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Rotax 912 iS Fuel injected aircraft engine Thomas Goigitzer BRP-Powertrain
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Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

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Page 1: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Rotax 912 iSFuel injected aircraft engineThomas GoigitzerBRP-Powertrain

Page 2: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

BRP – Bombardier Recreational Products

2Rotax 912 iS - FH Joanneum, Thomas Goigitzer

BRP is no. 1 in following markets:§Jetboat§Boat§Snowmobile§Roadster§Light Sport Aircraft

Page 3: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

BRP-Powertrain GmbH & Co KG, Gunskirchen, Austria

3Rotax 912 iS - FH Joanneum, Thomas Goigitzer

n 1.100 employees

Page 4: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Rotax Aircraft Engine Milestones

4Rotax 912 iS - FH Joanneum, Thomas Goigitzer 4

Ultralight engines 501, 505 developed based on snowmobile engine 503

1975 1978

Certification of the first ROTAX Aircraft Engine

1984

Start of development of ROTAX 912

SOP ROTAX 912A (80hp)

1989 1996

SOPRotax 914F (115 hp)

SOPROTAX 912S (100 hp)

1998 2006

Gunskirchen EASA certified for design and production of aircraft engines (DOA,POA)

912 /914 TBO up to 2000 hours

2010

4

Rotax 447 ULSOP:

Late 70sDiscontinued:

2008

2012

Rotax 503 ULSOP:

Early 80sDiscontinued:

2008

Rotax 582 ULSOP:1989

In production

Rotax 912 ULSOP:1989

In production

Rotax 912 ULSSOP:1999

In production

Rotax 914 ULSOP:1996

In production 912912 iSiS

Page 5: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

INDEX

§ Fuel Efficiency

§ Electric & Electronics

5Rotax 912 iS - FH Joanneum, Thomas Goigitzer

§ Control Strategy

§ Q&A

§ Mechanical Impact

Page 6: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Overview

912 iS Fuel Injected Aircraft Engine

Base technical data:n Max. Power:

100 hpn Max. RPM:

5800 RPMn Bore:

84mmn Stroke:

61 mmn Displacement:

1352 cm³n Compression ratio:

10,8:1

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Page 7: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Overview

912 iS Fuel Injected Aircraft Engine

Rotax 912 iS - FH Joanneum, Thomas Goigitzer 7

Human

Mechanics Electrics

Eyes/EarsHands/Feet

Eyes/EarsHands/Feet

Human

MechanicsElectrics/

Electronics

Control Calibration

912ULS 912iS

1989 2012

Page 8: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Fuel Efficiency

BSFC comparison

n Break Specific Fuel consumption comparison at sea level

BSFC in altitude

n Break Specific Fuel consumption at 5500 engine rpm over altitude

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Typical

cruising

speed

Page 9: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Fuel Efficiency

Test flight comparison

Measured average fuel consumption on the test aircraft:

n Benchmark engine : 17,6l/h

n EFI equipped engine: 12,3l/h.

è 30% fuel consumption reduction

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Page 10: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Electric & Electronics

Requirements The 912iS Engine Management System

n ECU consists of two separate control units, so called “Lanes”

n Redundant engine control system is capable of managing the redundant components

n Redundant implementation of all safety-critical sensors and actuators

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Requirement:Electronic fuel injection

Requirement:Aviation safety

Highly redundant Engine Management System

with intelligent redundancy management

Lane A Lane B

Page 11: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Electric & Electronics

Implementation of safety-critical sensors

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Redundant actuators Redundant sensors

Page 12: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Electric & Electronics

Redundant Power Supplies

n The 912 engine management system is supplied by redundant regulated power supplies.

n Two permanent magnet generators n Two independent regulators n Power distribution unit (Fuse Box)

n System A permanent magnet generator and regulator is assigned for supplying the EMS system only.

n System B permanent magnet generator and regulator is assigned for supplying the aircraft system.

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Page 13: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Electric & Electronics

Ignition System

n Sp1, SP3: Double ignition coils assigned to Lane A

n Sp2, SP4: Double ignition coils assigned to Lane B

n 1B…4B: Spark plugs assigned to Lane A

n 1T…4T: Spark plugs assigned to Lane B

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Page 14: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Electric & Electronics

Injection system

Auto AB mode

Auto A mode

Auto B mode

Rotax 912 iS - FH Joanneum, Thomas Goigitzer 14

Auto_AB

Auto_A, Only_ A

Auto_B, Only_ B

Page 15: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Electric & Electronics

Galvanic Separation of Engine and Aircraft

Complete separation of the EMS electrical ground from any vehicle ground

n Increased robustness against direct and indirect effects of a lightning striken Robustness against any type of short to vehicle failure

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Page 16: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Control Strategy

Redundancy Management - Software algorithms

Lane declares Faultn Possible loss of functionality, not significant enoughn to force a change in system mode.

Lane declares Failuren Critical functionality has been lost and a change to n a different system mode is required.

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Page 17: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Control Strategy

Redundancy Management

System Modes

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Page 18: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Electric & Electronics

Redundancy Management

Warning lamp matrix:

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Page 19: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Mechanical Impact

Overview

The Implementation of this unique EMS System forced nearly allmechanical systems on the engine to be changed:

n Crankcase: changedn Cranktrain: changedn Cylinderhead: changedn Gearbox/ transmission: changedn Induction system: changedn Fuel system: changedn Lubrication system: changedn Exhaust system: changedn Engine management system: changedn Cooling system: unchangedn Electric components: changed

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Page 20: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Mechanical Impact

Generator Performance

n Yellow line: Generator Lane An Blue line: Generator Lane Bn Pink line: Engine / EMS System need

Resulting Generator Temperatures

n Yellow line: Temp. Lane A, Oil 135°Cn Green line: Temp. Lane A, Oil 100°Cn Blue line: Temp. Lane B, Oil 135°Cn Pink line: Temp. Lane B, Oil 100°C

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Page 21: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Mechanical Impact

Generator Design Changes

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Base engine air cooled generator Oil cooled generator

Page 22: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

Questions?

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Page 23: Rotax 912 iS - FH JoanneumRotax 912 iS - FH Joanneum, Thomas Goigitzer Ultralight engines 501, 505 developed based on snowmobile engine 503 1975 1978 Certification of the first ROTAX

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