Browse Topic: Energy management
This study presents a comprehensive analysis of single-rotor failure tolerance for a classical octocopter configuration, examining both hover and forward flight at the best range speed. Using a state-of-the-art eVTOL comprehensive analysis to retrim the octocopter post-failure, the redistribution of rotor thrust, torque, and power following individual rotor failures was quantified, along with resulting aircraft-level power penalties. In hover, orthogonal rotors to the failed rotor provide primary lift compensation, the opposing rotor operates mostly unchanged, and the four opposite spinning rotors primarily provide pitch/roll moment compensation. This results in a total aircraft level power increase of approximately 10.4%, roughly half that of comparable hexacopters. In forward flight, at best range cruise speed, load redistributions were again calculated for various individual rotor failures. In the worst case, a maximum individual rotor torque increase of 62% and power increase of 108% was observed, while total aircraft power requirements increased between 7-12%. These results demonstrate the fault-tolerant capabilities of octocopters and provide practical guidance for propulsion system sizing, energy management, and failure-case assessment on classical octocopters.
Composite materials have become widely adopted in commercial aviation, as aerospace manufacturers look to use them to drive weight reduction and improved fuel efficiency in new aircraft designs. In the case of aircraft rotary blades, the poor wear properties of these materials have necessitated the development of metal leading edge guards that can provide critical protection against erosion and impact damage during flight. Electroforming has been a leading process for the manufacture of these protective guards, with nickel parts providing excellent wear resistance that significantly extends the service life of the rotary blade assembly. Currently there has not been a focus on utilizing direct electrodeposition of metal on to carbon filled epoxy composite structures, as traditional plating-on-plastics approaches require considerable effort in surface preparation and normally do not provide adequate adhesion to the underlying structure. Alpha Metalcraft Group has been working in cooperation with aerospace suppliers in the design of an electroplating ready composite structure that would allow for direct nickel deposition, provide excellent adhesion, and significantly reduce both the time and cost for the manufacture of ready-to-assembly rotary blade structures. Test panels were constructed of commercially available prepreg materials or by resin infusion of dry fabrics that incorporated different metal containing conductive layers to allow for the direct deposition through a nickel sulfamate electrodeposition process. Different surface modification strategies were investigated to expose the metal conducting layer and thereby provide the metal-to-metal bonding surfaces required for successful electrodeposition.
The induced and profile power of a hovering rotor was evaluated using experimental and computational methods. Momentum theory principles were coupled with experimental measurements over a range of thrust conditions to characterize the induced and profile power consumption at low Reynolds number conditions ∼ 105. An empirical induced power factor, κi, was extracted to quantify the non-ideal losses. Results show that these losses increase as the Reynolds number reduces, and nearly twice the power is required at Retip = 0.27×105 than the ideal momentum theory prediction. These results were compared with high-fidelity computational fluid dynamics simulations using the partial-pressure field (PPF) force/power decomposition to extract the induced and profile power contributions of the rotor. The PPF method decomposes the static pressure field of a numerical Reynolds-averaged Navier-Stokes solution into Euler and dissipative partial pressure fields. Simulations were performed across a range of thrust conditions, from which the induced power factor and profile drag coefficient,Cd0 , were computed for each simulation from the extracted power contributors.
Electrification could improve full-size rotorcraft performance by reducing peak turbine power demand, reducing transmission system weight and complexity, and reducing operating costs. Integrating electric machines with mechanical powertrains requires careful consideration of the system-level weight and efficiency impacts. This paper presents an optimization framework for evaluating parallel hybrid powertrain configurations using Geometric Programming (GP). Both retrofit and clean-sheet vehicle designs are considered. The results show that high-speed electric motors integrated into a parallel hybrid configuration using batteries can reduce the sized gas turbine power, enabling more efficient engine operation at lower power levels. For retrofit designs, with a fixed vehicle gross weight, adding batteries and motors reduces usable fuel, decreasing mission capability. Clean-sheet designs offer additional flexibility to re-size the vehicle and rotor, resulting in energy savings for an equivalent design mission.
Advanced Air Mobility (AAM) is an innovative concept that aims to revolutionize air transportation through electric and unmanned aircraft, enabling applications such as urban air taxis and medical transport. However, one of the key challenges to its widespread adoption is ensuring safety, particularly in collision avoidance. This study focuses on the development of a perception and guidance system for avoiding collisions with non-cooperative targets, which do not share their position or trajectory. To achieve this, a Frequency-Modulated Continuous Wave (FMCW) radar and an InfraRed(IR) camera are used. Compared to traditional pulsed or panel radars, FMCW radars offer higher resolution, better detection of small and slow-moving objects, and improved performance in cluttered environments. The IR camera enhances situational awareness by providing visual confirmation and additional tracking capability, making this sensor fusion approach particularly suitable for AAM applications. Our collision avoidance system follows ACAS Xu standards, which provide autonomous conflict detection and resolution for unmanned aerial vehicles. The maneuver selection process is based on precomputed lookup tables generated through a Markov Decision Process (MDP), optimizing responses based on risk and energy consumption. The entire system is tested in a simulation environment using Ansys AVxcelerate, a physics-based simulator capable of generating realistic sensor data. This approach allows for comprehensive testing of detection, tracking, and maneuver execution in a highly realistic scenario, ensuring the effectiveness of the proposed solution before real-world deployment.
Enhancing rotor efficiency has been a persistent challenge in the development of micro aerial vehicles (MAV) especially for surveillance and covert operations. This study introduces a new Hybrid Flapping Wing Rotor (Hybrid FWR) configuration inspired by insect's wing flapping mechanics to address the efficiency limitation of traditional rotor designs. Unlike traditional rotary systems that rely solely on rotational motion, the Hybrid FWR combines rotational and flapping motions to significantly enhance lift generation. A comprehensive mathematical model was developed to analyze and predict the optimal aerodynamic performance, demonstrating that the Hybrid FWR configuration achieves a substantial improvement, with a power efficiency increase of up to 2.148-fold compared to conventional micro rotorcraft. Experimental validation was conducted to confirm the theoretical predictions, identifying an optimal hybrid ratio of approximately 0.7, which effectively minimizes aerodynamic resistance during the upstroke phase while maximizing lift during the downstroke. This bio-inspired hybrid approach addresses critical limitations of existing MAV rotors, such as limited operational endurance and range. The findings of this research contribute significantly to the advancement of micro rotorcraft technology, presenting a promising direction for future MAV developments with enhanced flight performance and energy efficiency.
Helicopters' Vertical Take-Off and Landing (VTOL) capabilities are essential for maritime operations, especially for small-deck naval vessels. Unmanned Aerial Vehicles (UAVs) offer a cheaper, expendable, and efficient alternative for certain tasks, such as reducing pilot risk and lowering fuel consumption. While the procedures to approach and land on (moving) ships are standardized and bound to established operational limits in the case of crewed helicopters, UAVs lack such guidelines. This study investigates optimal rotary-wing UAV approach trajectories to a moving ship, for varying wind conditions and relative initial positions, and for different objectives. The goal is to provide preliminary guidelines for maritime UAV recovery operations, and a preliminary estimation of performance-based operational limits. The optimal trajectories are obtained using a global path-performance optimization framework based on Optimal Control Theory. The trajectories are compared to each other and to reference cases using the Longest Common SubSequence (LCSS) similarity measure, revealing how the unmanned helicopter adjusts its path to exploit the wind direction and profile for more efficient ground speeds. The violation of performance and/or geometric constraints is used to preliminarily indicate the presence of operational boundaries. The control effort and energy consumption are used to identify optimal starting positions for the helicopter approach phase for a given wind profile and intensity.
This paper presents experimental research aimed at developing novel low lubrication methods for rotorcraft and jet engines, focusing on sustaining minimal lubrication to prevent catastrophic bearing failure during loss of lubrication (LoL) events or to increase fuel consumption performance on once-through, fuel-oil bearing lubrication engines. Utilizing two high-speed bearing test rigs simulating low and high thrust class engine conditions, the study establishes lower bounds for oil flow rates necessary to maintain thermal stability and prevent thermal runaway in hybrid ball bearings. These findings inform the design of the Zulu Pod (ZPod), a passively driven, self-contained oil delivery system that uses engine compressor bleed air to precisely meter lubricant flow. Engine test stand results demonstrate that replacing traditional fuel-oil lubrication with the ZPod system reduces thrust specific fuel consumption (TSFC) by an average of 7%, with up to 11% savings, without compromising engine thrust or bearing health. The ZPod offers a simplified, efficient alternative to fuel-lubricated systems by eliminating fuel diversion for lubrication, enhancing fuel efficiency, and maintaining bearing performance in attritable or single-use engines. Additionally, the study highlights the potential of minimal lubrication supplied by the ZPod to extend operational life during LoL scenarios, enabling safer aircraft recovery. Future work will focus on extending testing to higher thrust classes and optimizing ZPod designs for broader applications.
This study investigates the effects of chord-to-radius ratio (c/R) and blade count on the aerodynamic and aeroacoustic performance of cyclorotors through experimental testing and a low-fidelity streamtube model. Cyclorotors with c/R ratios between 0.3 to 0.75 and blade counts ranging from 5 to 9 were tested across pitch amplitudes up to 51°. For a 5-bladed configuration, the pitch amplitude that maximizes the force-to-power coefficient (CF/CP) increases with c/R from approximately 32° at low c/R to around 51° at high c/R. However, the peak attainable CF/CP decreases with increasing c/R, indicating a trade-off between optimal pitch amplitude and aerodynamic efficiency. Increasing blade count enhances the generated force but reduces efficiency in all cases except for the lowest c/R configuration (0.3). Aeroacoustic analysis shows that tonal noise is primarily driven by pitch amplitude and intensifies with increasing c/R, while additional blades effectively mitigate it. In contrast, broadband noise is less sensitive to variations in pitch amplitude, c/R, and blade count. The streamtube model captures key aerodynamic trends, particularly at moderate pitch amplitudes. Scaling studies identify optimal configurations for a given disk loading, balancing power consumption and noise levels and highlighting key trade-offs critical to urban air mobility applications.
The transition phase of eVTOL aircraft poses a challenge in balancing energy efficiency and stability. This study presents the development and evaluation of an automatic flight control system for eVTOL transition phases, focusing on minimizing energy consumption while ensuring robust performance. The control architecture implements a hybrid response type combining Translational Rate Command below 5 knots and Acceleration Command Speed Hold above 5 knots, with control allocation dynamically adjusted based on airspeed and rotor shaft angle. Stability analysis reveals surge mode instability at high shaft angles due to negative speed stability derivatives, stabilized through carefully tuned feedback control. The system demonstrates Level 1 handling qualities against bandwidth, quickness, and disturbance rejection criteria when evaluated against MIL-DTL-32742 and MIL-STD-1797B standards. Simulation results verify the control system's ability to maintain precise acceleration/deceleration rates and attitude control while ensuring passenger comfort through limited pitch excursions. The control strategy achieves minimum energy transitions by locking rotor shaft angles to optimal schedules while avoiding excessive hub moments. Flight test maneuvers developed specifically for conversion phases confirm the system's capability to execute efficient transitions within defined performance boundaries. This research establishes a framework for certifiable eVTOL flight control systems that balance energy efficiency with robust performance across diverse flight regimes.
ABSTRACT The US Army is seeking improvements in the fuel efficiency of their military vehicles.. They have initiated a number of R&D projects aimed at advancing the state-of-the-art of powertrain efficiency including demonstration in a laboratory environment. This effort will set a benchmark for the vehicle integrators, allowing them to improve future vehicle offerings. The SAIC, AVL, Badenoch, QinetiQ and Ker-Train Research team offered powertrain solutions from 7 Tons to 40 Tons that achieved the goal of 44% thermal efficiency and the stringent flexible fuel and emissions requirements. In each of these offerings the team was able to identify modifications to existing engines that allowed dramatic improvements in the thermal efficiency. These efficiency improvements were achieved through a combination of techniques, combustion cycle adjustments using in-cylinder pressure monitoring and precise control of fuel injector timing, and turbo-compounding. For the R&D project, the fuel injector timing will be controlled using commercial engine development hardware and software. The high speed hardware emulates the engine control module but allows the developer to finely tune the fuel injection to maximize the 50% Maximum Fuel Burn point (MFB50) with only limited NOx production. This will be accomplished using a variety of fuels and maintaining the output power to within 2% of the engine’s nominal rating. This paper will describe the fundamental diesel combustion process that must be controlled and techniques for usable power extraction from the waste exhaust gases to provide this performance. It will describe the engine development tools that enable these controls changes to be realized within a vehicle development cycle and retain the baseline engine maturity.
Design modifications to a 3lb variant of DEVCOM Army Research Laboratory's Common Research Configuration (CRC-3) are assessed using simulation tools. To identify areas for improvement, the baseline CRC-3 is analyzed in hover and forward flight, and contributors to overall power consumption are identified, with the rotor drag consuming the greatest amount of power, due to the high rotational speeds required to maintain thrust in the face of the freestream velocity. Potential areas for improvement are identified as: wing airfoil, rotor blade pitch, and rotor orientation. Changing the airfoil has little to no measurable effect on the overall power consumption. Increasing the blade pitch improves cruise performance considerably, but at the cost of hover efficiency, for an overall range improvement of up to 28%. Changing the rotor orientation improves rotor efficiency as well, without substantial cost to hover power consumption, increasing the range by 37% but will require a redesign of the CRC-3 supporting structure to avoid the blades striking the structure. Experimentally determined trim sweeps of pitch and power requirement are shown for the quadrotor, tailsitter, and three different wing incidence angles (10◦, 20◦, and 40◦), showing up to 28% reductions in minimum power.
Modern aircraft have an established need for a high-performance, open standards solution to interconnect increasing number of digital components including sensors, actuators, controllers, processors, displays and data concentrators. The aircraft can be envisioned as a distributed system requiring highly available, reliable, and deterministic communication network - often termed as digital backbone - for safe operation. This paper introduces a new zonal architecture for aerospace onboard networks using Time-Sensitive Networking (TSN). TSN is an open standard based deterministic Ethernet solution for mission and safety critical networks in aerospace industry that truly meets the Modular Open Standards Approach (MOSA) requirements. This paper also presents a reference implementation of the proposed digital backbone architecture using commercial-off-the-shelf hardware from multiple vendors. Experimental data from laboratory evaluation shows stability, performance, and reliability that meets or exceeds the needs of aerospace use cases. The proposed next generation digital backbone provides significant size, weight, and power savings as well as enables hardware and software modularity using open standards. A specific use case of such a digital backbone is the US Army's Future Vertical Lift (FVL) program, but the proposed architecture is generally applicable to all aircraft networks.
In over actuated aircrafts a simple relationship between control inputs and forces/moments generated does not exist, however they have become very attractive for their wide range of applications. Control allocation aims at finding a unique surface control distribution as function of flight condition to perform the desired maneuver. The goal of this paper is to present a control allocation methodology applied on a generic over actuated aircraft aimed to determine the surface gearing matrix weights in different operative conditions to minimize the total power consumption. First, the non-linear model of the control forces and moments is derived for an over actuated aircraft. Then, two different optimization problems are introduced: the first to compute the trim equilibrium for any flight condition to minimize power consumption by the aircraft; the second to minimize the surface deflections required to produce desired control forces/moments starting from the trim point previously found. Finally, the optimized solution is subjected to engineering judgement to neglect the ineffective surfaces that do not provide a significant contribution to the required maneuver.
Unmanned Aerial Vehicles (UAVs), particularly Vertical Take-Off and Landing (VTOL) aircraft such as quad-rotors and helicopters, have gained attention for diverse applications in military and civilian domains. However, to increase applications, reducing their power consumption and their restricted payload capacity. This paper describes a method to enhance the thrust capabilities of typical shrouded rotors through a novel rotor design. Beginning with an airfoil with a high lift-to-drag ratio. Blade element momentum theory (BEMT) is used to optimize the rotor's chord and twist distributions systematically along with precise induced velocity prediction in shrouded rotors. Furthermore, a validation process requires rotor manufacturing and experimentation. BEMT harmonizes momentum and blade element theories, offering a comprehensive framework for rotor behavior modeling, especially in hovering conditions. First, second, and third degrees functions are used to express both the chord and twist distributions along the rotor radius from where the best rotor design is obtained, for this, an experimental validation is employed. The experimental tests demonstrate improved performance, especially when the rotor designed using the higher degree functions is employed. The proposed approach provides a comprehensive approach to shrouded rotor design, offering advancements.
The paper presents a novel strategy for minimum energy consumption in automatic conversion control of tiltrotor eVTOL aircraft, exemplified by the Aston Martin Volante Vision model. We introduce a tilt schedule methodology that strategically balances conversion and reconversion performance with climb, descent, and cruise phases to minimize overall energy expenditure. Our approach accounts for critical factors such as blade loading, operation handling qualities, and passenger ride comfort within a predefined conversion corridor. The optimized trajectories approximate the minimum energy pathway, essential for operational efficiency in urban air mobility. Analytical results demonstrate that our proposed conversion and reconversion phase profiles significantly reduce energy consumption, contributing to the sustainability of tiltrotor flight operations. This research not only enhances understanding of tiltrotor dynamics but also serves as a pivotal step toward achieving globally optimized energy usage, marking a significant advancement in autonomous flight technology for advanced air mobility systems.
ABSTRACT
There are a large number of curves and slopes in the mountainous areas. Unreasonable acceleration and deceleration in these areas will increase the burden of the brake system and the fuel consumption of the vehicle. The main purpose of this paper is to introduce a speed planning and promotion system for commercial vehicles in mountainous areas. The wind, slope, curve, engine brake, and rolling resistances are analyzed to establish the thermal model of the brake system. Based on the thermal model, the safe speed of the brake system is acquired. The maximum safe speed on the turning section is generated by the vehicle dynamic model. And the economic speed is calculated according to the fuel consumption model. The planning speed is provided based on these models. This system can guide the driver to handle the vehicle speed more reasonably. According to the simulation, compared to cruise control, speed planning can save fuel consumption at a mean value of 9.13% in typical mountainous areas. The field test of a typical commercial vehicle shows that this system can increase fuel efficiency by 4.26% compared to an experienced driver during a journey in a mountainous area.
Battery power and energy density are important parameters for emerging concepts for more / all-electric vehicles. Electric propulsion and power system performance is also important. To better understand how electric propulsion and power systems component performance influences overall vehicle design, a sensitivity assessment was performed noting changes in vehicle gross weight and energy usage. Updated versions of the Revolutionary Vertical lift Technology (RVLT) Project vertical takeoff and landing (VTOL) urban air mobility (UAM) reference vehicles and missions were used. NASA electric vehicle studies are discussed which were used to help select the range of electric propulsion and power system performance parameters used in this assessment. Thermal management systems (TMS) considerations are also important; new and innovative power management and distribution (PMAD) systems can reduce electric system weight and losses, reducing thermal management constraints often imposed by electric systems modest maximum use temperatures. Vehicles with higher disk loadings require higher power levels per unit weight for VTOL operations, which make them more sensitive to electric system weights and efficiencies. Battery, all-electric vehicles show different sensitivities to component performance than turboelectric or hybrids systems. Battery, all-electric propulsion systems may increase vehicle weight and size, but still results in lower mission energy usage than their hydrocarbon-fueled versions. Significant vehicle weight growth to electric propulsion and power system power-to-weight reductions also occurs at different levels among the various concepts. From these results, one can more readily identify required component performance levels, potential component choices, or research and development paths.
A novel stretchable material, when used in light-emitting capacitor devices, enables highly visible illumination at low operating voltages, and it is also resilient to damage due to its self-healing properties.
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