Browse Topic: Electric aircraft
Emerging technologies in the field of electrified propulsion systems offer a promising solution to reduce the dependence on fossil fuels and improve efficiency. However, the design of high-power density electric machines introduces new challenges, including limited passive cooling potential and the issue of the weight of electric motors. To address these challenges, this paper considers analysis and design methods for high torque-to-weight ratio axial flux motors. A magnetic equivalent circuit model coupled with a lumped parameter thermal network is developed for design space exploration and optimization. This inexpensive analytical model predicts the performance of a single-stator dual-rotor axial flux motor based on geometry, loading condition, and slot and pole pair combination. To enable comparisons against real-world data, the optimization study was demonstrated using the hover mission requirements from the Research Aircraft for eVTOL Enabling techNologies (RAVEN) vehicle to minimize the mass of the motor. In tandem with the analytical model, a higher-fidelity finite element model was also developed, and good agreement between predicted power and efficiency was demonstrated across a range of axial flux motor designs. The lightest weight design that satisfied the hover mission requirements was the 12 pole pair 27 slot (12PP 27S) configuration with a fixed weight of 9.28 kg. The analytic model undersized the output power of the electric motor by approximately 9% across a range of slot and pole pair combinations.
This paper presents an initial handling qualities analysis of an Electric Vertical Take-Off and Landing (eVTOL) hexacopter. The analysis uses the Distributed Electric Propulsion Simulation (DEPSim), developed by Penn State University (PSU) and the Comprehensive Hierarchical Aeromechanics Rotorcraft Model (CHARM), developed by Continuum Dynamics, Inc. (CDI). The study focuses on evaluating a generic AAM hexacopter performing Handling Qualities Task Elements (HQTE) as defined by the DOT / FAA. A trajectory controller was developed to enable simulation of prescribed flight paths, allowing automated simulation of four HQTEs: Heliport Approach, Hovering Turn and Hold, Pirouette, Lateral Reposition and Hold. Design modifications incorporating lateral mast tilt and Direct Side Force Control (DSFC) were implemented to enhance yaw control and ride qualities. Piloted simulations were conducted at the PSU rotorcraft flight simulation facility using DEPSim, employing an Attitude Command Attitude Hold (ACAH) architecture with mode switching to Translational Rate Command / Position Hold (TRC / PH) and TRC plus DSFC modes. Two of the four HQTEs were tested in piloted simulations. Though formal ratings were not collected at this time, pilot commands and performance indicated that TRC / PH and TRC plus DSFC modes enhance handling qualities over ACAH mode. The DSFC control law was found to have substantially reduced roll attitude, which could potentially enhance visual cueing, pilot comfort, and pilot-perceived handling qualities.
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.
NASA is conducting investigations in Advanced Air Mobility (AAM) aircraft and operations, including the development of Urban Air Mobility (UAM) aircraft designs that can be used to focus and guide research activities in support of AAM. This report is an investigation of the impact of technology and mission variations on several of the NASA AAM concept aircraft: quadrotor, quiet single main rotor, side-by-side, and tiltrotor configurations, with turboshaft and electric propulsion variants for each. First, the mission and aircraft models of the baseline designs were reassessed and updated, including rotor geometry optimization, update of the rotor performance models, and disk loading optimization. For these eight designs, technology and mission excursions were performed. Relative to the calibration cases that can be considered examples of good design practice, the impact of the weight technology factors is significant. For the electric aircraft, there is a very large impact of battery specific energy (Wh/kg), and correspondingly a very large impact of mission range. The vision of Advanced Air Mobility is driven by missions that will enable new transportation capabilities. Hence it is appropriate to compare Concept Vehicles of different lift and propulsive architectures, all designed to accomplish the same UAM mission. It is also useful however to consider specific missions that can take advantage of the strengths of individual aircraft configurations. So alternate designs were also developed for the concept vehicles: for turboshaft aircraft, longer unrefueled range, including faster cruise speed for the tiltrotor; for electric aircraft, shorter range and more realistic battery weight.
This paper details comprehensive analysis modeling and analysis supporting the development of the Research Aircraft for eVTOL Enabling techNologies (RAVEN). An isolated rotor model was developed in CAMRAD II, and predictions of rotor performance and rotor aeroelastic stability were generated. The rotor stability predictions are part of assessing airworthiness of the RAVEN vehicle. The performance predictions were used to calibrate the surrogate model for the NASA Design of Rotorcraft (NDARC).
Recent flight tests and simulations have suggested that the outwash from eVTOL air-taxis could be larger than conventional helicopters of equal weight and thus pose greater safety issues for their operation than previously anticipated. This has prompted interest in the analytical and experimental study of the aerodynamics related to multi-rotor aircraft outwash. This paper will describe work investigating some of the related issues, specifically (1) how wake models and wake model parameters impact outwash predictions in comprehensive rotorcraft analyses and (2) considerations when scaling results from model scale to full scale. This work will also compare outwash predictions for conventional and multi-rotor VTOL aircraft obtained with a Lagrangian free-vortex wake model and with an Eulerian velocity-vorticity grid based wake model.
A high-fidelity computational study is conducted to investigate the aerodynamic behavior and flight response of an electric Vertical Take-Off and Landing (eVTOL) multirotor configuration using unsteady computational fluid dynamics (CFD) framework. Four simulation cases are considered to examine the vehicle aerodynamics under both prescribed and fully coupled conditions. Prescribed hover and forward-flight cases isolate rotor aerodynamics and rotor-airframe interactions under constrained kinematics. Six-degree-of-freedom (6-DoF) free-flight maneuvering simulations capture the coupled evolution of aerodynamic loads, vehicle attitude, and translational motion. The results demonstrate that the high-fidelity unsteady CFD framework, coupled with rigid-body dynamics, effectively resolves the tightly coupled aerodynamic–dynamic interactions inherent to eVTOL configurations. This work provides a foundation for future investigations into trim strategies, control modeling, and expanded flight envelopes.
Researchers at the National Aeronautics and Space Administration (NASA) have conducted a series of module-level 50-ft dynamic drop tests on electric Vertical Take-off and Landing (eVTOL) Energy Storage Systems (ESS) for the generation of dynamic impact data to support standards developments. The tests were conducted on zero-state-of-charge Electric Power Systems (EPS) Electric Propulsion Ion Core (EPIC) modules at the National Institute for Aviation Research (NIAR), utilizing the NIAR outdoor drop test setup and conducted by NIAR test personnel. Four total tests were conducted on modules oriented in four different orientations. During initial post-test inspections at the drop facility, it was observed that the modules experienced varying amounts of damage in various locations and forms. The damage was quantified to the maximum extent possible via photogrammetric methods such as digital image correlation and marker tracking. Post-test modules were then disassembled, and forensics were conducted, which involved inspections into various containment structures and the cells themselves. A scoring rubric was developed in order to utilize a common methodology to quantitatively assess the damage incurred into each module as way of determining the least and most amount of damage present. Results in the form of post-test inspections, digital image correlation deformations, and scoring rubric values will be all presented, along with proposed paths forward for future work.
Electric aviation is advancing rapidly, with aircraft from manufacturers like Joby and Archer well on their way to certification, aircraft electrification will continue and begin to apply to larger aircraft. To support larger electrified rotorcraft, rotors will need to grow if disc-loading and hover efficiency are to be maintained. A consequence of this is the need to reduce rotor speed to maintain an acceptable acoustic signature, especially for operation in urban environments. Most current applications utilize radial flux motors, sometimes with a reduction gearbox. Gearboxes can improve overall propulsion system power density by enabling higher motor speeds but are generally not preferred as they introduce additional potential failure modes and maintenance schedules. In this paper a holistic approach is used to understand the trade-offs between rotor and motor and their consequences on propulsion system power density.
Electric vertical take-off and landing vehicles are proposed as a viable solution for urban air mobility due to their potential for reducing carbon emissions, noise, and operational costs. However, the shift towards electrified aircraft introduces new thermal management issues due to the excess heat generated by electric motors and power electronics. This heat is challenging to dissipate during the mission, resulting in transient motor temperatures, especially during high-power mission segments. In addition, electrified aircraft also encounter design challenges associated with the fixed weight of electric motors and batteries. To address these challenges, this work presents a multifidelity framework for performing shape optimization of an electric motor subject to performance, geometric, and thermal transient constraints. A preliminary sizing of the electric motor is performed using a low fidelity Fourier series model. Next, the sizing is refined by utilizing a coupled electromagnetic-thermal finite element model of the the motor physics. To demonstrate the framework, a numerical optimization is performed for a hover hold mission with a relevant scale eVTOL vehicle, reducing the structural mass of the motor by 2.7kg while ensuring power and thermal constraints are satisfied.
The performance and acoustics of a scaled propeller designed for an eVTOL vehicle were investigated in axial and edgewise flight. The measured performance compared well with BEMT predictions in axial flight conditions. The noise produced by the propeller is dominated by broadband noise sources, where there is evidence of contributions from blade wake interaction noise, turbulent boundary layer trailing edge noise, and laminar boundary layer vortex shedding noise. The directivity of the noise was found to be dependent on the advance ratio. Beamform maps also identified changes in the dominant noise source at different observer locations as a function of advance ratio.
This paper describes the design, development, and testing of a full-scale eVTOL propulsor optimized for quiet and efficient operation. To design the propulsor, a design tool was developed for predicting the aerodynamic and acoustic performance of eVTOL propellers and rotors. The design tool consists of an aerodynamic prediction code, AMP (Aerodynamic Modeling of Propulsor), and an acoustics prediction code, OpenCOPTER, coupled with an acoustics propogator, PSU-WOPWOP, which can receive inputs from either an acoustic solver or high-fidelity CFD. The tool was used to design a coaxial eVTOL propulsor, and both subscale and full-scale blades were manufactured. The aerodynamic and acoustic performance of the subscale propulsor was tested in hover and edgewise flight in an anechoic wind tunnel. A custom test stand was developed and used to measure the aerodynamic and acoustic performance of the 8-ft diameter full-scale propeller in hover. The experimental results were used to validate the design tool.
This paper presents insights into a comparative approach to down-select on the most suitable pilot control schemes for eVTOL and powered-lift aircraft. The investigation examines three main areas: (1) experimental flight test performance, (2) flight control analysis, and (3) Human-Machine Interface (HMI) factors. Experiments were conducted to evaluate how various inceptor control schemes were perceived by people of various experience levels, ranging from manned aviation pilots with experience in flying F-16 jets, AH-64D helicopters and high-performance turboprop trainers, to unmanned aviation pilots of various backgrounds, such as with remote control (RC) rotorcraft and RC fixed-wing aircraft, and finally to participants with zero experience with either of these. In this experimental surveying study, all participants were briefed on a standardized mission profile and tasked to fly a VTOL drone and a computer based flight simulator using various flight control schemes. Videos were recorded for each test and reviewed for in-depth flight performance and controls scoring and analysis. At the end, feedback on key Human Machine Interface (HMI) factors for each flight control method is obtained. These results in totality provided insights, strengths and weaknesses for each flight control scheme. Upon identification of the most optimal control methodology, a novel energy-based control method to unify both multirotor drone and fixed wing aircraft control logics was developed, future testing will involve incorporating the 3+1 control inceptor scheme with the energy-based control method for further testing and optimization in a simulation environment. The goal of this study is providing a design framework to help eVTOL and powered-lift aircraft designers optimize their pilot control methodology; to become more instinctive, easier to operate, safer and more cost-effective to train new eVTOL and powered-lift pilots and operators.
This paper presents handling qualities (HQs) research findings for electrical Vertical Take-off and Landing vehicles. Testing in the Vertical Motion Simulator (VMS) investigated handling qualities of vehicle configurations having a degraded powertrain. Powertrain components, including batteries and electric motors, can degrade as the vehicle is flown. This paper investigates the impact of low battery charge and high motor temperature degradations on the pilot's ability to execute precise maneuvers. Pilot comments and ratings that were collected from four rotorcraft test pilots in VMS testing are used to quantify the effects that powertrain degradations had on the HQs of the vehicle.
This paper presents the development and implementation of a complete flight control architecture for a 200kg-class tilt-wing eVTOL aircraft, designed and tested by Dufour Aerospace. The system enables fully automated flight across all regimes, including hover, transition, and cruise. A modular control architecture is described, incorporating a unified vehicle controller, envelope protection, and a guidance system. The control design leverages classical and modern techniques, including model-based synthesis, control allocation, and gain scheduling. A structured software development and validation pipeline is outlined, combining simulation, software- and hardware- in-the-loop testing, and flight testing on both subscale and full-scale platforms. Results from recent autonomous flight trials of the Aero2 aircraft demonstrate precise trajectory tracking and robust performance. The presented approach highlights the feasibility of rapid development cycles while maintaining high standards of safety and reliability for certifiable eVTOL platforms.
Researchers at the National Aeronautics and Space Administration (NASA) have conducted a series of module-level tests on electric Vertical Take-off and Landing (eVTOL) Energy Storage Systems (ESS) for the generation of dynamic impact data to support standards developments. The tests were conducted on zero-state-of-charge Electric Power Systems (EPS) Electric Propulsion Ion Core (EPIC) modules at the National Institute for Aviation Research (NIAR), utilizing the NIAR outdoor drop test setup and personnel. Four total tests were conducted. For each test, the module was dropped at a specific orientation from a height of 50 feet while connected to a guided trolley in order to assess the effects of a 50-foot drop test on the ESS. The test velocities ranged between 46.9 and 52.8 ft/s with impact angles ranging between a flat, zero-degree impact and 18 degrees. Data were recorded in the form of temperatures, cell-level voltage, module level acceleration and digital image correlation from the tests. Accelerations were in the range of 1,500 g for a few millisecond duration, which were indicative of a shock type loading condition. No modules entered thermal runaway, and post-test inspections revealed a variety of internal deformations and damage present in the various modules tested, with specific damage occurring for specific orientations. The modules were ranked according to a custom developed scoring rubric developed by utilizing the test and post-test inspection results. The results were compiled, reported, and will be used to guide future ESS testing. Part 1 discusses the loading environments in the modules, while Part 2 will discuss the deformation and damage in the modules.
The emergence of electric Vertical Takeoff and Landing (eVTOL) air vehicles is transforming how people and freight are moved in short distances. This transformation has a profound impact on surrounding infrastructure necessary to provide Aircraft On Ground support for eVTOLs. The hover capabilities of eVTOLs have similar operating characteristics within terminal and uncontrolled airspace. However, the need to conserve battery energy via rapid approaches and departures affects terminal airspace management. To attract eVTOL operators, existing airports, landing zones, and vertiports are modifying their infrastructure to include fixed electric charging stations, additional taxiways, upgraded fire suppression systems, separate hangers, and capable MRO facilities. Augusta Regional Airport (KAGS) is the base airport for the annual Masters Golf Tournament which experiences five times the normal airport traffic and some 40,000 commuting patrons. eVTOLs can offset land traffic issues associated with commuters and supplies. Since KAGS is centroid to 32,000 square miles of territory void of major highways, basing eVTOLs can offer expedited transit services for people and goods which will have a profound impact on the economic viability and quality of life in the area.
This paper demonstrates methods of aircraft sizing, flight dynamics modeling, and performance analysis using a lift+cruise concept vehicle with an electric powertrain and variable-speed rotors. The central focus is the development of methods to relate the aircraft design sizing constraints to achievable maneuverability and predicted handling qualities. A toolchain is demonstrated that performs aircraft sizing, mass moment of inertia estimation, powertrain modeling, trim optimization, dynamics linearization, handling qualities prediction, and quantification of achievable maneuverability under both nominal conditions and control effector failures. A convex optimization problem framework is introduced to compute agility bound estimates without requiring control system design or control allocation, potentially supporting rapid design iteration as well as early detection of deficiencies and undesirable operating conditions. This analysis is supplemented with more conventional methods of analysis to provide additional perspective and observations. Overall, the results suggest that each modeling and analysis element in the demonstrated toolchain adds significant value, with the combined approach supporting a more efficient and comprehensive exploration of trade-offs within the design space.
To document noise characteristics and provide validation data for acoustic modeling of rotor systems appropriate for eVTOL/UAM aircraft, the authors performed an outdoor static test of a subscale 5-blade proprotor. The testing was carried out as part of a program to demonstrate feasibility and overall performance of a quiet proprotor system in support of the eVTOL industry. The authors designed a low-tip speed proprotor to approximate performance required by a 4-5 passenger UAM vehicle. A driving design feature was low-tip speed operation (Mtip ˜0.27) at system disk loadings of 7 to 8 psf (˜3.7 N/m2). The test article was designed as a ground adjustable pitch 5-blade proprotor, with aerodynamic and acoustic data collected in outdoor static hover testing. The test article diameter of 3 feet (0.91 m) represented a scale factor of approximately 30% to 40% compared to vehicles currently in operation or development. The aerodynamic performance in hover was consistent with other rotor systems tested in the past by the authors (Figure of Merit ˜0.72-0.75), and the effects of naturally occurring turbulence on rotor acoustics were measured using a 180-deg arc array of ground plane microphones at the Virginia Tech Drone Park test facility. The paper closes with a prop diameter scaling investigation using lattice-Boltzmann method CAA with and without atmospheric turbulence.
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.
An experimental investigation was conducted on a 1.108 m radius coaxial co-rotating (or stacked) rotor and a coaxial counter-rotating (CCR) rotor of identical geometry to compare the acoustics and loads of both rotor configurations in hover. The rotors were operated at a tip Mach number of 0.40, tip Reynolds number of 765,000 and an axial spacing of 1.55 chord lengths, and the index angle between the upper and lower blades of the stacked rotor was varied. The overall sound pressure level (OASPL) was significantly larger for the CCR rotor. For example, total rotor noise at -45◦ angle of elevation was 6 dB greater for the CCR rotor than the stacked rotor at 8◦ collective. These increases in OASPL were driven by large increases in tonal noise for the CCR rotor, of up to 10 dB higher than the stacked rotor at some angles of elevation. This was attributed to additional tonal noise occurring at harmonics of 2Nb/rev, due to vibratory loads from 2Nb/rev blade crossings. The results of the experimental study suggest that, in terms of reduced noise and increased hover efficiency, the stacked rotor is preferable to the CCR rotor for eVTOL vehicle configurations that implement compact or closely spaced designs.
The engineering model determining the onset of Vortex Ring State (VRS) was applied to eVTOL aircraft, and the effect of different landing trajectories and aircraft drag was investigated. Next, the new model to compare the VRS susceptibility according to the different blade geometries and trajectories is proposed by extending Ahlin & Brown's model to incorporate the two-dimensional thrust and inflow distribution on the rotor disc. For validation, two different trajectories crossing the boundary of the onset of the VRS were simulated, and the results were compared with the Vorticity Transport Method (VTM). Furthermore, the disturbance distribution of moderately and highly twisted blades are compared. The extended model can capture the physical phenomena by the distribution of the disturbances and reflect the effect of blade geometries and trajectories. It is essential to investigate the model further through a correlation analysis using experiments or numerical analysis.
This paper deals with the influence of engine failure during hover on the wiring harness mass of electrical Vertical Take-Off and Landing (eVTOL) aircraft. It starts by presenting possible strategies which can be used to distribute the additional thrust needed during an engine failure among the remaining engines. The most efficient strategy is selected and the impact of different single engine failures on the overall thrust share, while using this strategy, is discussed. The paper proceeds by applying the selected thrust compensation strategy to the mission simulation of three common reference models, which are representative of current eVTOL aircraft configurations. This simulation is used to determine the worst flight phase for the One Engine Inoperative (OEI) condition to occur. The main purpose of the simulation is to optimize the wire sizes of the wiring harness of each configuration while satisfying different design objectives. The results of these optimizations are used to discuss the criticality of each engine failure and its influence on the wiring harness design, especially its mass. It concludes with design recommendations for the wiring harness of eVTOL aircraft.
This paper examines the effect of automation on learning for two different types of pilots, rotary-wing and fixed-wing, on flight maneuvers including hovering, vertical takeoff, en route navigation, and approach and landing. Building on existing research, the performance of 11 rotary-wing pilots and 28 fixed-wing pilots was examined during the final repetition of a flight profile to evaluate the level of proficiency gained in approximately 2 hours of training. Our findings suggest that although rotary-wing pilots benefit from their previous hover and take off experience, automation still improved their performance for these maneuvers. Additionally, fixed-wing pilots benefited from higher automation for hovering, en route navigation, and approach and landing maneuvers. These results are discussed in detail in the following sections, along with recommendations for training programs, curricula designers, and manufacturers in the evolving eVTOL landscape.
This paper analyses the possibility of using photovoltaics as additional energy provider for small to medium-sized eVTOL UAVs. A simplified model for eVTOL UAVs, which covers all relevant areas of aircraft design, including aerodynamics, structural mechanics, propulsion and systems modelling, is presented. Sensitivity studies covering various design parameters, such as airfoil, wing geometry and propulsion system selection are performed to show their influence on the configurations' performance. The first result of this paper is, that a photovoltaic powered configuration can outperform a battery electric and it can be worth the effort to implement the solar cells. To achieve this, the aircraft needs to be as aerodynamic efficient as possible. Also higher efficiency solar cells increase the possible performance. Additionally there is a big influence of the time of year and the latitude onto the performance. Secondly a multi mission study is performed. This uses a more detailed model, as the preliminary study. It is to find the best solar eVTOL for a set of missions. A summary of this study's results is presented. Finally the best aircraft configuration, following this study, is presented. The main take aways are, that solar cells can have a positive effect on the overall performance of eVTOL UAVS. However some possible drawbacks are also identified, as the resulting aircraft require rather low speeds and a more complicated mission planning, because solar irradiance needs to be taken into account and monitored during the whole mission.
This study examines the acoustics of a wing operating in the wake of a propeller. The propeller wing system is simulated at 24 knots cruise and 8° wing angle of attack. The propeller is simulated using an actuator line model, while the wing is simulated using two different turbulence models: a DDES turbulence model and a higher fidelity LES model. Chordwise compact loads, on-wing pressure surfaces, and pressure surfaces at distances of 2.34% and 10% thickness around the wing surface are used as inputs to PSU-WOPWOP to predict noise at an observer below the wing. Using on-wing surface pressures, the LES broadband noise predictions are 13.5 dB higher than DDES. Chordwise compact loads result in lower noise predictions than on-wing surface pressures, by 11.3 dB for LES and 2.3 dB for DDES. Using off-body pressure surfaces, DDES results remain similar to noise predictions from on-wing pressure surfaces, but with LES the broadband noise predictions are about 2.5 dB lower.
NRC developed a higher-order mathematical model structure of coupled rotor-body flapping dynamics for inflight control applications. The hybrid (rigid body fuselage state and rotating hub rotor state) 8DOF model was developed utilizing explicit measurements from a novel rotor hub state measurement system enabling estimation rotor blade dynamics. The method identified second-order rotor flap dynamics, attitude-rate and rotor flap dynamics response correlation, and response lead of rotor flap dynamics over rigid body dynamics. Reducing implementation resource burdens of past approaches, this novel rotor state measurement and modelling methodology may prove useful in applied development cycles across a spectrum of needs for articulated (helicopter) and non-articulated rotor (tiltrotor, eVTOL) aeromechanics, modelling, monitoring, and operations.
Electric aviation represents a new arena for battery engineering and development. In contrast to automotive applications, the electrification of aviation and aerospace is both less mature and requires higher safety and performance regulations. This work addresses a first step towards the development of standards and algorithms for measuring remaining useful energy for the battery system. Battery pack flight test data from 134 tests and two different manufacturers was analyzed to determine the weakest cell blocks in the pack, defined as cell blocks having the lowest voltage at the end of the test. It was found that the maximum initial voltage and voltage integral were two features with predictive power. Using the first five minutes of flight test data, accurate predictions were made ~85% of the time, in contract to the status quo where ~30 minutes of flight test data may be required. Sources of error and pathways to improve upon this result are discussed, such as improving data logging, adding additional logic to handle well-balanced packs, and engineering new voltage features with greater predictive power. It is possible to increase the accuracy beyond 95% this way. Future work will build on this to develop algorithms and standards for on-line fuel gauging for electric aircraft.
This paper investigates optimal wing arrangements for electric Vertical Take-Off and Landing (eVTOL) aircraft, leveraging on their design flexibility with electric propulsion system. The study employs a multidisciplinary approach with the objective of integrating aerodynamic analysis, static and dynamic stability assessments, and pilot feedback to evaluate various wing configurations. Analytical techniques were adopted to evaluate aerodynamic performance and static stability, while experimental flight testing on scale models was conducted to validate these findings. Additionally, the Cooper-Harper rating system was introduced to capture pilot perceptions of aircraft handling qualities. Results inform eVTOL designers on wing arrangements that offer enhanced aerodynamic efficiency, stability, and handling qualities, ultimately expanding the operational scope and applications of eVTOL aircraft. The study concludes the versatility of the high aspect ratio conventional wing on eVTOL aircraft, providing excellent overall performance in the various aspects. This research aims to provide a comprehensive understanding on how different wing configurations influence range and handling qualities in eVTOL aircraft.
The design of a powertrain for an eVTOL is a complex, multidisciplinary challenge whose solution is best approached as a constrained optimization problem. We use a motor and drive optimization tool based on both first principles and empirical models to examine the design space for a medium-sized eVTOL aicraft. The tool is used to perform optimizations based on continuous power requirements in conjunction with time-dependent mission profiles to achieve an optimal powertrain system weight given efficiency and diameter constraints. Additionally, efficiency and diameter sweeps are performed to illuminate the trades surrounding the "optimal" design point. Access to both detailed system-level optimizations and multi-dimensional sensitivity studies gives eVTOL aircraft designers unique and pivotal insights into the interaction between the propulsion system and the rest of the aircraft. A bespoke, integrated, approach also provides significant weight savings over a commercial off-the-shelf (COTS) solution.
This paper proposes a highly integrated 3-in-1 e-Propulsion unit that exceeds current state-of-the-art power density, utilising low-risk, high TRL technologies. The design process of the e-Propulsion unit is outlined, including the development of a high integrity, fault-tolerant system design targeting DAL-A safety levels. The resulting system concept embodies redundancy throughout the electrical system - two sets of windings in the motor and redundancy built into the power electronics create a robust and efficient architecture. The electrical machine is connected to an optimised single stage planetary gearbox to realise output shaft speed and torque suitable for an eVTOL or eCTOL type application. Both systems are cooled and lubricated by a standalone cooling loop.
In 2010, Leonardo Helicopters (formerly known as AgustaWestland) activated a confidential research initiative under the name of "Project Zero", having the goal to position the Company at the forefront of the latest and disruptive rotorcraft technology. Notably, rather than incubating the single technologies separately and demonstrating their advantages onboard a conventional platform, the company decided to combine them in the form of a flying testbed with a highly innovative architecture. Conceived to substantiate a vision of new possible things to come and developed in co-operation with an international team of specialists. The project aimed to achieve the first all-electric flight in a very tight window, leveraging the expertise of also non-aeronautical partners to make the most of the available building blocks, which represented both a technical and organizational challenge. 10 years on, the resulting testbed could be considered a forerunner of modern electric Vertical Take-Off and Landing (eVTOL) air vehicles and some of the incubated technologies an established asset of the rising Advanced Air Mobility (AAM). However, many technical solutions stemmed from trials and errors and the team had to work hard to keep on time and on budget regardless of the contingencies. Now that the project is over and the vehicle has been presented at multiple airshows, the authors disclose more information about its original design. Going into the technical details of the individual enabling technologies and their integration at aircraft system level. Discussing the pros and the cons, with the purpose of drawing some lessons that may be beneficial to the progress of vertical flight and the development of more sustainable air transports.
This study addresses safety concerns within the rapidly evolving Electric Vertical Takeoff and Landing (eVTOL) aircraft domain, focusing on efficient tools to quantify uncertainties in lithium-ion battery behavior - a critical aspect of eVTOL. One major issue with quantifying uncertainty is the prohibitive computational cost associated with many queries of an expensive-to-evaluate computational model. This work employs three physics-based battery models models of varying fidelity and cost to estimate the mean and the variance of the selected quantities of interest through a multifidelity method to reduce the computation cost. By combining information from multiple cheaper, lower-fidelity models through the Multifidelity Monte Carlo method, we significantly reduce the number of high-fidelity samples required for a prescribed mean-squared error, consequently reducing computational costs down to a tractable level. The proposed methodology is applied to estimate the mean and the variance of the battery temperature and voltage, accounting for uncertainties in flight conditions and materials. The first example focuses on a 580-second flight and is benchmarked against a standard Monte Carlo sampling technique. Results indicate a notable fourfold speed-up using the Multifidelity Monte Carlo method compared to the standard Monte Carlo method for the same mean-squared error for the voltage estimate. To showcase the method's generality, the multifidelity method is then applied to a longer flight of 3580 seconds for estimating the mean and the variance and utilizing these statistics to approximately estimate the probability of the flight completion. This demonstrates the adaptability of the methodology to various power profiles and considered uncertainties, with potential extensions to any battery chemistry. In conclusion, the presented multifidelity method offers a robust approach to enhance eVTOL safety by efficiently estimating uncertainties in battery behavior.
Effective development of emerging vertical lift solutions, including eVTOL and hybrid-propulsion configurations, demands efficient and accurate analysis tools. Due to similarities between conventional rotorcraft and eVTOL configurations, many of the critical technologies needed for analysis of eVTOL are available in existing rotorcraft comprehensive analysis tools. However, unique features of eVTOL configurations pose challenges that limit the accuracy and efficiency of existing analysis codes. In this paper we present a coarse parallelization strategy applied to RCAS that significantly reduces the computation time of multi-rotor and eVTOL configurations. Verification has been performed for trim and maneuver analysis for various aerodynamic inflow models, including Viscous Vortex Particle Method (VVPM) and CFD coupling. Linearization, eigenanalysis and modal reduction were part of the stability analysis verification. A feature to automatically generate parallel RCAS setup files from a standard RCAS script was developed in GRCAS (GUI version of RCAS) for ease of use. Additionally, a new parallel processing window was added to GRCAS to facilitate executing and monitoring paralellized models.
Pilot models have been successfully utilized for design and analysis of rotorcraft for decades. These models are commonly used as analysis tools, usually coupled to flight dynamics models. A method that has been developed is the Task-Pilot-Vehicle (TPV) approach, which utilizes the pilot model in a specific task. This paper presents results from the application of the TPV approach to investigate envelope protection (EP) methods. Four EP methods were chosen for these studies, i) Control Limiting, ii) Command Limiting, iii) MPC Based, iv) Virtual Control Limiting. These methods are exercised with pilot models inside a specifically designed toolbox across several different vehicles, including representative Tiltwing and Quadrotor vehicles, and Handling Qualities Task Elements (HQTEs). Results show that each envelope protection method has advantages and disadvantages, ranging from ease of implementation to potential adverse interactions with the pilot-vehicle system. Overall, the TPV approach shows promise as a method to investigate EP methods for eVTOL/VTOL aircraft.
The paper deals with the status of development and qualification/certification of electromechanical actuation for Helicopters and VTOL applications with the focus on aspects relevant to the Fault-Tolerance. In particular a linear Electromechanical Actuator (EMA) architecture is presented, derived from a fault tolerant ballscrew-based differential (speed-summing arrangement) actuation system patented by UMBRAGROUP S.p.A. The focus is on safety-critical and high reliability/availability requirements for electromechanical actuation certification. The main characteristic is the use of two independent mechanical actuation channels in the same envelope driven by independent Motor Control Electronics (MCEs). At the state of the art, the presented fault-tolerant architecture is under development in flight-critical swashplate application for eVTOL platform and under feasibility study in flight-critical swashplate application for CS27 platform.
The Eagle Flight Research Center (EFRC) at Embry-Riddle Aeronautical University (ERAU) is investigating the handling qualities of partial and full rotor failure modes of a multi-rotor vehicle testbed employing Distributed Electric Propulsion (DEP) systems intended for Advanced Air Mobility (AAM) vehicles. In order to pave the way for commercial operations, the AAM industry requires a deeper understanding of the handling characteristics and the vehicle's dynamics and controllability under rotor failure conditions. The objective of the research performed at the EFRC centered around designing and testing different thrust and moment control allocation methods for an electric Vertical Take-Off and Landing (eVTOL) vehicle, in addition to assessing their performance in both nominal and failure modes of operation. This paper focuses on analyzing the predicted handling qualities for a full-scale quadrotor testbed vehicle with RPM, collective, and cyclic blade pitch control allocation. The study uses flight-test data to develop a bare airframe dynamic model to optimize the controller gains, which are used to evaluate the predicted handling qualities though development of vehicle specific Handling Qualities Task Elements (HQTE) maneuvers. The evaluation is performed using an in-house built flight simulator together with the Cooper-Harper Rating Scale (CHRS) for Handling Qualities test evaluation. The handling qualities were evaluated and compared for different control strategies and a method for quantitative evaluation of handling qualities is presented.
The development of turbulence criteria to provide early guidance for the design of vertiports is presented in this paper. For any aircraft, winds, in particular crosswinds and gusty winds, are top of mind for all pilots engaging in take-off and landing maneuvers. It is anticipated that the same will be true for VTOL and eVTOLs landing on vertiports, in particular as new vertiports are built closer and closer to urban centres. First, a review of the current design criteria for vertiports around the world related to wind is presented, highlighting the commonality between the guidance and the gaps in their content. Second, the controllability criteria that VTOL and eVTOLs will likely need to meet in the pursuit of an airworthiness certification are reviewed and their pertinence with regards to vertiport design are discussed. Third, the characters of the wind and their impact on eVTOL flights at or near take-off and landing infrastructure is explored. Finally, a set of turbulence criteria for vertiports and a turbulence index are proposed. The index includes a scale for conditions ranging from favorable for take-off and landing; to more and more demanding conditions; up to turbulence conditions to be firmly avoided.
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.
Fusion Artificial Intelligence Link Synchronization Array for eVTOL Systems (FAILSAFES™) is a resilient and redundant timing and positioning architecture based on low Size, Weight, Power, and Cost (SWaP-C) RF Ranging links for eVTOL systems navigating with Global Navigation Satellite System (GNSS) in degraded or denied environments. This paper describes the overall FAILSAFES™ concept and discusses the underlying Complementary Positioning, Navigation, and Timing (CPNT) capabilities based on ENSCO's PicoRangerTM Array technology (PRAT). PRAT provides an array of low-cost RF ranging links between FAILSAFES™ ground stations and aircrafts to support navigation and timing distribution in GNSS degraded or denied environments. This paper will explore components of FAILSAFES™ and discuss initial PRAT based fusion results with respect to frequency and time stability.
Fundamental advancements in aircraft design over the past 50 years have enabled a range of Vertical Takeoff and Landing (VTOL) air vehicle configurations and have significantly enhanced aircraft performance, safety, and reliability. This summary paper chronicles the evolution of rotorcraft design from 1974-2024 as presented by the Vertical Flight Society (VFS) Aircraft Design Technical Committee (TC). It is segregated into three key pillars of aircraft design preceded by an aircraft design overview. The three pillars are: processes and tools, technology, and air vehicle configuration. The first pillar on design processes and tools describes advancements in technology, methodologies, and computational capabilities such as the transition from design solely by wind tunnel testing, physical models, and hand calculations to computer aided design/synthesis and simulation in a model-based engineering digital-twin environment. The second pillar on technology focuses on advances in disciplinary technologies and how they have been incorporated into aircraft design. Technologies discussed include composite materials; rotor systems; propulsion systems, ranging from advancements in turbine engines to all- and more-electric propulsion technologies utilizing various energy storage systems to convertible engines; fly-by-wire systems; avionics and cockpit architectures, including digital displays, navigation aids, and communication equipment; and autonomous and semi-autonomous systems. The third pillar on air vehicle configuration focuses on platform architectures. Major architectures discussed are high-speed VTOLs such as the thrust-vectored aircraft, tiltrotors, lift/thrust compounded helicopters and all- and more-electric aircraft.
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