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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - FLHYSAFE (Fuel CelL HYdrogen System for AircraFt Emergency operation)

Teaser

Summary

Today, all aircraft and equipment manufacturers are embarked in the current trend towards â€œMore Electric Aircraftâ€ (MEA), in which the traditional hydraulic and pneumatic systems are replaced by electrically driven systems offering higher performance and reliability, combined with lower operating costs and also allowing to meet the increasing demand to reduce fuel consumption and Green House Gas emissions while optimising aircraft performances. To this regard, fuel cell systems are considered as one of the best options for efficient power generation systems.
The main objective of FLHYSAFE is thus to demonstrate that a cost-efficient modular fuel cell system can replace the most critical safety systems and be used as an Emergency Power Unit aboard a commercial airplane providing enhanced safety functionalities. Also, the project has the ambition to virtually demonstrate that the system is able to be integrated into current aircraft designs respecting both installation volumes and maintenance constraints.
In order to shift from demonstrator levels (achieved in other projects), to the ready-to-certify product level, it is necessary to optimise the different components of the fuel cell system to reduce its weight, increase its lifetime, ensure its reliability, certify its safety and make its costs compatible with market requirements.
FLHYSAFE proposes fuel cell technologies using Proton Exchange Membrane fuel cell stacks, more integrated power converters and air bearing compressors.
FLHYSAFE has three specific objectives:
1. Design a modular Fuel Cell based Emergency Power Unit with a power range from 15kw to 60kw;
2. Develop and validate the FC system based EPU at TRL6;
3. Prepare the roadmap for exploitation.

Work performed

On the technical side and, firstly, at the system level, the performance of the existing Ram Air Turbine (RAT) has been used to derive the EPU specification. Additionally, a functional and safety analysis process has allowed the consortium to produce a clear and consistent PID diagram.
Following this step, it has then been possible to detail to the different sub-systems, starting with the Fuel-Cell System (FCS). A technical specification of the FCS has been prepared, allowing the creation of a preliminary design integrating all planned components (stack, cathode humidification system, H2 recirculation loop, sensors and actuators), except for the integrated converter. Two short stacks have also been provided to the consortium to perform start / stop study at stack level, in order to define the optimised strategy to comply with the emergency application requirements.
Furthermore, the first versions of the other subsystemsâ€™ specifications, such as anode and cathode loops, have been written on one side, while modelling and simulations have been performed on the other sides.
The preliminary design of the electrical and power management system (EPMS), in charge of powering all the electrical consumers (sensors, actuators and Aircraft loads) has been initiated through two activities: the design of a preliminary EPMS architecture and the analysis of the electrical load. The EPMS preliminary architecture and voltage buses have been frozen and both converters entered in detailed design phase.
Finally, the development of a Virtual Reality (VR) tool to create Assembly and Maintenance tasks and procedures through VR manipulations has been worked on. The projection of the system in VR environment is currently functional although some increments are still needed to permit direct creation of documentation during the VR session. Nevertheless, it is possible to program assembly task scenarios and to perform them in VR for validation or training.
While the scientific activities of the project were progressing, the FLHYSAFE partners have also initiated dissemination activities to raise awareness of the project: a public website was set up and a general project presentation was produced at the project start.

Final results

Thanks to the hybridisation of the fuel cell stack with a secondary power source, a battery, the system will be able to start-up within 5 seconds as required for an EPU. Furthermore, the FC-based EPU will offer an operating time of up to 3 hours with full power availability all along, independently from the aircraft speed, and until it is stopped and safe on the ground. This functionality will be an important breakthrough and will increase safety during the most critical phase of an emergency landing. An FC-based EPU, contrary to a RAT, can be located in many different locations of the aircraft as it does not require to unfold or to directly interact with the exterior environment. Thus, the developed system will be generic and possible to integrate into different types of aircraft. This modularity will allow to address various power demands according to the different single aisle aircraft needs with a common system architecture and common equipment sizing and development.
Regarding impacts, it should be noted that the aeronautic industry is still behind as a very stringent safety and weight are critical issues to take into account. FLHYSAFE expects to strongly contribute to this market objective. For the adoption of the technology, if FCH technologies fly with measurable results in terms of emission reductions, noise reduction, safety, efficiency and cost, with significant applications such as an EPU, the demonstration will also be crucial to convince adoption in less demanding sectors.
Furthermore, fuel cells are also a promising solution for generating electrical power on aircraft, providing solution to minimise the environmental impact and ways of producing decentralised energy. FLHYSAFE has fixed its environmental impact objectives according to the use of a life-cycle assessment methodology to assess potential environmental impacts associated with all the stages of the FC system life cycle. A general analysis will be refined in the project and evaluated according to measures obtained when performing tests. If the first application (EPU) has limited saving possibilities when replacing the RAT, the other applications targeted by the FLHYSAFE partners â€“ cabin/hotel loads and APU â€“ have much important capabilities.
Finally, one of the most key objectives of the development roadmap of the aeronautic industry for 2020 to 2050 is the reduction of emissions with a focus on electrical power supply obtained from renewable energies. FC are outlined as one of the technologies to deliver on-board electrical energy and in particular an e-APU independent of the aircraft engines. In particular, FLHYSAFE will be a major contributor to the topic Sustainable energy regarding Fully on-board electrical energy by 2035 as part of the ACARE SRIA Challenge 3 â€“ Protecting the environment and the energy supply according to the following development path.