Airbus's ZEROe: First engine fuel cell powers up
for hydrogen flight
Successful
activation at 1.2 MW marks a pivotal step on Airbus’ ZEROe roadmap, aiming for
a hydrogen-propelled aircraft by 2035.
Updated: Feb 02, 2024 05:12 PM EST
ZEROe teams powered on the iron pod, the future hydrogen-propulsion
system designed for Airbus’ electric concept aircraft.
Airbus has achieved a significant milestone on the
journey toward hydrogen-powered flight by successfully activating its first
ZEROe engine fuel cell.
In late 2023, the iron pod, a pivotal component of
Airbus's electric concept aircraft, was powered by the ZEROe teams.
This innovative hydrogen-propulsion system
integrates the hydrogen fuel cell system, the essential electric motors
required for propeller rotation, and the necessary cooling and control
units.
Achieving a successful power output of 1.2
megawatts marks a significant milestone on Airbus' ZEROe roadmap, aiming to
deploy a hydrogen-propulsion aircraft into commercial service by 2035.
Significant advancement
In 2020, Airbus unveiled four hydrogen-powered
aircraft concepts to the public. Among these, three utilized hydrogen
combustion and hybrid
engines, while the fourth employed a fully electric system,
integrating hydrogen fuel cells and a propeller propulsion mechanism.
These fuel cells operate by converting hydrogen
into electricity through a chemical process, with water vapor as the sole
emission.
Recognizing the immense potential of hydrogen fuel
cells in aviation decarbonization, Airbus prioritized its exploration for the
ZEROe demonstrator.
However, a significant challenge arose: existing
hydrogen fuel cells on the market needed more energy output for aircraft
propulsion while maintaining acceptable weight levels.
To address this, Airbus established Aerostack in
October 2020, a joint venture with ElringKlinger, tasked with developing
high-performance hydrogen fuel cell stacks for ZEROe aircraft.
The electric motors of the iron pod were powered on with the hydrogen fuel cells for the first time.
Extensive fuel cell system testing occurred at
Ottobrunn, Germany, near Munich, within the E-Aircraft System House (EAS),
Europe's largest facility for testing alternative propulsion systems and fuels.
Here, crucial components of the propulsion system
underwent rigorous testing, setting the groundwork for the project's
advancement.
In June 2023, Airbus announced the successful
completion of the hydrogen fuel cell system's testing, achieving its full power
capacity of 1.2 megawatts.
According to Airbus, this milestone marked the
aviation industry's most potent fuel cell test for large-scale aircraft, paving
the way for the next phase: integrating the complete propulsion system with the
electric motor.
In late 2023, following the successful testing of
the fuel cell system at 1.2 megawatts in June and the powertrain at 1 megawatt
in October, a pivotal moment arrived: the initial activation of the electric
motors within the iron pod, synchronized with the hydrogen fuel
cells.
This event marked a crucial step forward in the
project's progress and signified the successful integration of essential
components essential for hydrogen propulsion.
“We measure how the propulsion system as a whole
works by testing the power needed for several different flight phases, such as
takeoff, where we are reaching maximum power levels, and cruising when we use
less power but over a longer period of time," said Hauke Peer-Luedders,
Head of Fuel Cell Propulsion System for ZEROe, in a statement.
Crucial phase
Key to enabling the next stages of the project is
the observation of how the various systems interact during testing. This
process is instrumental in understanding the adjustments necessary to render
the technology flight-worthy.
This meticulous examination gives insights into
the intricacies of system integration and performance, guiding the refinement
process essential for achieving airworthiness.
Throughout 2024, testing of the initial version of
the iron pod will continue. Following its conclusion, the ZEROe team will
optimize the propulsion system's size, mass, and qualifications to align with
flight requirements.
These qualifications encompass the system's
response to various factors such as vibration, humidity, and altitude,
according to Airbus.
Upon the completion of optimizations and
assessments, the fuel cell propulsion system will be integrated into the ZEROe
multimodal flight test platform, designated as MSN001, which notably marks the
first-ever A380 manufactured by Airbus.
Subsequently, rigorous ground testing of the
integrated systems will ensue. This phase will culminate in a pivotal stage –
the in-flight testing of the systems aboard the A380, an event currently slated
for 2026.
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