Turnkey VSD Technology June 2016 - public

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105 Corporate Drive, Suite D, Spartanburg, SC

Micro Pump &

Variable Speed Drive Technology


Presented by:Robert Kennedy, Owner

Turnkey Design Services, LLC

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Why technology was initially developed

• Temperature of the F-35 Warfighter fuel and oil systems is high due to:– Limited ability to reject heat to the environment due to stealth requirements

– Increased heat loads from modern avionics and advance mission systems

• To handle the fuel and oil systems temperature rise thermal bypass loops which include large heat exchangers have been employed

– Increases weight and cost of warfighter

– Higher fuel/oil temperatures reduce component life

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Why technology was initially developed

• Engine driven accessory gearbox pumps contribute a significant portion of the total generated heat load

– Main engine fuel and lubrication pump

– Actuator pump

• Why – they generate more flow than required at the low power flight conditions

– The volumetric flow rate of legacy pumps are directly proportional to the rotor speed of the high-pressure engine core which are driven via the engine gearbox.

– Main engine fuel and actuator pumps could each have a 80° F rise during flight idle

– Lube system temperature rise due to churning effects in gear and bearing compartments

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Temperature rise solution

• Transform engine driven accessory gearbox pumps into Flow On Demand pumps so that required flow can be system generated

• Variable Speed Drive Technology allows the pump to operate at the correct speed to deliver the demanded flow – Developed under SBIR Phase II contract to reduce the thermal output

of the F-35 lubrication system

• Converts a fixed displacement pump into a flow on demand pump without the weight penalty of a motor driven device

• Reduces lubrication system thermal output by an estimated 20% to 35%

• Reduces fuel system thermal output by an estimated 50% to 65%

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Variable Speed Drive Technology Overview

• Patent Pending Technology

• Electro-mechanical device

• Product of two proven aerospace technologies integrated together

• Driven by a prime mover

• Behaves like a electronically controlled continuous variable transmission• Self powering

• Capable of setting a particular speed ratio via an input signal

• Can either increase or decrease speed ratio on demand

• Can be used to power other devices or charge battery

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Electronic Controller

PlanetaryGearbox

GeneratorPrime Mover

Up to two output shafts VoltageSpeed

Speed ControlInput Signal

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30 HP Drive Shown4.5” diameter X 4.8” longProduction weight 4.4 lbs


Connects to Prime Mover

Two Output Shafts

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Flow On Demand Schematic

Pump

Pump Inlet

Discharge

Variable Speed Drive

Engine Gearbox

VSD connected in series between prime mover and

controllable device

Controller

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Comparison with Other Approaches

• Weight Factor- Higher number reflects higher projected weight

Topology Weight Factor

Single Stage 2

Single Stage 1

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Variable Displacement Vane Pumps

Variable Displacement Gear Pumps


Flow On Demand Approach

Vary displacement by

changing vane stroke


varying speed

Methodology

Variable Displacement Vane Pumps

Two Stage


unloading a pumping

stage

Hysteresis and

controllability

High efficiency (85%)

metering device

Outcome

Controllability, not a

metering device

Requires two high output force

actuators to position cam

Requires CVT type device with

electronic controller

Employed Technique

Requires complex fuel control to

regulate stage back pressure

• Lighter Weight

• More thermal efficient – controllability

• Lower number of active components – Lower cost and higher reliability

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Those that will benefit using Variable Speed Drive Technology

• Aircraft & UAV’s – Flow On Demand Pumps

– Auxiliary Power Units

– Constant Speed Alternators

– Propeller Speed Control

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• Flow On Demand Pumps– Refuse trucks

– Loader backhoe

– Mining Machinery

– Dump truck lifts

• Benefits– Fuel savings

– Reduced maintenance costs


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• Accessory Drive– Alternators/Generators, AC

Compressors, Superchargers, Water Pumps


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• Micro-turbines

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PropellerVSD

Technology

GeneratorGenerator

Power Unit

Engine

Battery

Avionics/Payload

Speed Control Input

Tran

smis

sion

Variable Speed Drive Advantages in UAV

VSD Technology:• Controls propeller speed • Maintains generator at best efficiency speed• Charges battery

Voltage

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Variable Speed Drive Advantages

Increases alternator output power by 90% while vehicle is loitering

Alternators oversized to achieve the performance required at engine idle speed,

Documents

Turnkey VSD Technology June 2016 - public