SBIR-STTR Award

Turnkey Design Services, LLC of Blue Island, IL proposes to create a small lightweight “smart” fuel pump for unmanned vehicles using a small very efficient brushless motor with integrated controls and an internally-generated rotor pump. The overall size of the motor driven pump including electronics is about 2.5 ” long x 1” diameter. The proposed pump provides flow metering capability by adjusting the motor speed. The proposed motor uses high energy density rare earth magnets and specially designed windings to create the best efficiency for the required operating range of the pump. The controller is sensor less in order to eliminate the need for hall effects which take a significant amount of space. The smart pump is capable of monitoring and transmitting its current health status, as well as monitoring sensors for use in its internal control algorithms. The smart pump would be able to determine its rotary position, drive the pump to the commanded rotary speed (or flow), while managing its speed within a certain tolerance.

Keywords:
Miniature, Fuel, Pump, Smart, Motor, Lightweight, Turnkey, Uav

Small lightweight fuel pumps capable of supplying heavy fuels at low flows are currently needed for multiple IC and gas turbine engines under development by various engine manufacturers. The market need is for highly reliable and efficient pumps that extend the mission of UAVs, UGSs and UMSs. A very small, lightweight pump with flows ranging from 2-30 PPH and pressures up to 200 psi, integral electronics and PHM capability will be produced to meet the needs of gas turbine engines in this phase II effort. A custom designed brushless motor will provide good power density and efficiency along with a specially designed low flow pumping element that saves space and weight. The pump’s electronic controller will provide closed loop flow control with high accuracy as well as health monitoring capability. A high temperature motor and pump will also be produced that is capable of operation up to 250C. To further enhance PHM capabilities and reduce overall engine weight, a prototype integrated engine/pump controller will be created. The produced fuel pump will be ready for engine testing by the end of the first quarter 2010, while the integrated engine/fuel controls will be ready for engine testing by the end of 2010. BENEFIT

Keywords:
Miniature Fuel Pump, Heavy Fuel, High Temperature, Engine Controls, Phm, Health Monitoring, Brushless Motor, Sensorless Control