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- hydrogen (4)
- solar sail (4)
- MASCOT (3)
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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.