedate ways of development of interplanetary missions it seems we can only stand and stare until we know well enough where to tell people to pack up all that can be moved at all and save themselves. But then, it could just as well be a smaller bright rock. The best estimate is 120 m diameter from optical observation alone, by 13% standard albedo. NASA's upcoming DART mission to binary asteroid (65803) Didymos is designed to hit such a small target, its moonlet Dimorphos. The Deep Impact mission's impactor in 2005 successfully guided itself to the brightest spot on comet 9P/Tempel 1, a relatively small feature on the 6 km nucleus. And 'space' has changed: By the end of this decade, one satellite communication network plans to have launched over 11000 satellites at a pace of 60 per launch every other week. This level of series production is comparable in numbers to the most prolific commercial airliners. Launch vehicle production has not simply increased correspondingly – they can be reused, although in a trade for performance. Optical and radio astronomy as well as planetary radar have made great strides in the past decade, and so has the design and production capability for everyday 'high-tech' products. 60 years ago, spaceflight was invented from scratch within two years, and there are recent examples of fast-paced space projects as well as a drive towards 'responsive space'. It seems it is not quite yet time to abandon all hope. We present what could be done and what is too close to call once thinking is shoved out of the box by a clear and present danger, to show where a little more preparedness or routine would come in handy – or become decisive. And if we fail, let's stand and stare safely and well instrumented anywhere on Earth together in the greatest adventure of science.
Small Spacecraft in Planetary Defence Related Applications–Capabilities, Constraints, Challenges
(2015)
In this paper we present an overview of the characteristics and peculiarities of small spacecraft missions related to planetary defence applications. We provide a brief overview of small spacecraft missions to small solar system bodies. On this background we present recent missions and selected projects and related studies at the German Aerospace Center, DLR, that contribute to planetary defence related activities. These range from Earth orbit technology demonstrators to active science missions in interplanetary space. We provide a summary of experience from recently flown missions with DLR participation as well as a number of studies. These include PHILAE, the lander recently arrived on comet 67P/Churyumov-Gerasimenko aboard ESA’s ROSETTA comet rendezvous mission, and the Mobile Asteroid Surface Scout, MASCOT, now underway to near-Earth asteroid (162173) 1999 JU3 aboard the Japanese sample-return probe HAYABUSA-2. We introduce the differences between the conventional methods employed in the design, integration and testing of large spacecraft and the new approaches developed by small spacecraft projects. We expect that the practical experience that can be gained from projects on extremely
compressed timelines or with high-intensity operation phases on a newly explored small solar system body can contribute significantly to the study, preparation and realization of future planetary defence related missions. One is AIDA (Asteroid Impact & Deflection Assessment), a joint effort of ESA,JHU/APL, NASA, OCA and DLR, combining JHU/APL’s DART (Double Asteroid Redirection Test) and ESA’s AIM (Asteroid Impact Monitor) spacecraft in a mission towards
near-Eath binary asteroid (65803) Didymos.
The results of a statistical investigation of 42 fixed-wing, small to medium sized (20 kg−1000 kg) reconnaissance unmanned air vehicles (UAVs) are presented. Regression analyses are used to identify correlations of the most relevant geometry dimensions with the UAV’s maximum take-off mass. The findings allow an empirical based geometry-build up for a complete unmanned aircraft by referring to its take-off mass only. This provides a bridge between very early design stages (initial sizing) and the later determination of shapes and dimensions. The correlations might be integrated into a UAV sizing environment and allow designers to implement more sophisticated drag and weight estimation methods in this process. Additional information on correlation factors for a rough drag estimation methodology indicate how this technique can significantly enhance the accuracy of early design iterations.
The paper presents the derivation of a new equivalent skin friction coefficient for estimating the parasitic drag of short-to-medium range fixed-wing unmanned aircraft. The new coefficient is derived from an aerodynamic analysis of ten different unmanned aircraft used on surveillance, reconnaissance, and search and rescue missions. The aircraft are simulated using a validated unsteady Reynolds-averaged Navier Stokes approach. The UAV's parasitic drag is significantly influenced by the presence of miscellaneous components like fixed landing gears or electro-optical sensor turrets. These components are responsible for almost half of an unmanned aircraft's total parasitic drag. The new equivalent skin friction coefficient accounts for these effects and is significantly higher compared to other aircraft categories. It is used to initially size an unmanned aircraft for a typical reconnaissance mission. The improved parasitic drag estimation yields a much heavier unmanned aircraft when compared to the sizing results using available drag data of manned aircraft.
A review of guidelines and best practices for subsonic aerodynamic simulations using RANS CFD
(2019)
This paper describes the results and methods used during the 8th Global Trajectory Optimization Competition (GTOC) of the DLR team. Trajectory optimization is crucial for most of the space missions and usually can be formulated as a global optimization problem. A lot of research has been done to different type of mission problems. The most demanding ones are low thrust transfers with e.g. gravity assist sequences. In that case the optimal control problem is combined with an integer problem. In most of the GTOCs we apply a filtering of the problem based on domain knowledge.
The recovery of waste heat requires heat exchangers to extract it from a liquid or gaseous medium into another working medium, a refrigerant. In Organic Rankine Cycles (ORC) on Combustion Engines there are two major heat sources, the exhaust gas and the water/glycol fluid from the engine’s cooling circuit. A heat exchanger design must be adapted to the different requirements and conditions resulting from the heat sources, fluids, system configurations, geometric restrictions, and etcetera. The Stacked Shell Cooler (SSC) is a new and very specific design of a plate heat exchanger, created by AKG, which allows with a maximum degree of freedom the optimization of heat exchange rate and the reduction of the related pressure drop. This optimization in heat exchanger design for ORC systems is even more important, because it reduces the energy consumption of the system and therefore maximizes the increase in overall efficiency of the engine.
This paper presents an approach for UAV propulsion system qualification and validation on the example of FH Aachen's 25 kg cargo UAV "PhoenAIX". Thrust and power consumption are the most important aspects of a propulsion system's layout. In the initial design phase, manufacturers' data has to be trusted, but the validation of components is an essential step in the design process. This process is presented in this paper. The vertical takeoff system is designed for efficient hover; therefore, performance under static conditions is paramount. Because an octo-copter layout with coaxial rotors is considered, the impact of this design choice is analyzed. Data on thrust, voltage stability, power consumption, rotational speed, and temperature development of motors and controllers are presented for different rotors. The fixed-wing propulsion system is designed for efficient cruise flight. At the same time, a certain static thrust has to be provided, as the aircraft needs to accelerate to cruise speed. As for the hover-system, data on different propellers is compared. The measurements were taken for static conditions, as well as for different inflow velocities, using the FH-Aachen's wind-tunnel.
Kawasaki Heavy Industries, Ltd. (KHI), Aachen University of Applied Sciences, and B&B-AGEMA GmbH have investigated the potential of low NOx micro-mix (MMX) hydrogen combustion and its application to an industrial gas turbine combustor. Engine demonstration tests of a MMX combustor for the M1A-17 gas turbine with a co-generation system were conducted in the hydrogen-fueled power generation plant in Kobe City, Japan.
This paper presents the results of the commissioning test and the combined heat and power (CHP) supply demonstration. In the commissioning test, grid interconnection, loading tests and load cut-off tests were successfully conducted. All measurement results satisfied the Japanese environmental regulation values. Dust and soot as well as SOx were not detected. The NOx emissions were below 84 ppmv at 15 % O2. The noise level at the site boundary was below 60 dB. The vibration at the site boundary was below 45 dB.
During the combined heat and power supply demonstration, heat and power were supplied to neighboring public facilities with the MMX combustion technology and 100 % hydrogen fuel. The electric power output reached 1800 kW at which the NOx emissions were 72 ppmv at 15 % O2, and 60 %RH. Combustion instabilities were not observed. The gas turbine efficiency was improved by about 1 % compared to a non-premixed type combustor with water injection as NOx reduction method. During a total equivalent operation time of 1040 hours, all combustor parts, the M1A-17 gas turbine as such, and the co-generation system were without any issues.
Application of Low NOx Micro-mix Hydrogen Combustion to 2MW Class Industrial Gas Turbine Combustor
(2019)
Kawasaki Heavy Industries, LTD. (KHI) has research and development projects for a future hydrogen society. These projects comprise the complete hydrogen cycle, including the production of hydrogen gas, the refinement and liquefaction for transportation and storage, and finally the utilization in a gas turbine for electricity and heat supply. Within the development of the hydrogen gas turbine, the key technology is stable and low NOx hydrogen combustion, namely the Dry Low NOx (DLN) hydrogen combustion.
KHI, Aachen University of Applied Science, and B&B-AGEMA have investigated the possibility of low NOx micro-mix hydrogen combustion and its application to an industrial gas turbine combustor. From 2014 to 2018, KHI developed a DLN hydrogen combustor for a 2MW class industrial gas turbine with the micro-mix technology. Thereby, the ignition performance, the flame stability for equivalent rotational speed, and higher load conditions were investigated. NOx emission values were kept about half of the Air Pollution Control Law in Japan: 84ppm (O2-15%). Hereby, the elementary combustor development was completed.
From May 2020, KHI started the engine demonstration operation by using an M1A-17 gas turbine with a co-generation system located in the hydrogen-fueled power generation plant in Kobe City, Japan. During the first engine demonstration tests, adjustments of engine starting and load control with fuel staging were investigated. On 21st May, the electrical power output reached 1,635 kW, which corresponds to 100% load (ambient temperature 20 °C), and thereby NOx emissions of 65 ppm (O2-15, 60 RH%) were verified. Here, for the first time, a DLN hydrogen-fueled gas turbine successfully generated power and heat.
In this paper the way to a 5-day-car with respect to a modular valve train systems for spark ignited combustion engines is shown. The necessary product diversity is shift from mechanical or physical components to software components. Therefore, significant improvements of logistic indicators are expected and shown. The working principle of a camless cylinder head with respect to an electromagnetical valve train (EMVT) is explained and it is demonstrated that shifting physical diversity to software is feasible. The future design of combustion engine systems including customisation can be supported by a set of assistance tools which is shown exemplary.
In Europe, efforts are underway to develop key technologies that can be used to explore the Moon and to exploit the resources available. This includes technologies for in-situ resource utilization (ISRU), facilitating the possibility of a future Moon Village. The Moon is the next step for humans and robots to exploit the use of available resources for longer term missions, but also for further exploration of the solar system. A challenge for effective exploration missions is to achieve a compact and lightweight robot to reduce launch costs and open up the possibility of secondary payload options. Current micro rover concepts are primarily designed to last for one day of solar illumination and show a low level of autonomy. Extending the lifetime of the system by enabling survival of the lunar night and implementing a high level of autonomy will significantly increase potential mission applications and the operational range. As a reference mission, the deployment of a micro rover in the equatorial region of the Moon is being considered. An overview of mission parameters and a detailed example mission sequence is given in this paper. The mission parameters are based on an in-depth study of current space agency roadmaps, scientific goals, and upcoming flight opportunities. Furthermore, concepts of the ongoing international micro rover developments are analyzed along with technology solutions identified for survival of lunar nights and a high system autonomy. The results provide a basis of a concise requirements set-up to allow dedicated system developments and qualification measures in the future.
The search for life on Mars and in the Solar System - strategies, logistics and infrastructures
(2018)
The question "Are we alone in the Universe?" is perhaps the most fundamental one that affects mankind. How can we address the search for life in our Solar System? Mars, Enceladus and Europa are the focus of the search for life outside the terrestrial biosphere. While it is more likely to find remnants of life (fossils of extinct life) on Mars because of its past short time window of the surface habitability, it is probably more likely to find traces of extant life on the icy moons and ocean worlds of Jupiter and Saturn. Nevertheless, even on Mars there could still be a chance to find extant life in niches near to the surface or in just discovered subglacial lakes beneath the South Pole ice cap. Here, the different approaches for the detection of traces of life in the form of biosignatures including pre-biotic molecules will be presented. We will outline the required infrastructure for this enterprise and give examples of future mission concepts to investigate the presence of life on other planets and moons. Finally, we will provide suggestions on methods, techniques, operations and strategies for preparation and realization of future life detection missions.
The downsizing of spark ignition engines in conjunction with turbocharging is considered to be a promising method for reducing CO₂ emissions. Using this concept, FEV has developed a new, highly efficient drivetrain to demonstrate fuel consumption reduction and drivability in a vehicle based on the Ford Focus ST. The newly designed 1.8L turbocharged gasoline engine incorporates infinitely variable intake and outlet control timing and direct fuel injection utilizing piezo injectors centrally located. In addition, this engine uses a prototype FEV engine control system, with software that was developed and adapted entirely by FEV. The vehicle features a 160 kW engine with a maximum mean effective pressure of 22.4 bar and 34 % savings in simulated fuel consumption. During the first stage, a new electrohydraulically actuated hybrid transmission with seven forward gears and one reverse gear and a single dry starting clutch will be integrated. The electric motor of the hybrid is directly connected to the gear set of the transmission. Utilizing the special gear set layout, the electric motor can provide boost during a change of gears, so that there is no interruption in traction. Therefore, the transmission system combines the advantages of a double clutch controlled gear change (gear change without an interruption in traction) with the efficient, cost-effective design of an automated manual transmission system. Additionally, the transmission provides a purely electric drive system and the operation of an air-conditioning compressor during the engine stop phases. One other alternative is through the use of CAI (Controlled Auto Ignition), which incorporates a process developed by FEV for controlled compression ignition.
Phase change materials offer a way of storing excess heat and releasing it when it is needed. They can be utilized as a method to control thermal behavior without the need for additional energy. This work focuses on exploring the potential of using phase change materials to passively control the thermal behavior of a star tracker by infusing it with a fitting phase change material. Based on the numerical model of the star trackers thermal behavior using ESATAN-TMS without implemented phase change material, a fitting phase change material for selected orbits is chosen and implemented in the thermal model. The altered thermal behavior of the numerical model after the implementation is analyzed for different amounts of the chosen phase change materials using an ESATAN-based subroutine developed by the FH Aachen. The PCM-modelling-subroutine is explained in the paper ICES-2021-110. The results show that an increasing amount of phase change material increasingly damps temperature oscillations. Using an integral part structure some of the mass increase can be compensated.
Scientific questions
- How can a non-stationary heat offering in the commercial vehicle be used to reduce fuel consumption?
- Which potentials offer route and environmental information among with predicted speed and load trajectories to increase the efficiency of a ORC-System?
Methods
- Desktop bound holistic simulation model for a heavy duty truck incl. an ORC System
- Prediction of massflows, temperatures and mixture quality (AFR) of exhaust gas
In addition to very high safety and reliability requirements, the design of internal combustion engines (ICE) in aviation focuses on economic efficiency. The objective must be to design the aircraft powertrain optimized for a specific flight mission with respect to fuel consumption and specific engine power. Against this background, expert tools provide valuable decision-making assistance for the customer. In this paper, a mathematical calculation model for the fuel consumption of aircraft ICE is presented. This model enables the derivation of fuel consumption maps for different engine configurations. Depending on the flight conditions and based on these maps, the current and the integrated fuel consumption for freely definable flight emissions is calculated. For that purpose, an interpolation method is used, that has been optimized for accuracy and calculation time. The mission boundary conditions flight altitude and power requirement of the ICE form the basis for this calculation. The mathematical fuel consumption model is embedded in a parent program. This parent program presents the simulated fuel consumption by means of an example flight mission for a representative airplane. The focus of the work is therefore on reproducing exact consumption data for flight operations. By use of the empirical approaches according to Gagg-Farrar [1] the power and fuel consumption as a function of the flight altitude are determined. To substantiate this approaches, a 1-D ICE model based on the multi-physical simulation tool GT-Suite® has been created. This 1-D engine model offers the possibility to analyze the filling and gas change processes, the internal combustion as well as heat and friction losses for an ICE under altitude environmental conditions. Performance measurements on a dynamometer at sea level for a naturally aspirated ICE with a displacement of 1211 ccm used in an aviation aircraft has been done to validate the 1-D ICE model. To check the plausibility of the empirical approaches with respect to the fuel consumption and performance adjustment for the flight altitude an analysis of the ICE efficiency chain of the 1-D engine model is done. In addition, a comparison of literature and manufacturer data with the simulation results is presented.
This study investigates the influence of pressure on the temperature distribution of the micromix (MMX) hydrogen flame and the NOx emissions. A steady computational fluid dynamic (CFD) analysis is performed by simulating a reactive flow with a detailed chemical reaction model. The numerical analysis is validated based on experimental investigations. A quantitative correlation is parametrized based on the numerical results. We find, that the flame initiation point shifts with increasing pressure from anchoring behind a downstream located bluff body towards anchoring upstream at the hydrogen jet. The numerical NOx emissions trend regarding to a variation of pressure is in good agreement with the experimental results. The pressure has an impact on both, the residence time within the maximum temperature region and on the peak temperature itself. In conclusion, the numerical model proved to be adequate for future prototype design exploration studies targeting on improving the operating range.
Experimental and numerical investigation on the effect of pressure on micromix hydrogen combustion
(2021)
The micromix (MMX) combustion concept is a DLN gas turbine combustion technology designed for high hydrogen content fuels. Multiple non-premixed miniaturized flames based on jet in cross-flow (JICF) are inherently safe against flashback and ensure a stable operation in various operative conditions.
The objective of this paper is to investigate the influence of pressure on the micromix flame with focus on the flame initiation point and the NOx emissions. A numerical model based on a steady RANS approach and the Complex Chemistry model with relevant reactions of the GRI 3.0 mechanism is used to predict the reactive flow and NOx emissions at various pressure conditions. Regarding the turbulence-chemical interaction, the Laminar Flame Concept (LFC) and the Eddy Dissipation Concept (EDC) are compared. The numerical results are validated against experimental results that have been acquired at a high pressure test facility for industrial can-type gas turbine combustors with regard to flame initiation and NOx emissions.
The numerical approach is adequate to predict the flame initiation point and NOx emission trends. Interestingly, the flame shifts its initiation point during the pressure increase in upstream direction, whereby the flame attachment shifts from anchoring behind a downstream located bluff body towards anchoring directly at the hydrogen jet. The LFC predicts this change and the NOx emissions more accurately than the EDC. The resulting NOx correlation regarding the pressure is similar to a non-premixed type combustion configuration.
An Interstellar – Heliopause mission using a combination of solar/radioisotope electric propulsion
(2011)
There is common agreement within the scientific community that in order to understand our local galactic environment it will be necessary to send a spacecraft into the region beyond the solar wind termination shock. Considering distances of 200 AU for a new mission, one needs a spacecraft travelling at a speed of close to 10 AU/yr in order to keep the mission duration in the range of less than 25 yrs, a transfer time postulated by ESA.Two propulsion options for the mission have been proposed and discussed so far: the solar sail propulsion and the ballistic/radioisotope electric propulsion. As a further alternative, we here investigate a combination of solar-electric propulsion and radioisotope-electric propulsion. The solar-electric propulsion stage consists of six 22 cm diameter “RIT-22”ion thrusters working with a high specific impulse of 7377 s corresponding to a positive grid voltage of 5 kV. Solar power of 53 kW BOM is provided by a light-weight solar array. The REP-stage consists of four space-proven 10 cm diameter “RIT-10” ion thrusters that will be operating one after the other for 9 yrs in total. Four advanced radioisotope generators provide 648 W at BOM. The scientific instrument package is oriented at earlier studies. For its mass and electric power requirement 35 kg and 35 W are assessed, respectively. Optimized trajectory calculations, treated in a separate contribution, are based on our “InTrance” method.The program yields a burn out of the REP stage in a distance of 79.6 AU for a usage of 154 kg of Xe propellant. With a C3 = 45,1 (km/s)2 a heliocentric probe velocity of 10 AU/yr is reached at this distance, provided a close Jupiter gravity assist adds a velocity increment of 2.7 AU/yr. A transfer time of 23.8 yrs results for this scenario requiring about 450 kg Xe for the SEP stage, jettisoned at 3 AU. We interpret the SEP/REP propulsion as a competing alternative to solar sail and ballistic/REP propulsion. Omiting a Jupiter fly-by even allows more launch flexibility, leaving the mission duration in the range of the ESA specification.
Under DLR-contract, Giessen University and DLR Cologne are studying solar-electric propulsion missions (SEP) to the outer regions of the solar system. The most challenging reference mission concerns the transport of a 1.35-tons chemical lander spacecraft into an 80-RJ circular orbit around Jupiter, which would enable to place a 375 kg lander with 50 kg of scientific instruments on the surface of the icy moon "Europa". Thorough analyses show that the best solution in terms of SEP launch mass times thrusting time would be a two-stage EP module and a triple-junction solar array with concentrators which would be deployed step by step. Mission performance optimizations suggest to propel the spacecraft in the first EP stage by 6 gridded ion thrusters, running at 4.0 kV of beam voltage, which would save launch mass, and in the second stage by 4 thrusters with 1.25 to 1.5 kV of positive high voltage saving thrusting time. In this way, the launch mass of the spacecraft would be kept within 5.3 tons. Without a launcher's C3 and interplanetary gravity assists, Jupiter might be reached within about 4 yrs. The spiraling-down into the parking orbit would need another 1.8 yrs. This "large mission" can be scaled down to a smaller one, e.g., by halving all masses, the solar array power, and the number of thrusters. Due to their reliability, long lifetime and easy control, RIT-22 engines have been chosen for mission analysis. Based on precise tests, the thruster performance has been modeled.
By DLR-contact, sample return missions to the large main-belt asteroid “19, Fortuna” have been studied. The mission scenario has been based on three ion thrusters of the RIT-22 model, which is presently under space qualification, and on solar arrays equipped with triple-junction GaAs solar cells. After having designed the spacecraft, the orbit-to-orbit trajectories for both, a one-way SEP mission with a chemical sample return and an all-SEP return mission, have been optimized using a combination of artificial neural networks with evolutionary algorithms. Additionally, body-to-body trajectories have been
investigated within a launch period between 2012 and 2015. For orbit-to-orbit calculation, the launch masses of the hybrid mission and of the all-SEP mission resulted in 2.05 tons and 1.56 tons, respectively, including a scientific payload of 246 kg. For the related transfer
durations 4.14 yrs and 4.62 yrs were obtained. Finally, a comparison between the mission scenarios based on SEP and on NEP have been carried out favouring clearly SEP.
Electric flight has the potential for a more sustainable and energy-saving way of aviation compared to fossil fuel aviation. The electric motor can be used as a generator inflight to regenerate energy during descent. Three different approaches to regenerating with electric propeller powertrains are proposed in this paper. The powertrain is to be set up in a wind tunnel to determine the propeller efficiency in both working modes as well as the noise emissions. Furthermore, the planned flight tests are discussed. In preparation for these tests, a yaw stability analysis is performed with the result that the aeroplane is controllable during flight and in the most critical failure case. The paper shows the potential for inflight regeneration and addresses the research gaps in the dual role of electric powertrains for propulsion and regeneration of general aviation aircraft.
Research on robotic lunar exploration has seen a broad revival, especially since the Google Lunar X-Prize increasingly brought private endeavors into play. This development is supported by national agencies with the aim of enabling long-term lunar infrastructure for in-situ operations and the establishment of a moon village. One challenge for effective exploration missions is developing a compact and lightweight robotic rover to reduce launch costs and open the possibility for secondary payload options. Existing micro rovers for exploration missions are clearly limited by their design for one day of sunlight and their low level of autonomy. For expanding the potential mission applications and range of use, an extension of lifetime could be reached by surviving the lunar night and providing a higher level of autonomy. To address this objective, the paper presents a system design concept for a lightweight micro rover with long-term mission duration capabilities, derived from a multi-day lunar mission scenario at equatorial regions. Technical solution approaches are described, analyzed, and evaluated, with emphasis put on the harmonization of hardware selection due to a strictly limited budget in dimensions and power.
Dynamic loads significantly impact the structural design of propeller blades due to fatigue and static strength. Since propellers are elastic structures, deformations and aerodynamic loads are coupled. In the past, propeller manufacturers established procedures to determine unsteady aerodynamic loads and the structural response with analytical steady-state calculations. According to the approach, aeroelastic coupling primarily consists of torsional deformations. They neglect bending deformations, deformation velocities, and inertia terms. This paper validates the assumptions above for a General Aviation propeller and a lift propeller for urban air mobility or large cargo drones. Fully coupled reduced-order simulations determine the dynamic loads in the time domain. A quasi-steady blade element momentum approach transfers loads to one-dimensional finite beam elements. The simulation results are in relatively good agreement with the analytical method for the General Aviation propeller but show increasing errors for the slender lift propeller. The analytical approach is modified to consider the induced velocities. Still, inertia and velocity proportional terms play a significant role for the lift propeller due to increased elasticity. The assumption that only torsional deformations significantly impact the dynamic loads of propellers is not valid. Adequate determination of dynamic loads of such designs requires coupled aeroelastic simulations or advanced analytical procedures.
This work presents a methodology for automated
damage-sensitive feature extraction and anomaly
detection under multivariate operational variability
for in-flight assessment of wings. The
method uses a passive excitation approach, i. e.
without the need for artificial actuation. The
modal system properties (natural frequencies and
damping ratios) are used as damage-sensitive
features. Special emphasis is placed on the use
of Fiber Bragg Grating (FBG) sensing technology
and the consideration of Operational and
Environmental Variability (OEV). Measurements
from a wind tunnel investigation with a composite
cantilever equipped with FBG and piezoelectric
sensors are used to successfully detect an impact
damage. In addition, the feasibility of damage
localisation and severity estimation is evaluated
based on the coupling found between damageand
OEV-induced feature changes.
Flight times to the heliopause using a combination of solar and radioisotope electric propulsion
(2011)
We investigate the interplanetary flight of a low-thrust space probe to the heliopause,located at a distance of about 200 AU from the Sun. Our goal was to reach this distance within the 25 years postulated by ESA for such a mission (which is less ambitious than the 15-year goal set by NASA). Contrary to solar sail concepts and combinations of allistic and electrically propelled flight legs, we have investigated whether the set flight time limit could also be kept with a combination of solar-electric propulsion and a second, RTG-powered upper stage. The used ion engine type was the RIT-22 for the first stage and the RIT-10 for the second stage. Trajectory optimization was carried out with the low-thrust optimization program InTrance, which implements the method of Evolutionary Neurocontrol,using Artificial Neural Networks for spacecraft steering and Evolutionary Algorithms to optimize the Neural Networks’ parameter set. Based on a parameter space study, in which the number of thrust units, the unit’s specific impulse, and the relative size of the solar power generator were varied, we have chosen one configuration as reference. The transfer time of this reference configuration was 29.6 years and the fastest one, which is technically
more challenging, still required 28.3 years. As all flight times of this parameter study were longer than 25 years, we further shortened the transfer time by applying a launcher-provided hyperbolic excess energy up to 49 km2/s2. The resulting minimal flight time for the reference configuration was then 27.8 years. The following, more precise optimization to a launch with the European Ariane 5 ECA rocket reduced the transfer time to 27.5 years. This is the fastest mission design of our study that is flexible enough to allow a launch every
year. The inclusion of a fly-by at Jupiter finally resulted in a flight time of 23.8 years,which is below the set transfer-time limit. However, compared to the 27.5-year transfer,this mission design has a significantly reduced launch window and mission flexibility if the
escape direction is restricted to the heliosphere’s “nose".
The scientific interest in near-Earth asteroids (NEAs) and the classification of some of those as potentially hazardous asteroid for the Earth stipulated the interest in NEA exploration. Close-up observations of these objects will increase drastically our knowledge about the overall NEA population. For this reason, a multiple NEA rendezvous mission through solar sailing is investigated, taking advantage of the propellantless nature of this groundbreaking propulsion technology. Considering a spacecraft based on the DLR/ESA Gossamer technology, this work focuses on the search of possible sequences of NEA encounters. The effectiveness of this approach is demonstrated through a number of fully-optimized trajectories. The results show that it is possible to visit five NEAs within 10 years with near-term solar-sail technology. Moreover, a study on a reduced NEA database demonstrates the reliability of the approach used, showing that 58% of the sequences found with an approximated trajectory model can be converted into real solar-sail trajectories. Lastly, this second study shows the effectiveness of the proposed automatic optimization algorithm, which is able to find solutions for a large number of mission scenarios without any input required from the user.