Electrical Systems Engineering & Integration in AIRBUS · Design space for potential solution recognized and potential for value assessed At least one feasible solution identified

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.

Electrical Systems Engineering &

Integration in AIRBUS

Presented by

Stefan ROEMELT

Vice President - Head of

Avionics Platforms & Electrical Systems

Airbus Operations S.A.S. - Toulouse

August 2015ICAS Biennial Workshop 2015 – Electrical Systems Engineering & Integration in AIRBUS

ICAS Biennial Workshop 2015

Krakow (Poland), 31/08/2015


Content

• Electrical System Architecture

• Development Process

• Functional Integration

• Physical Integration

• Electrical Structure Network (ESN)

• Future Trends

ICAS Biennial Workshop 2015 – Electrical Systems Engineering & Integration in AIRBUS August 2015

Page 2


ICAS Biennial Workshop 2015 – Electrical Systems Engineering & Integration in AIRBUS

43

7

56

2

1

1

2

3

4 & 6

5

71 : Main Generator

2 : Auxiliary Generator

3 : Electrical Energy Transport

4 : Distribution & Protection of

Primary Energy

5 : Voltage Adaptation

(Transformers)

6 : Secondary Distribution &

Protection

7 : Electrical Energy Transport to

Consumers


Page 3

Electrical System Principles (Generation & Distribution)

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document. PAGE 4


TOP LEVEL

REQUIREMENTS

SYS

REQUIREMENTS

DESIGN

ACTIVITY

VALIDATED

END

PRODUCT

DESIGN

ACTIVITY

DESIGNED

SOLUTION

= PRODUCT

PRODUCT UNDER

INTEGRATION

USER

NEEDS

Sub-SYS and/or EQ

REQUIREMENTS

AIRBUS

SUPPLIERS

Loss of whole System Probability

must be lower than 10-9

/FH

(Systems Development i.a.w. DO-178B DAL A)

System Architecture has to follow

Redundancy, Segregation & Dissimilarity

Design Rules

Electrical System Top Level Requirements (JAR/FAR-25) are leading to SAFETY

Classification “CATASTROPHIC”

August 2015

Architectural Design Drivers

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document. PAGE 5

Emergency

power

source

Side 1

Normal power

source side 2Normal power

source side 1

Power Centres

EPDC1 EPDC2

Side 2

NO

RM

AL

AC

& D

C

NO

RM

AL

AC

& D

C

EM

ER

GE

NC

Y

AC

& D

C

EM

ER

GE

NC

Y

AC

& D

C

Side 1 Side 2

EPDC2


August 2015

A350XWB Electrical System Architecture


• Particular Risk Analysis

• Engine Burst

• Tire Burst

• Bird Strike

• Short Circuit

• Lightning Strike

• EMI/EMC (e.g. Antennas)

EWIS (Electrical Wiring Interconnection

System) Regulation applicable since A380

Wiring considered as “System” with Analysis of

Physical Aspects and Functional Impacts (e.g.

Short Circuit etc.) on Wires and Bundles (Safety

Analysis)

EWIS Regulation introduced Requirement on

Technology, Segregation and Installation

Rules.


Page 6

Particular Risk Analysis (PRA)


R&T Activities


TOP LEVEL

REQUIREMENTS

SYS

REQUIREMENTS

DESIGN

ACTIVITY

VALIDATED

END

PRODUCT

DESIGN

ACTIVITY

DESIGNED

SOLUTION

= PRODUCT

PRODUCT UNDER

INTEGRATION

USER

NEEDS

Sub-SYS and/or EQ

REQUIREMENTS

AIRBUS

SUPPLIERS

Page 7

Development Process


TRL1 TRL2 TRL3 TRL4 TRL5 TRL6

DescriptionBasic principles

observed and reported

Technology concept and/or application

formulated

Analytical and experimental critical

function and/or characteristics proof

of concept

Component and/or breadboard validation in laboratory

environment

Component and/or breadboard

validation in relevant environment

Systems /subsystems model

or prototype demonstration in a

relevant environment

Han

d O

ver

to P

rog

ram

s

Maturity phase Discover Understand Adapt Validate

Main Objective of this phase

Problematic and associated

requirements explicitly identified

Design space for potential solution recognized and

potential for value assessed

At least one feasible solution identified

and evaluated against reference

De-risk of solution(s) critical elements in

lab and value of solution(s) confirmed

De-risk of solution(s) at higher level of

integration in relevant environment

and value of solution(s) confirmed

De-risk of fully integrated

solution(s) in relevant environment

and value of solution(s) confirmed

cri

teri

a

Performance and integration

Value and risk

Engineering readiness

Manuf. and Industrial readiness

Operability

Roadmap to next steps


Page 8

Introduction of new Technology (TRL Criteria)



Design Verification

at A/C Level

Choice/Validation ofConcepts, Laws &

Technologies

Supplier Tests

Design Verification

at System Level

Multi-System Simulator

Aircraft -1

Electrical Simulation

SABER

Page 9

Early Design Verification through Simulation

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document. PAGE 10August 2015

ATA28

(Pump)

ATA21

(Fan)

ATA24

(GEN)

…..

SUPPLIERS’ MODELS

FUNCTIONAL

Models

SABER

BEHAVIORAL

Models

SABER

Equipment Models

NETWORK

Reconfigur.,

Distribution,

Load Mgmt.,

Failure analy.,

Protection

NETWORK

QUALITY

Normal,

Transients,

Protection,

DC Ripple

AIRBUS SYSTEM SIMULATIONS

Voltage at busbar level

Maximumpeak power

RAT start-up sequence

Maximum THDv

Electrical Network Management


SABER Electrical System Simulation


Physical Simulators (S5x)

Aircraft 0

EPDS EPGS

Flight Test

A/C

Batteries

EFIB

• Product Verification starts Supplier Level

• Interfaces must be representative at all Benches!

Supplier Tests

Final Validationper Flight Test

Verification/Integrationat System/Function Level

Validation/Integrationat Aircraft Level


New on

A350XWB !!!

PISTB (Pre-Integration & Systems Test BenchPre-Integration

at System Level in Supplier Lab

Pre-integration “around”

EPDS

… and other ATA24 Equipment

Page 11

Verification/Validation and Testing Strategy


• Electrical Functional Integration Bench (EFIB)

• Full real Equipment under Test

• Remaining A/C Environment simulated

EFIB

Supplier Tests

Final ValidationFlight tests


Pre-Integrationat System Level



x PISTB

Page 12

Electrical Systems Test Rig (EFIB)


• A/C 0 -> Iron Bird coupled to full scale Cockpit Simulator

• Cabin 0 -> Fully integrated Cabin Systems

• Nearly Test A/C Instrumentation

• Key means to prepare First Flight and PAX Operations


Page 13

Iron Bird/Aircraft 0 and Cabin 0

Aircraft 0

Supplier Tests

Final ValidationFlight Tests


Pre-Integrationat System Level


Cabin 0


All A350XWB Test A/C are operated like Airline A/C -> “Airline 1”


Page 14

Flight Test



Mat A Mat B Mat C

3D Layout Feasibility Mat A

Integration of “sizing” Systems

Page 15

Physical Integration Strategy

3D Layout Integrity Mat B

System Integration to ensure critical

A/C Functions in Particular Risk Scenarios

3D Layout Optimization Mat C

Detailed Design Freeze



Page 16

Virtual Reality supports Physical Integration



Page 17

Physical Mock-Ups still mandatory (Case-by-Case)


Empty Space

To

Skin equipped by Rapid Prototyping(3D Printing)

Scale 1:1


Mock-Ups installed

Page 18

Application of Rapid Prototyping



Page 19

Electrical Structure Network (ESN)


More Demand for Electrical Power

X 3Number of Electrical Loads

on A380 vs. A320

180

230

400

600

0 500 1000

A320

A330

A350 XWB

A380

Main electrical generation (kVA)


Page 20

Enhanced Technologiesfor A350XWB Systems

New 230 VAC network

Electrical Trimmable

Horizontal Stabilizer Actuator

New APU Starter/Generator

Future Trend: More Electrical Aircraft (MEA)


Modular Electrical Centers

Reversible Electrical Network

Electrical Pack & ModularCooling

Modular Power Electronics Bay

Low PowerElectrical WIPS

Generate Convey, Convert, Protect Use

IGGB®

Fuel Cell

Essential Main PowerGeneration

Flight ControlElectrical MechanicalActuation

Physical

Integration

Functional Integration


Page 21

MEA Systems Evolution


A350XWB (1st European composite A/C) with Junkers F13 (1st world all-metal commercial A/C - 1919) – WISCONSIN (USA)


Page 22

Questions?


August 2015ICAS Biennial Workshop 2015 – Electrical Systems Engineering & Integration in AIRBUS

Page 23

© AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS Operations S.A.S. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS Operations S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS Operations S.A.S will be pleased to explain the basis thereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.

Documents

Electrical Systems Engineering & Integration in AIRBUS · Design space for potential solution recognized and potential for value assessed At least one feasible solution identified