Hyperion 1.0 symposium presentation 2011
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Transcript of Hyperion 1.0 symposium presentation 2011
2011 Aerospace Engineering Design Symposium
32-Student Global Team
Michaela Cui Tyler Drake Arthur Kreuter Gavin Kuti l Brett Mil ler Corey Packard Marcus Rahimpour Gauravdev Soin
Mart in Arenz Holger Kurz David Pfeiffer Matthias Seitz Baris Tunali Jonas Schwengler
Kai Lehmkuehler Matthew Anderson Joshua Barnes Byron Wilson Andrew McCloskey
Mikhai l Kosyan Derek Nasso
Julie Price Eric Serani Tom Wiley
Richard Zhao
2011 Aerospace Engineering Design Symposium
Project Motivation and Goals
System Configuration
Hybrid-Electric Engine
Aerodynamics and Structures
Electronics and Control
Integration & Test
Lessons Learned
Index
- Index- 3
2011 Aerospace Engineering Design Symposium
NASA’s goal:
• Reduce aircraft fuel consumption
• Reduce emissions
• Reduce noise
…Simultaneously!
4
Motivation: Green Aviation
Motivation
Image credit: NASA
“In 2009, … [the] United States flew 704 million passengers, a number forecast to reach 1.21 billion by 2030.” – NASA Facts [1]
2011 Aerospace Engineering Design Symposium
Noise Challenge
5
Motivation: Reduce Noise
Motivation
Image credit: NASA
Aircraft noise regarded most significant hindrance to National Airspace System
Goal Develop Aircraft technology and airspace system operations to shrink the nuisance noise footprint to the airport boundary
[1]
[1]
2011 Aerospace Engineering Design Symposium
Fuel Problem
6
Motivation: Reduce Fuel Burn
Motivation
In 2008 U.S. Commercial air burned 19.7 Billion Gallons D.O.D. burned an additional 4.6 Billion Gallons
Goal
[1]
+
250,000,000… Tons of Carbon Dioxide (CO2)
Harmful Nitrogen Oxide Emissions (NOx)
Reduce NOx Emissions:
20% by 2015 50% by 2020
>50% beyond 2025 [1]
Reduce Fuel Burn:
33% by 2015 50% by 2020
>70% beyond 2025 [1]
2011 Aerospace Engineering Design Symposium 7
Motivation: Blended Wing Body
Motivation
[2]
2011 Aerospace Engineering Design Symposium 8
Motivation: Hybrid Technology
Motivation
Features
• Twin Engine Safety
• Variable Optimization
Internal Combustion Engine
Electric Motor
Patent Pending Hybrid Gearbox
• Efficiency Optimization
• Modular Configurations
2011 Aerospace Engineering Design Symposium
Need: Improved Efficiency in Global Industry Collaborations
9
Motivation: Follow-The-Sun
Motivation
[3]
Concept 3 Teams…
Distributed 8 hours apart…
Relay work daily …
Following the Sun
Result: 3 work-days in one 24 hour period
2011 Aerospace Engineering Design Symposium 10
HYPERION Goal
Goal
1. Conceive, design, implement, and operate (CDIO) an aerial platform to investigate new technologies for improvements in capabilities and efficiencies
2. Practice international collaboration in academia under the Follow-The-Sun (FTS) concept
has 2 goals:
2011 Aerospace Engineering Design Symposium 11
System Configuration
- System Configuration-
Hybrid-Electric Engine
6⁰ Canted, Raked Wingtips
Fiberglass Composite Skin Carbon Fiber/Foam Core Structure
Tricycle Landing Gear
2011 Aerospace Engineering Design Symposium 12
System Concept of Operations
- System Configuration-
2011 Aerospace Engineering Design Symposium 13
Hybrid Gas-Electric Engine
- Hybrid Electric Engine-
Project Goal and Objectives Design, build and test a hybrid propulsion system to be integrated
into the Hyperion blended wing-body aircraft
Offset drive
No control system
Focus: Efficiency, proof of
concept
Coaxial drive
Multiple flight mode control
Focus: Reliability, operations
Objective
2011 Aerospace Engineering Design Symposium 14
Project Requirements
-Hybrid-Electric Engine-
Project
System
Subsystem
Software Mechanical/Structural
Thermal
Temperature Constraints
Power output
4 hp at propeller
Multiple flight modes
Alternate ICE & EM
2 hp from ICE and 2 hp from
EM
Skin temperature below 60oC
LabView & Matlab
2011 Aerospace Engineering Design Symposium 15
System Architecture
-Hybrid-Electric Engine-
Connections Physical: Data: Power:
Receiver Transmitter
EM Throttle
ICE Throttle
Propeller EM
ICE
Gearbox
Control System
User Controls
LiPo Batteries
Fuel Remote
Start
Electric Motor & Gearbox
Batteries
Internal Combustion Engine
Fuel
2011 Aerospace Engineering Design Symposium 16
System Operations
-Hybrid-Electric Engine-
ICE Only – Cruise mode
EM Only – Quiet and Landing modes
Combination – Takeoff, Climb and Dash modes
Utilizes unique in-flight remote restart
technology
2011 Aerospace Engineering Design Symposium 17
Test Plan
-Hybrid-Electric Engine-
Dynamometer testing
Measures system torque output
Obtain power, RPM data
Satisfy Hyperion ConOps
Thermal testing
Not exceed fiberglass softening point
System fully enclosed for worst case
scenario
Test Like You Fly
2011 Aerospace Engineering Design Symposium 18
Thermal Testing and Verification
-Hybrid-Electric Engine-
Passive air cooling is required for safe engine operation
0 2 4 6 8 10 12 14 16 18 200
5
10
15
20
25
30
35ICE only for 10 min, then EM only for 10 min
Time [min]
Am
bie
nt
Tem
pera
ture
[C
]
ICE
EM
Side Wall
Gearbox
ESC
Upper Wall Surface
ICE Only EM Only
ICE Heat Sink = Greatest Thermal Output
Upper surface remains below required 60oC
Gearbox reaches steady state
Propeller wash about box from EM to rapidly cool cavity
The ConOps requirements are verified
2011 Aerospace Engineering Design Symposium 19
Power Testing and Verification
-Hybrid-Electric Engine-
1500 2000 2500 3000 3500 40000
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
RPM
EM
/Gearb
ox O
utp
ut
Pow
er
[HP
]
EM/GB Power [HP] versus RPM after Modifications
Data
polyfit
Power/RPM linear function obtained – EM 85% efficient
Power requirement of 2 hp verified at 7000 RPM
Dynamometer test setup inadequate
Force transducer inaccurate due to vibrations
2011 Aerospace Engineering Design Symposium 20
Risk & Mitigation
-Hybrid-Electric Engine-
Co
nse
qu
ence
Comm Failure
Structural Failure from
Vibrations
Failure to Interface Engine Control
Hyperion Thermal
Integration
Failure of Aircraft Delivery
Starting ICE Remotely
Possibility
Co
nse
qu
ence
Failure to Interface Engine Control
Hyperion Thermal
Integration
Structural Failure from
Vibrations
Failure of Aircraft Delivery
Starting ICE Remotely
Comm Failure
Possibility
Major Tall Poles ICE remote starting system
Overheating aircraft skin
Structural vibrations
Mitigation Utilized modified COTS system
Analytical modeling, redundant testing
Precise machining; design modifications
2011 Aerospace Engineering Design Symposium 21
Primary System Validation
-Hybrid-Electric Engine-
Mechanical
Engine/Aircraft
Integration
ICE & EM produce 2 hp
each (4 hp total)
Independent &
Concurrent Engine
Operations
Software/Control
Control Logic
Interface with sbRIO
Operational engine
control logic
System Operational
Operational reliability
through endurance
testing
Stretch Goal:
Flight Testing
2011 Aerospace Engineering Design Symposium 22
Aerodynamics & Structures
- Aerodynamics & Structures-
L/D greater than 20 Statically stable Stall velocity less than 15 m/s Span efficiency (e) greater than 0.8 Wing loading less than 15 kg/m²
Aerodynamic Requirements Structures, propulsion, control are highly dependent on aerodynamic shape Design locked at PDR
Design Alternatives
Geometry 3.0 m wing span 1.25 m max chord
Airfoils Body-S5016 Wing-S5010
Wing Endings Raked Wing Tips
Rudders H-Tail
2011 Aerospace Engineering Design Symposium 23
Aerodynamics & Structures
- Aerodynamics & Structures-
Safety factor greater than 1.5 Structure weight less than 10.0kg (22.0 lbs) Engine and wings to be modular
Structural Requirements
• Two spar design • Main spar designed to withstand entire load
Design at CDR
Initial Design at PDR
• With aero shape locked, able to complete detailed design • Worked closely with Boeing engineers
• Added shear device
2011 Aerospace Engineering Design Symposium 24
Aerodynamics & Structures
- Aerodynamics and Structures-
½ Scale Wind Tunnel Model Internal Structure Center Body/Integration
Aerodynamic Validation
CFD Validation
Wing Integration/Assembly
2011 Aerospace Engineering Design Symposium
Electronics & Control
- Electronics & Control-
Ground Station
Radio Controller
Video Receiver Video Monitor
Human Pilot
Control System Data Acquisition System
First Person Vision System
Radio Receiver
Flight Computer
Flight Computer Power Supply
Servos
Control Surface
Data Transmitter GPS
Pitot Tube Propulsion
Sensors
Flight Computer Sensors
Camera
OSD Overlay
Data Receiver Laptop PC
Video Transmitter
Main Electronics Power Supply
Legend
Power
Signal
Data Logger
25
Aircraft
2011 Aerospace Engineering Design Symposium
Roll Rate
Pitch Rate
Yaw Rate
Aileron Deflection
Elevator Deflection
Rudder Deflection
Electronics & Control
- Electronics & Control-
Commands Received from
Pilot
Flight Computer
PWM Signals to Servos
AoA
Sideslip Angle Yaw Rate
Pitch Rate
Roll Rate 3-Axis IMU Alpha/ Beta Probe
26
[1]
[3]
[2]
Photo Credit: [1]National Instruments [2]Memsense [3]RCATS
2011 Aerospace Engineering Design Symposium 27
Testing
Purpose for ½ prototype testing:
• Test aircraft capability and characteristics.
• Identify unforeseen problems.
• Pilot familiarization
• Test: Taxi, takeoff, cruise, land
• Test: Mass sensitivity, cg
Dynamically (1/2) Scale Model Prototype
Moving Test-Bed • Test flight power system • Test landing gear stability
- Integration & Testing-
2011 Aerospace Engineering Design Symposium 28
Global Integration Mitigation
IDT (Interface Dimension Template)
• Device used to ensure German center body matches USA wings
Flat Sat (Simulation and Test-bed) - Used while center body is in Germany -
• Full Scale Mockup of Center Body
• Wire Length and placement
• Hardware placement platform
• Full system testing for electronics
- Integration & Testing-
2011 Aerospace Engineering Design Symposium
29
Integration & Test
- Integration & Testing-
Mission Operations Manual
2011 Aerospace Engineering Design Symposium 30
Budget
- Lessons Learned-
2011 Aerospace Engineering Design Symposium 31
Lessons Learned
- Lessons Learned-
Technical
Composite Manufacturing Planning ahead is key Prototype first, then refine processes Software/Electrical Integration “Always behind on software” Components don’t integrate as easily as advertised Testing Early and multiple prototypes Change one thing at a time Always establish a baseline first
2011 Aerospace Engineering Design Symposium 32
Lessons Learned
- Lessons Learned-
Language and Cultural Barriers Although everyone speaks English… Interpretations may vary! Special attention to wording Ask questions if something is unclear Follow-the-Sun True FTS is difficult in academic environment Implemented “Follow-the-Week” Great for CAD International Shipping Unforeseen delay and charges from Customs Easily mitigated with preparation
Operations
2011 Aerospace Engineering Design Symposium 33
Acknowledgements
-Acknowledgements-
A special thanks to… Mike Kisska of Boeing
Diane Dimeff of eSpace Frank Doerner of Boeing Blaine Rawdon of Boeing Tom Hagen of Boeing Prof. Jean Koster of CU Joseph Tanner of CU/NASA Steven Yahata of Boeing Dr. Robert Liebeck of Boeing/USC Norman Princen of Boeing Brian Taylor of NASA Trent Yang of Rasei Dr. Donna Gerren of CU Prof. Eric Frew of CU James Mack of LASP Skip Miller of Skip Miller Models Matt Rhode of CU Trudy Schwartz of CU
Questions?