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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 predictive control of commercial vehicle energy management systems, such as vehicle thermal management or waste heat recovery (WHR) systems, are discussed on the basis of information sources from the field of environment recognition and in combination with the determination of the vehicle system condition.
In this article, a mathematical method for predicting the exhaust gas mass flow and the exhaust gas temperature is presented based on driving data of a heavy-duty vehicle. The prediction refers to the conditions of the exhaust gas at the inlet of the exhaust gas recirculation (EGR) cooler and at the outlet of the exhaust gas aftertreatment system (EAT). The heavy-duty vehicle was operated on the motorway to investigate the characteristic operational profile. In addition to the use of road gradient profile data, an evaluation of the continuously recorded distance signal, which represents the distance between the test vehicle and the road user ahead, is included in the prediction model. Using a Fourier analysis, the trajectory of the vehicle speed is determined for a defined prediction horizon.
To verify the method, a holistic simulation model consisting of several hierarchically structured submodels has been developed. A map-based submodel of a combustion engine is used to determine the EGR and EAT exhaust gas mass flows and exhaust gas temperature profiles. All simulation results are validated on the basis of the recorded vehicle and environmental data. Deviations from the predicted values are analyzed and discussed.
The number of case studies focusing on hybrid-electric aircraft is steadily increasing, since these configurations are thought to lead to lower operating costs and environmental impact than traditional aircraft. However, due to the lack of reference data of actual hybrid-electric aircraft, in most cases, the design tools and results are difficult to validate. In this paper, two independently developed approaches for hybrid-electric conceptual aircraft design are compared. An existing 19-seat commuter aircraft is selected as the conventional baseline, and both design tools are used to size that aircraft. The aircraft is then re-sized under consideration of hybrid-electric propulsion technology. This is performed for parallel, serial, and fully-electric powertrain architectures. Finally, sensitivity studies are conducted to assess the validity of the basic assumptions and approaches regarding the design of hybrid-electric aircraft. Both methods are found to predict the maximum take-off mass (MTOM) of the reference aircraft with less than 4% error. The MTOM and payload-range energy efficiency of various (hybrid-) electric configurations are predicted with a maximum difference of approximately 2% and 5%, respectively. The results of this study confirm a correct formulation and implementation of the two design methods, and the data obtained can be used by researchers to benchmark and validate their design tools.
Innovative interplanetary deep space missions, like a main belt asteroid sample
return mission, require ever larger velocity increments (∆V s) and thus ever
more demanding propulsion capabilities. Providing much larger exhaust velocities than chemical high-thrust systems, electric low-thrust space-propulsion
systems can significantly enhance or even enable such high-energy missions. In
1995, a European-Russian Joint Study Group (JSG) presented a study report
on “Advanced Interplanetary Missions Using Nuclear-Electric Propulsion”
(NEP). One of the investigated reference missions was a sample return (SR)
from the main belt asteroid (19) Fortuna. The envisaged nuclear power plant,
Topaz-25, however, could not be realized and also the worldwide developments
in space reactor hardware stalled. In this paper, we investigate, whether such
a mission is also feasible using a solar electric propulsion (SEP) system and
compare our SEP results to corresponding NEP results.
A melting probe equipped with autofluorescence-based detection system combined with a light scattering unit, and, optionally, with a microarray chip would be ideally suited to probe icy environments like Europa’s ice layer as well as the polar ice layers of Earth and Mars for recent and extinct live.
Manufacturing process simulation enables the evaluation and improvement of autoclave mold concepts early in the design phase. To achieve a high part quality at low cycle times, the thermal behavior of the autoclave mold can be investigated by means of simulations. Most challenging for such a simulation is the generation of necessary boundary conditions. Heat-up and temperature distribution in an autoclave mold are governed by flow phenomena, tooling material and shape, position within the autoclave, and the chosen autoclave cycle. This paper identifies and summarizes the most important factors influencing mold heat-up and how they can be introduced into a thermal simulation. Thermal measurements are used to quantify the impact of the various parameters. Finally, the gained knowledge is applied to develop a semi-empirical approach for boundary condition estimation that enables a simple and fast thermal simulation of the autoclave curing process with reasonably high accuracy for tooling optimization.
Assistance systems have been widely adopted in the manufacturing sector to facilitate various processes and tasks in production environments. However, existing systems are mostly equipped with rigid functional logic and do not provide individual user experiences or adapt to their capabilities. This work integrates human factors in assistance systems by adjusting the hardware and instruction presented to the workers’ cognitive and physical demands. A modular system architecture is designed accordingly, which allows a flexible component exchange according to the user and the work task. Gamification, the use of game elements in non-gaming contexts, has been further adopted in this work to provide level-based instructions and personalised feedback. The developed framework is validated by applying it to a manual workstation for industrial assembly routines.
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.
A multi-functional device applying for the safe maintenance at high-altitude on wind turbines
(2015)
To meet the challenges of manufacturing smart products, the manufacturing plants have been radically changed to become smart factories underpinned by industry 4.0 technologies. The transformation is assisted by employment of machine learning techniques that can deal with modeling both big or limited data. This manuscript reviews these concepts and present a case study that demonstrates the use of a novel intelligent hybrid algorithms for Industry 4.0 applications with limited data. In particular, an intelligent algorithm is proposed for robust data modeling of nonlinear systems based on input-output data. In our approach, a novel hybrid data-driven combining the Group-Method of Data-Handling and Singular-Value Decomposition is adapted to find an offline deterministic model combined with Pareto multi-objective optimization to overcome the overfitting issue. An Unscented-Kalman-Filter is also incorporated to update the coefficient of the deterministic model and increase its robustness against data uncertainties. The effectiveness of the proposed method is examined on a set of real industrial measurements.
To meet the challenges of manufacturing smart products, the manufacturing plants have been radically changed to become smart factories underpinned by industry 4.0 technologies. The transformation is assisted by employment of machine learning techniques that can deal with modeling both big or limited data. This manuscript reviews these concepts and present a case study that demonstrates the use of a novel intelligent hybrid algorithms for Industry 4.0 applications with limited data. In particular, an intelligent algorithm is proposed for robust data modeling of nonlinear systems based on input-output data. In our approach, a novel hybrid data-driven combining the Group-Method of Data-Handling and Singular-Value Decomposition is adapted to find an offline deterministic model combined with Pareto multi-objective optimization to overcome the overfitting issue. An Unscented-Kalman-Filter is also incorporated to update the coefficient of the deterministic model and increase its robustness against data uncertainties. The effectiveness of the proposed method is examined on a set of real industrial measurements.
A review of guidelines and best practices for subsonic aerodynamic simulations using RANS CFD
(2019)
Next-generation aircraft designs often incorporate multiple large propellers attached along the wingspan. These highly flexible dynamic systems can exhibit uncommon aeroelastic instabilities, which should be carefully investigated to ensure safe operation. The interaction between the propeller and the wing is of particular importance. It is known that whirl flutter is stabilized by wing motion and wing aerodynamics. This paper investigates the effect of a propeller onto wing flutter as a function of span position and mounting stiffness between the propeller and wing. The analysis of a comparison between a tractor and pusher configuration has shown that the coupled system is more stable than the standalone wing for propeller positions near the wing tip for both configurations. The wing fluttermechanism is mostly affected by the mass of the propeller and the resulting change in eigenfrequencies of the wing. For very weak mounting stiffnesses, whirl flutter occurs, which was shown to be stabilized compared to a standalone propeller due to wing motion. On the other hand, the pusher configuration is, as to be expected, the more critical configuration due to the attached mass behind the elastic axis.
This paper presents a thermal simulation environment for moving objects on the lunar surface. The goal of the thermal simulation environment is to enable the reliable prediction of the temperature development of a given object on the lunar surface by providing the respective heat fluxes for a mission on a given travel path. The user can import any object geometry and freely define the path that the object should travel. Using the path of the object, the relevant lunar surface geometry is imported from a digital elevation model. The relevant parts of the lunar surface are determined based on distance to the defined path. A thermal model of these surface sections is generated, consisting of a porous layer on top and a denser layer below. The object is moved across the lunar surface, and its inclination is adapted depending on the slope of the terrain below it. Finally, a transient thermal analysis of the object and its environment is performed at several positions on its path and the results are visualized. The paper introduces details on the thermal modeling of the lunar surface, as well as its verification. Furthermore, the structure of the created software is presented. The robustness of the environment is verified with the help of sensitivity studies and possible improvements are presented.
Next-generation aircraft designs often incorporate multiple large propellers attached along the wingspan (distributed electric propulsion), leading to highly flexible dynamic systems that can exhibit aeroelastic instabilities. This paper introduces a validated methodology to investigate the aeroelastic instabilities of wing–propeller systems and to understand the dynamic mechanism leading to wing and whirl flutter and transition from one to the other. Factors such as nacelle positions along the wing span and chord and its propulsion system mounting stiffness are considered. Additionally, preliminary design guidelines are proposed for flutter-free wing–propeller systems applicable to novel aircraft designs. The study demonstrates how the critical speed of the wing–propeller systems is influenced by the mounting stiffness and propeller position. Weak mounting stiffnesses result in whirl flutter, while hard mounting stiffnesses lead to wing flutter. For the latter, the position of the propeller along the wing span may change the wing mode shapes and thus the flutter mechanism. Propeller positions closer to the wing tip enhance stability, but pusher configurations are more critical due to the mass distribution behind the elastic axis.
The impact of wake model effects is investigated for two highly
non-planar lifting systems. Dependent on the geometrical
arrangement of the configuration, the wake model shape is found
to considerably affect the estimation. Particularly at higher angles
of attack, an accurate estimation based on the common linear wake
model approaches is involved.
To fulfil the CO2 emission reduction targets of the European Union (EU), heavy-duty (HD) trucks need to operate 15% more efficiently by 2025 and 30% by 2030. Their electrification is necessary as conventional HD trucks are already optimized for the long-haul application. The resulting hybrid electric vehicle (HEV) truck gains most of the fuel saving potential by the recuperation of potential energy and its consecutive utilization. The key to utilizing the full potential of HEV-HD trucks is to maximize the amount of recuperated energy and ensure its intelligent usage while keeping the operating point of the internal combustion engine as efficient as possible. To achieve this goal, an intelligent energy management strategy (EMS) based on ECMS is developed for a parallel HEV-HD truck which uses predictive discharge of the battery and adaptive operating strategy regarding the height profile and the vehicle mass. The presented EMS can reproduce the global optimal operating strategy over long phases and lead to a fuel saving potential of up to 2% compared with a heuristic strategy. Furthermore, the fuel saving potential is correlated with the investigated boundary conditions to deepen the understanding of the impact of intelligent EMS for HEV-HD trucks.
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.
This paper discusses a new way of inflight power regeneration for electric or hybrid-electric driven general aviation aircraft with one powertrain for both configurations. Three different approaches for the shift from propulsion to regeneration mode are analyzed. Numerical cal-culation and wind tunnel results are compared and show the highest regeneration potential for the "Windmill" approach, where the propeller blades are flipped, and rotation is reversed. A combination of all regeneration approaches for a realistic flight mission is discussed.
In the chapter “Son of Concorde, a Technology Challenge” one of the new challenges for a Supersonic Commercial Transport (SCT) is multi-point design for the four main design points:
- supersonic cruise
- transonic cruise
- take-off and landing
- transonic acceleration.