Integrated Systems Design of Composite Casings for Power Electronic Converters for Aircraft Applications

飞机电气化是实现减少飞机燃料燃烧和相关温室气体排放(包括一氧化二氮和二氧化碳)的宏伟目标的核心。本博士将开发和演示集成碳纤维增强聚合物(CFRP)外壳的电力电子转换器(PEC)的方法，以实现未来飞机中PEC的轻量化和最小体积。这些集成系统将形成一个模块，可以很容易地插入和离开飞机的电气系统，增加了减少由于维护而停止服务的时间的额外好处。综合设计将考虑到与更广泛的机载电力系统的相互依存关系。集成电气和结构系统是一个重要的研究机会，能够优化整个飞机的性能。这包括在设计门槛范围内，开发具有多功能作用的材料。特别是模块化机载电力系统的设计，每个模块都集成了一段复合结构，可以很容易地插入和离开飞机或发动机。这样做的好处不仅在于最大限度地减少体积和重量，还可以最大限度地缩短发动机或飞机停用的时间。模块化木筏的概念过去曾由航空航天工业提出，但需要进一步了解将CFRP与电气系统和部件紧密结合的方法。为了成功设计一个集成的电力电子转换器CFRP模块，该项目将确定电力系统、电力电子转换器拓扑以及CFRP的电、热和机械性能的关键设计门槛。结构、热力和电力系统的整合带来了复杂的挑战，需要采取多学科方法。这包括选择转换器拓扑、热管理系统、控制电路、电磁屏蔽和适当的过滤器。更广泛的系统考虑因素包括系统参数、接地拓扑和故障管理策略。热管理系统可能通过空气冷却，也可能需要液体冷却。与CFRP壳体铺层的设计相关性对于集成系统设计是至关重要的。另一个设计挑战是，集成系统必须足够坚固，以承受恶劣的操作环境，系统经历低压、极端温度、振动和潮湿的组合。最后，模块化的程度也将被考虑在内。例如，将辅助系统集成到复合材料壳体中的限制。项目中设计的集成系统将通过硬件样机的设计、测试和搭建进行验证。

Electrification of aircraft is central to achieving ambitious targets for reduction of aircraft fuel burn and associated emissions of greenhouse gasses including Nitrous Oxides and Carbon Dioxide. This PhD will develop and demonstrate methods for the integrated design of power electronic converters (PEC) with carbon fibre reinforced polymer (CFRP) cases, for the light-weighting and minimised volume of PEC in future aircraft. These integrated systems will form a module that can be easily slotted in and out of an aircraft's electrical systems, adding an additional benefit of reduced time out of service due to maintenance. The integrated design will take into account interdependencies with the wider on-board electrical power system.A significant research opportunity exists to integrate the electrical and structural systems, to enable optimisation of the full aircraft performance. This includes, where possible within design thresholds, the development of materials with multifunctional roles. In particular the design of a modularised on-board electrical power system, with each module integrated with a section of composite structure that can be easily slotted in and out of the aircraft, or engine. This has the advantage of not only minimising volume and weight, but minimises the time an engine or aircraft is out of service. The concept of modular rafts has been proposed by the aerospace industry in the past, but further understanding of methods to closely integrate CFRP with electrical systems and components is required. For the successful design of an integrated power electronic converter CFRP module, the project will identify the key design thresholds for the electrical power system, power electronic converter topology and electrical, thermal and mechanical properties of CFRP. The integration of the structural, thermal and electrical system introduces complex challenges and requires a multi-disciplinary approach. This includes the choice of converter topology, thermal management system, control circuitry, electromagnetic shielding and appropriate filters. Wider systems considerations include the system parameters, grounding topology and fault management strategy. The thermal management system may be possibly via air cooling, or liquid cooling may be required. The design interdependencies with the layup of the CFRP casing are critical to the integrated system design. An additional design challenge is that the integrated system must be robust enough to withstand the harsh operating environment, with the system experiencing a combination of low pressure, extreme temperature, vibration and moisture. Finally, the level of modularisation will also be taken into account. For example, the limitations on integrating auxiliary systems into the composite casing. The integrated systems designed in the project will be verified by the design, test and build of hardware prototypes.