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Hyperion Global AIAA-ASM-final


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Paper presented at AIAA-ASM Conference 2012, Nashville, TN

Paper presented at AIAA-ASM Conference 2012, Nashville, TN

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  • 1. Hyperion UAV: An International Collaboration Jean Koster,University of Colorado Boulder AIAA-ASM 2012, Nashville, TN, January 12, 2012
  • 2. CollaborationJean Koster – University of Colorado Boulder, USAClaus-Dieter Munz, Ewald Kraemer – University of Stuttgart, GermanyKC Wong, Dries Verstraete – University of Sydney Australia Collaboration AIAA-ASM 2012
  • 3. Motivation: Green Aviation NASA’s ERA Goals Reduce: Aircraft fuel consumption Emissions Noise Image credit: NASA …Simultaneously! “In 2009, … [the] United States flew 704 million passengers, a[1] number forecast to reach 1.21 billion by 2030.” – NASA Facts -Motivation- AIAA-ASM 2012 3
  • 4. Motivation: Reduce Noise Airport Noise Challenge: Aircraft noise regarded most significant hindrance to National Airspace System [1] Image credit: NASA -Motivation- AIAA-ASM 2012 4
  • 5. Motivation: Reduce Fuel Burn Fuel Problem: In 2008 U.S. Commercial air burned 19.7 Billion Gallons + D.O.D. burned an additional 4.6 Billion Gallons 250,000,000… Tons of Carbon Dioxide (CO2) [1] Nitrogen Oxide (NOx) Reduce NOx Emissions: Goals Reduce Fuel Burn: 20% by 2015 33% by 2015 50% by 2020 50% by 2020 [1] [1] >50% beyond 2025 >70% beyond 2025 -Motivation- AIAA-ASM 2012 5
  • 6. Motivation: Blended Wing Body [2] Image credit: NASA -Motivation- AIAA-ASM 2012 6
  • 7. PurposeWHY HYPERION?• Society/ industry needs: – Aerodynamically & energy efficient aircraft Image credit: NASA – Prepare workforce in global environment• History: – Colorado students developed hybrid propulsion system – Boeing interest in follow-the–sun design process – AIAA-ASM Meeting January 2010, Orlando: o NASA: “Environmentally Responsible Aviation (ERA) Project”  Boeing X-48B prominently presented o Focus on aviation alternative fuels, fuel savings, reduced noise -Purpose- AIAA-ASM 2012
  • 8. Global Project Why a global project? • Global companies operate Design Bureaus around the world. – Opportunities to expedite design work on new systems – Opportunities made available by software and internet – Opportunities to harvest bright minds • Manufacturing dispersed in many countries – For Boeing’s Dreamliner, 28 suppliers are located outside USA • Wings produced in Japan • Ailerons produced in Australia • Fairings produced in Canada • Doors produced in France and Sweden • Final assembly in USA -Purpose- AIAA-ASM 2012 8
  • 9. G.B. Shaw said: “If you have an apple and I have an apple and we exchange apples then you and I will still each have an apple. But if you have an idea and I have an idea and we exchange these ideas, then each of us will have two ideas.” GBS AIAA-ASM 2012
  • 10. Global Team - Purpose - AIAA-ASM 2012 10
  • 11. Goals Boulder + Stuttgart + Sydney 1. Investigate new technologies for improved capabilities and efficiencies 2. Practice international collaboration in education Undergraduate CU Team 1. Conceive, design, build, and test a 2nd generation hybrid propulsion system to be integrated into the Hyperion Thank you to our sponsors! -Project Overview- AIAA-ASM 2012 11
  • 12. System Configuration • Aerodynamic design started by Sydney team See: AIAA-2012-0878 • Raked wingtips & vertical stabilizers designed by Stuttgart team • Management, electronics, internal structure design & systems integration by CU •Hybrid-Electric Engine to explore quiet take-off and landings, quiet loitering, and improved efficiencies (CONOPS dependent) -Project Overview- AIAA-ASM 2012 12
  • 13. Subsystem Design Aerodynamics Manufacturing Weights Materials/Structures Electronics -Technology Overview- AIAA-ASM 2012
  • 14. Schedule Flight Start PDR CDR Testing -Global Collaboration- AIAA-ASM 2012 14
  • 15. Aerodynamics & Structures ½ Scale Wind Tunnel Model Internal Structure Center Body/Integration Aerodynamic Validation Wing Integration/Assembly CFD Validation -Technology Overview- AIAA-ASM 2012 15
  • 16. Aerodynamic Analysis Aerodynamic Requirements: Aerodynamic testing was performed using L/D greater than 20 multiple methods Statically stable CFD Stall velocity less than 15 m/s 1/2 scale wind tunnel testing Span efficiency (e) greater than 0.8 Wing loading less than 15 kg/m² -Technology Overview- AIAA-ASM 2012 16
  • 17. Manufacturing: Center Body Project Goal and Objectives Distributed Manufacturing • Negative molds milled • Integration of internal from CAD-data structure from University • Fiberglass-foam-core skin of Colorado laminated by hand -Technology Overview- AIAA-ASM 2012 17
  • 18. Global Integration Manufacturing Delocalized manufacturing increases integration risk! Risk MitigationIDT (Interface Dimension Similar ideas used forTemplate) wing manufacturing • Device used to ensure German center body Winglet  Wing matches USA wings -Integration- AIAA-ASM 2012 18
  • 19. Global IntegrationNeed: Electronics integration into plane Problem: Plane center body in Germany!Imagecredit:NASA Cubesat Broken Down Flat Layout Electronics Solution “Flat Sat” Approach (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 -Global Collaboration- AIAA-ASM 2012 19
  • 20. FTS Example Colorado Team • Changes structure component • Does it meet Requirements? 8 Hours • What does this mean for manufacturing and aerodynamics? Sydney Team • Evaluates Structural Implications on Aerodynamic Design 8 Hours • Proposes design changes • Provides aerodynamic feedback 8 Hours Stuttgart Team • Evaluates Manufacturing implications on aerodynamic and structural designs • Proposes design changes • Provides manufacturing feedback -Global Collaboration- AIAA-ASM 2012
  • 21. Hybrid Gas-Electric Engine Project Goal and Objectives Objective: Design, build and test a hybrid propulsion system to be integrated into the aircraft Offset drive Coaxial drive No control system Multiple flight mode control Focus: Efficiency, proof of Focus: Reliability, operations concept See: AIAA-2012-0147 -Technology Overview- AIAA-ASM 2012 21
  • 22. TestingDynamically (1/2) Scaled Prototype • Test aircraft capability and characteristics. • Identify unforeseen problems. • Pilot familiarization • Test: Taxi, takeoff, cruise, land • Test: Mass sensitivity, cg • Test: International analysis of data -Technology Overview- AIAA-ASM 2012 22
  • 23. System Testing • Electric propulsion – Hybrid Engine fully bench tested, but not flight tested (maturity) • R/C Piloted – Successful takeoff, cruise, and landing Flight Test AIAA-ASM 2012 23
  • 24. FTS Collaboration ExperimentPain: Efficiency in Global Industry Collaborations: needs improvement Concept 3 Teams, distributed 8 hours apart relay work daily. Follow-the-Sun (FTS), produces 3 work-days in one 24 hour periodResults• Accelerated project design progress: o Complete design drawn in CATIA in 5 weeks o Conceived, designed, manufactured, and delivered aircraft to customer under budget and on time o Inception to Completion ~ 9 Months -Global Collaboration- AIAA-ASM 2012 24
  • 25. Best Practices IT Plan Systems Engineering Concept of Operations Operation Develop and define mission phases Verification and Validation Testing Project Requirements Determine verification method Integration and develop tests System Architecture Manufacturing Identify subsystem interfaces and risks Implement Project Detail IT Plan IT Plan Decomposition Time - Integration & Testing - 12 Internet Communication and Cloud File Sharing -Global Collaboration- AIAA-ASM 2012
  • 26. Lessons Learned Language and Cultural Barriers Although everyone speaks Englineerish…. Encodes/Writes Decodes/Misinterprets Message Message Decodes Message Encodes Counter Productive Feedback Cloud Noise Filter Can Cause: Message -Loss of Tone -Loss of Intent -Misinterpretation -Global Collaboration- AIAA-ASM 2012 26
  • 27. Lessons Learned Follow-the-Sun (FTS): • Great for CAD design work • Ideas across border • Dynamic positive synergy • Benefit of diversity in critical thinking • Helps mitigate risk through smaller team delegation • Difficult in academic environment due to schedules Follow-The-Week (FTW) • Suited for concept designs • Task assignments to small local teams • Finished tasks reviewed by global team • Weekly global team meetings. -Global Collaboration- AIAA-ASM 2012 27
  • 28. Lessons Learned • Project needs managerial infrastructure – Needs strong Project Manager – MBA candidate on team – Economics student on team • Understand international shipping requirements – ITAR – Understand international trade and regulations • Collaboration on “trust” and “respect” – Limited control over non-local teams’ efforts – Understand skills and capabilities of partners – Free sharing of information leads to IP issues • Planning – Extend the planning process significantly! – Better understand skills and capabilities of partners – Each partner should have own funding - Global Collaboration- AIAA-ASM 2012 28
  • 29. Conclusion• Successes: – Designed, built, and flew HYPERION in 9 months • Planning for 3 months • Design layout within 4 months • Aerodynamics and structures analysis using FTS • Controls system development • Delocalized manufacturing in 3 months • Under mass and finance budgets • Successful maiden flight AIAA-ASM 2012
  • 30. Current Development• Current Project Charter: – Design and Manufacturing shared by Stuttgart and Colorado – New wing design  From Flying Wing to Blended Wing Body – Autonomous Control System – FAA COA – Integrate hybrid propulsion system and flight test - Current - AIAA-ASM 2012 30
  • 31. AcknowledgementsA special thanks to… Skip Miller of Skip Miller Models Mike Kisska of Boeing James Mack of LASP (Pilot) Frank Doerner of Boeing Blaine Rawdon of Boeing Tom Hagen of Boeing Dr. Robert Liebeck of Boeing/USC Steven Yahata of Boeing Norman Princen of Boeing Diane Dimeff of eSpace Brian Taylor of NASA Joseph Tanner of CU Trent Yang of RASEI Dr. Donna Gerren of CU Prof. Eric Frew of CU Matt Rhode of CU Trudy Schwartz of CU Prof. Claus-Dieter Munz of Stuttgart Prof. Ewald Kraemer of Stuttgart Dr. KC Wong of Sydney Dr. Dries Verstraete of Sydney -Acknowledgements- AIAA-ASM 2012 31
  • 32. Student Global Team Derek Nasso Michael Johnson Julie Price Eric Kenney E r i c S e r a ni Jeremy Klammer Tom Wiley Lydia Mcdowell Richard Zhao Boris Papazov Kristen Brenner Taylor Petersen C o r r i na G i b s o n Robert Whitehill N a t h a n J a s t r am Michaela Cui Martin Arenz Kai Lehmkuehler Tyler Drake Holger Kurz M a t t he w A n d e r s o n A r t h ur K r e u t e r David Pfeiffer J o s hu a B a r n e s Gavin Kutil M a t t hi a s S e i t z Byron Wilson Brett Miller Baris Tunali Andrew McCloskey C o r e y P a c k a rd J o n a s S c h w e ng l e r M a r c u s R a h i m po ur Gauravdev Soin -Team- AIAA-ASM 2012 32
  • 33. Questions?Contact:
  • 34. Budget Sponsors - Budget- AIAA-ASM 2012 34