Presentation ＠Europe-Japan Symposium
T-IDG® Technology Overview
March 26, 2015
Dr. Tatsuhiko Goi
Sr. Manager, Drive System Engineering
Kawasaki Heavy Industries,Ltd.
KHI PROPRIETARY
Introduction
The IDG(Integrated Drive Generator) is an aircraft power generation
device which houses a Continuously Variable Transmission(CVT) to
generate 400Hz constant frequency power regardless of the engine speed.
Traction Drive IDG (T-IDG® ) is an innovative IDG which employs a
traction drive mechanism as the CVT instead of a hydro-mechanical CVT
used in conventional IDGs.
T-IDG® was selected as the main generator for JSDF P-1/XC-2 aircraft and
have shown its good reliability since 2007.
XC-2
P-1
*IDG: Integrated Drive Generator
KHI PROPRIETARY
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
2
Principle of Traction Drive CVT
TRUNNION
POWER ROLLER
INPUT DISC
OUTPUT DISC
R1
R2
R2
R1
Generator
Engine
Loading Cam
TILTING
Speed Decreasing Mode
Speed Increasing Mode
Speed Ratio＝R1/R2
Typical Configuration of Traction Drive CVT*
*Continuously Variable Transmission
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
KHI PROPRIETARY
3
Outline of T-IDG® MK III
Traction Drive CVT
（Speed Ratio 0.5~2.0）
Input Shaft
(4500-9200rpm
variable)
T-IDG Data
•Cont.Rating：90kVA
•5 min. Rating：112.5kVA
•5 sec. Rating : 150kVA
•Frequency：400±5Hz(3）
•Voltage：115/200V
•Size：375L×460W×330Hmm
•Weight：54.0kgf(dry)
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
Main Generator
(90kVA；24000rpm const.)
Output Terminal
T-IDG Cutaway
KHI PROPRIETARY
4
Major Features of T-IDG®
 High Efficiency (Low Heat Rejection or Low Power Loss)
= leads to
low fuel consumption
smaller oil cooler (substantial weight reduction)
 High Reliability
 Compatibility with the existing IDG
(interface, envelope, weight, overhang moment, etc.)
 Growth Potential up to 200kVA
 No straight thorough speed(no operational limitation)
 Competitive Total Life Cycle Cost(TLCC)
 Aluminum Housing(high corrosion resistance)
 Less Maintenance
Longer Servicing Interval
No intermediate checks such as oil level, filter condition, etc)
No speed control adjustment
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
KHI PROPRIETARY
5
T-IDG® Development Status
 1999-2005: prototypes Mk I to Mk III were developed and
tested (total 9 prototype IDGs were used). A series of
development tests as well as an actual engine test using RR
Trent 500 were performed.
 In 2005 the qualification test for Mk IV version
for P-1/XC-2 was completed.
 Total 110,000 hour Lead The Fleet Test
since Mar.2006 ( av.22,000hr5 T-IDGs)
was completed in Sept.2013.
 P-1 first flight: Sept.2007,
XC-2 first flight: Jan. 2010
Since then good reliability has been proven.
T-IDG on
Trent 500 Engine
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
KHI PROPRIETARY
6
Typical Test Results(1/2)
Endured Traction
Drive Parts
Power Roller
1000hr Endurance Test
Per MIL-E-85583
IDG Load
MIL-STD-704E Frequency Allowable
Limits
Output Frequency(Hz)
Load(kW)
Output Frequency
Disc
T-IDG Heat Rejection
(@90kW Load)
Time Elapse(sec)
150%(112.5kW) Step Load
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
KHI PROPRIETARY
7
Typical Test Results(2/2）
Tilting Bed
Drive Motor
T-IDG
T-IDG
Oscillator
Drive
Motor
Attitude Test
EMI Test
Vibration Test
30deg Nose Down
Refrigerator
T-IDG
Altitude/Cold Temp Chamber
Drive Motor
Oil Cooler
T-IDG
Furnace
T-IDG
Inside the Chamber
Drive Motor
High Temperature Test
Cold Temperature/ Altitude Test
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
KHI PROPRIETARY
8
Technology Update
Extensive R&Ds have been conducted for the next generation T-IDG
development.
Compact
High Durability
High
Responsiveness
High Efficiency
Optimization of
oil flow and
parts cooling
High stiffness
structure
High Durability
High Efficiency
Hydraulic
clamp control
High Stability
High Efficiency
Optimization of
CVT geometry
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
High
Responsiveness
Compact
Optimization of
control system
KHI PROPRIETARY
9
Summary
 Traction Drive IDG(T-IDG® ) has proved its high
reliability and high efficiency on the P-1/XC-2 aircraft
and in the 110,000 hour “Lead the Fleet Test”.
 In parallel KHI has been improving the CVT technology
to enhance its competitiveness.
 The T-IDG® will meet the requirements for future MEAs.
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
KHI PROPRIETARY
10
KHI PROPRIETARY
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
KHI PROPRIETARY
11