Speaker Dr. Jan Wenske

Modular Power Supply System for UAV Application

4'th UAV Conference 2010-03-11 ESW GmbH 2

Modular Power Supply Systems for UAV-ApplicationOverview

State of the Art Generator-System (Alternator)

New Modular Power Supply / Starter-Generator-System

Comparing the Systems (Capabilities and Performance)

Technical System Description

“Fly wheel“-PM-Starter/Generator

Generator Control Unit

Examples of Starter/Generator-Systems already designed

Abstract & Outlook

4'th UAV Conference 2010-03-11 ESW GmbH 3

Modular Power Supply Systems for UAV-ApplicationState of the Art Generator-System (Alternator)

G

Compound Winding

Voltage

control

=

=

Enable

logic

Internal Power Supply

VCC

GND

28VDC_GND

En

able

/Dis

ab

le+

28

VD

C_O

utp

ut

-28V

DC

_O

utp

ut

EMI-Filter

3-phase Stator

Winding

Exciter

Winding

Brushes

Start-Up supply

B6U-Rectifier

Generator Control Unit

Claw-Pole-Generator200mm

20

0m

m

Claw-pole-

Generator

Generator Control Unit

(GCU)

System

1,2kW @ 4000rpm

28

VD

C (

50

A)

~ 6 kg~ 1 kg

4'th UAV Conference 2010-03-11 ESW GmbH 4

S/G Winding-System I

S/G Winding-System II

~~~

=

+2

8V

DC

28

VD

C_

GN

D

=

=

=

=

=

=

=

=

28V-Modul

~~~

=

~~~

=

~~~

=

28V-Modul 14V-Modul

+14

VD

C1

4V

DC

_G

ND

=

=

=

=

Starter Modul

Modular Power Supply Systems for UAV-ApplicationsNew Modular Power Supply / Starter-Generator-System

Rectifier

Rectifier

PM-Generator

Inverter

DC-

ConvertersEMC-Filters

~ 4,5 kg

170 mm

100 mmL

System

3kW @ 2000rpm

Starter-/GCU

~5kg

DC-Link Ch1

DC-Link Ch2

Exernal

DC-power

4'th UAV Conference 2010-03-11 ESW GmbH 5

Modular Power Supply Systems for UAV-ApplicationsComparing the Systems

Type of System Claw-Pole-Generatorsystem PM-Starter/Generatorsystem

power/weight ratio 150 - 350 W/kg (incl. pulley) 250 - 550 W/kg (S/G & GCU)

engine speed range 1 : 2,5 (for nominal Power) 1 : 4,5 (for nominal Power)

overload capability appr. 20% appr. 20%

overall efficiency ~ 70 - 75% ~ 85 – 90%

voltage control loop 100 ms (10% <> 100% load) 10-20 ms (0% <> 100% load)

power quality & EMC MIL-STD 704 E ; MIL-STD 461E/F ; RCTA DO-160 E

Environmental Req. MIL-STD 810 F

Temperature range -40°C – +100°C (Gen.) / +60°C (GCU) (air cooled)

Functionality Generator Mode Generator / Starter / External Supply Mode

Characteristics/

Parameter

Systems

0,5 – 5kW

4'th UAV Conference 2010-03-11 ESW GmbH 6

Modular Power Supply Systems for UAV-Applications„Fly wheel“-PM-Starter/Generator Family

1,2 – 2,8kg

3,5 – 4,8kg

0,5 – 0,9kg

Cranking Run-up

Starter Support OFFG

en

era

tor

Mo

de

28

VD

C O

N

6000W

5000W

4000W

3000W

2000W

1000W

114 mm

22 - 50 mmL

150 mm

30 - 55 mmL

70 mm

20 - 45 mmL

L

14 V

DC

ON

Active S/G material

4'th UAV Conference 2010-03-11 ESW GmbH 7

Modular Power Supply Systems for UAV-Applications„Fly-wheel“-PM-Starter/Generator-Integration

Overview

Stator fixed by set srews

1 2 3

Overview Overview

4'th UAV Conference 2010-03-11 ESW GmbH 8

Modular Power Supply Systems for UAV-ApplicationsGenerator Control Unit (Example of 28VDC Alternator Design)

generator temperature 1, 2 °C

°C

overtemperature generator

°C

°C

S/G Winding-System I

S/G Winding-System II

GND_28V1

28V1

PWM Current

Controller

28V_Ch1

actual current

actual

current

current reference 28V

°C

overtemperature 28V_Ch1

°C

failure 28V_Ch1

enable 28V_Ch1

PWM

Logic

Current

Controller

28V_Ch2

Main-Board

Central logic and control

28 VDC

GND

External

Power Supply

Interface

DC-Converter-Board(s)

EMC-Board

4'th UAV Conference 2010-03-11 ESW GmbH 9

Modular Power Supply Systems for UAV-ApplicationExamples of Starter/Generator-Systems already designed

1,8kW@ 3500rpm

28VDC / 60A

14VDC / 10A

no Starter Functionality

KZO

Skyblade V

ATLANTE

0,7kW@ 4000rpm

28VDC / 22A

14VDC / 6A

Extern. Starter Functionality

3,6kW@ 2600rpm

28VDC / 125A

Intern. Starter Functionality

ALCA

Source: CybAero AB

Source: CASSIDIAN

Source: ST Aerospace

Source: Rheinmetall Defence

2,2kW@ 5500rpm

28VDC / 70A

14VDC / 10A

Intern. Starter Functionality

114 mm

27 mmL

PM-S/G

70 mm

38 mmL

PM-S/G

150 mm

48 mmL

PM-S/G

114 mm

22 mmL

PM-S/G

UAV PlattformsS/G Systems

4'th UAV Conference 2010-03-11 ESW GmbH 10

Modular Power Supply Systems for UAV-ApplicationAbstract & Outlook

Summary of the main Characteristics:

Enhanced functionality / performance

Coupling/Management of different on-board power source

Modular system design out of standard components

Outlook (future Improvements):

Generator-System power/weight ratio up to 1 kW/kg

• Hybrid Technology

• Axial Flux Machines

• Inductive power transmission

Generator System Efficiency up to 92 - 95%

System Reliability MTBF > 105 (MIL-HDBK 217F, AIC, TEnv.= 85°C)

4'th UAV Conference 2010-03-11 ESW GmbH 11

Modular Power Supply Systems for UAV-Application

Thank you for your Attention !