32-Student Global Team                                                                           Mikhail Kosyan           ...
Index Project Motivation and Goals System Configuration Hybrid-Electric Engine Aerodynamics and Structures Electronics and...
Motivation: Green AviationNASA’s goal:  • Reduce aircraft fuel consumption  • Reduce emissions  • Reduce noise            ...
Motivation: Reduce Noise     Noise Challenge            Aircraft noise regarded most significant                          ...
Motivation: Reduce Fuel Burn      Fuel Problem     In 2008            U.S. Commercial air burned 19.7 Billion Gallons     ...
Motivation: Blended Wing Body                                                            [2]                              ...
Motivation: Hybrid Technology Internal Combustion Engine                                                                  ...
Motivation: Follow-The-Sun  Need: Improved Efficiency in Global Industry Collaborations                                  C...
HYPERION Goal                        has 2 goals:  1. Conceive, design, implement, and operate (CDIO)     an aerial platfo...
System Configuration 6⁰ Canted, Raked WingtipsFiberglass Composite SkinCarbon Fiber/Foam CoreStructure                    ...
System Concept of Operations                       - System Configuration-              2011 Aerospace Engineering Design ...
Hybrid Gas-Electric Engine Project Goal and Objectives Objective Design, build and test a hybrid propulsion system to be i...
Project Requirements                   Mechanical/Structural                         Software               Power         ...
System Architecture                                                                                     Fuel              ...
System Operations    ICE Only                                Utilizes unique in-flight    – Cruise mode                   ...
Test PlanDynamometer testingMeasures system torque outputObtain power, RPM dataSatisfy Hyperion ConOpsThermal testingNot e...
Thermal Testing and Verification                                             ICE only for 10 min, then EM only for 10 min ...
Power Testing and Verification                                                                                            ...
Risk & Mitigation                                 Structural                      Comm         Failure                    ...
Primary System Validation      Mechanical                   Software/Control                     System Operational       ...
Aerodynamics & Structures    Aerodynamic Requirements                       Structures, propulsion, control are highly L/D...
Aerodynamics & Structures     Structural Requirements Safety factor greater than 1.5                                      ...
Aerodynamics & Structures ½ Scale Wind Tunnel Model              Internal Structure                 Center Body/Integratio...
Electronics & Control                                                 Ground Station      Legend                          ...
Electronics & Control                                    Flight Computer                Roll Rate                         ...
TestingDynamically (1/2) Scale ModelPrototypePurpose for ½ prototype testing:   • Test aircraft capability and     charact...
Global Integration Mitigation IDT (Interface Dimension Template)      • Device used to ensure German center body matches U...
Integration & Test                                                                29     Mission Operations Manual        ...
Budget                    - Lessons Learned-         2011 Aerospace Engineering Design Symposium   30
Lessons Learned Technical             Composite Manufacturing                  Planning ahead is key                  Prot...
Lessons Learned Operations          Language and Cultural Barriers                Although everyone speaks English…       ...
AcknowledgementsA special thanks to…       Mike Kisska of Boeing       Diane Dimeff of eSpace       Frank Doerner of Boein...
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Hyperion 1.0 symposium presentation 2011
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Hyperion 1.0 symposium presentation 2011

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presentation given at the AES Symposium in 2011

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Hyperion 1.0 symposium presentation 2011

  1. 1. 32-Student Global Team Mikhail Kosyan Derek Nasso Julie Price Eric Serani Tom Wiley Richard Zhao M i c ha e la C ui M a rt i n A r e nz K a i L e hm k uehl e r Tyl e r Dr a k e H ol g e r K ur z M a t t he w A nd e rso n A rt hur K r e ut er D a v i d Pf e i f f e r J os hua Ba r ne s G a v i n K ut i l M a t t hi a s S e i t z B yron W i l s o n B re t t M i l l e r B a ri s T una l i A nd rew Mc C l o s key Corey Pa c k a r d J ona s S c hw e ngl e r M a rc us R a hi m p o ur G a ura v d ev S o i n 2011 Aerospace Engineering Design Symposium
  2. 2. Index Project Motivation and Goals System Configuration Hybrid-Electric Engine Aerodynamics and Structures Electronics and Control Integration & Test Lessons Learned - Index- 2011 Aerospace Engineering Design Symposium 3
  3. 3. Motivation: Green AviationNASA’s goal: • Reduce aircraft fuel consumption • Reduce emissions • Reduce noise …Simultaneously! 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] Motivation 2011 Aerospace Engineering Design Symposium 4
  4. 4. Motivation: Reduce Noise Noise Challenge Aircraft noise regarded most significant [1] hindrance to National Airspace System Goal Develop Aircraft technology and airspace system operations to shrink the nuisance noise footprint to [1] the airport boundary Image credit: NASA Motivation 2011 Aerospace Engineering Design Symposium 5
  5. 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] Harmful Nitrogen Oxide Emissions (NOx) Reduce NOx Emissions: Goal Reduce Fuel Burn: 20% by 2015 33% by 2015 50% by 2020 50% by 2020 [1] [1] >50% beyond 2025 >70% beyond 2025 Motivation 2011 Aerospace Engineering Design Symposium 6
  6. 6. Motivation: Blended Wing Body [2] Motivation 2011 Aerospace Engineering Design Symposium 7
  7. 7. Motivation: Hybrid Technology Internal Combustion Engine Electric Motor Patent Pending Hybrid Gearbox Features • Twin Engine Safety • Efficiency Optimization • Variable Optimization • Modular Configurations Motivation 2011 Aerospace Engineering Design Symposium 8
  8. 8. Motivation: Follow-The-Sun Need: Improved Efficiency in Global Industry Collaborations Concept3 Teams… Distributed 8 hours apart… Relay work daily … Following the Sun Result: 3 work-days in one 24 hour period [3] Motivation 2011 Aerospace Engineering Design Symposium 9
  9. 9. HYPERION Goal has 2 goals: 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 Goal 2011 Aerospace Engineering Design Symposium 10
  10. 10. System Configuration 6⁰ Canted, Raked WingtipsFiberglass Composite SkinCarbon Fiber/Foam CoreStructure Tricycle Landing Gear Hybrid-Electric Engine - System Configuration- 2011 Aerospace Engineering Design Symposium 11
  11. 11. System Concept of Operations - System Configuration- 2011 Aerospace Engineering Design Symposium 12
  12. 12. Hybrid Gas-Electric Engine Project Goal and Objectives Objective Design, build and test a hybrid propulsion system to be integrated into the Hyperion blended wing-body aircraft Offset drive Coaxial drive No control system Multiple flight mode control Focus: Efficiency, proof of Focus: Reliability, operations concept - Hybrid Electric Engine- 2011 Aerospace Engineering Design Symposium 13
  13. 13. Project Requirements Mechanical/Structural Software Power Multiple Project Thermal output flight modes 4 hp at Temperature Alternate System Constraints ICE & EM propeller 2 hp from ICE Skin temperature LabView & Subsystem and 2 hp from EM below 60oC Matlab -Hybrid-Electric Engine- 2011 Aerospace Engineering Design Symposium 14
  14. 14. System Architecture Fuel Internal CombustionTransmitter Receiver Engine User Control Batteries Controls System Electric Motor LiPo & Gearbox Batteries EM EM Gearbox Propeller Throttle ICE ICE Connections Throttle Physical: Remote Data: Start Fuel Power: -Hybrid-Electric Engine- 2011 Aerospace Engineering Design Symposium 15
  15. 15. System Operations ICE Only Utilizes unique in-flight – Cruise mode remote restart EM Only technology – Quiet and Landing modes Combination – Takeoff, Climb and Dash modes -Hybrid-Electric Engine- 2011 Aerospace Engineering Design Symposium 16
  16. 16. Test PlanDynamometer testingMeasures system torque outputObtain power, RPM dataSatisfy Hyperion ConOpsThermal testingNot exceed fiberglass softening pointSystem fully enclosed for worst casescenario Test Like You Fly -Hybrid-Electric Engine- 2011 Aerospace Engineering Design Symposium 17
  17. 17. Thermal Testing and Verification ICE only for 10 min, then EM only for 10 min 35 ICE ICE Heat Sink = Greatest Thermal EM 30 Output Side Wall GearboxAmbient Temperature [C] 25 ESC Upper surface remains Upper Wall Surface below required 60oC 20 15 Gearbox reaches steady state 10 Propeller wash about box from 5 EM to rapidly cool cavity ICE Only EM Only 0 0 2 4 6 8 10 12 14 16 18 20 Time [min] The ConOps requirements are verified Passive air cooling is required for safe engine operation -Hybrid-Electric Engine- 2011 Aerospace Engineering Design Symposium 18
  18. 18. Power Testing and Verification  Power/RPM linear EM/GB Power [HP] versus RPM after Modifications 1 function obtained – EM 0.9 Data 85% efficient polyfit 0.8  Power requirement of 2EM/Gearbox Output Power [HP] 0.7 hp verified at 7000 RPM 0.6  Dynamometer test setup 0.5 inadequate 0.4  Force transducer 0.3 inaccurate due to 0.2 vibrations 0.1 0 1500 2000 2500 3000 3500 4000 RPM -Hybrid-Electric Engine- 2011 Aerospace Engineering Design Symposium 19
  19. 19. Risk & Mitigation Structural Comm Failure Failure from Vibrations Failure to Failure to Structural Hyperion Hyperion Interface Interface Failure Thermal Thermal Engine Engine from Integration Integration Control Control Vibrations Consequence Consequence Failure of Failure of Starting ICE Starting ICE Comm Aircraft Aircraft Remotely Remotely Failure Delivery Delivery Possibility Possibility Major Tall Poles Mitigation  ICE remote starting system  Utilized modified COTS system  Overheating aircraft skin  Analytical modeling, redundant  Structural vibrations testing  Precise machining; design modifications -Hybrid-Electric Engine- 2011 Aerospace Engineering Design Symposium 20
  20. 20. Primary System Validation Mechanical Software/Control System Operational Operational reliability Engine/Aircraft Control Logic through endurance Integration Interface with sbRIO testing ICE & EM produce 2 hp Operational engine each (4 hp total) control logic Independent & Concurrent Engine Stretch Goal: Operations Flight Testing -Hybrid-Electric Engine- 2011 Aerospace Engineering Design Symposium 21
  21. 21. Aerodynamics & Structures Aerodynamic Requirements Structures, propulsion, control are highly L/D greater than 20 dependent on aerodynamic shape Statically stable Design locked at PDR Stall velocity less than 15 m/s Span efficiency (e) greater than 0.8 Wing loading less than 15 kg/m² Design Alternatives Geometry Wing Endings 3.0 m wing span Raked Wing Tips 1.25 m max chord Rudders Airfoils H-Tail Body-S5016 Wing-S5010 - Aerodynamics & Structures- 2011 Aerospace Engineering Design Symposium 22
  22. 22. Aerodynamics & Structures Structural Requirements Safety factor greater than 1.5 Design at CDR Structure weight less than 10.0kg (22.0 lbs) Engine and wings to be modular Initial Design at PDR • With aero shape locked, able to complete detailed design • Worked closely with Boeing engineers • Added shear device• Two spar design• Main spar designed to withstand entire load - Aerodynamics & Structures- 2011 Aerospace Engineering Design Symposium 23
  23. 23. Aerodynamics & Structures ½ Scale Wind Tunnel Model Internal Structure Center Body/Integration Aerodynamic Validation Wing Integration/Assembly CFD Validation - Aerodynamics and Structures- 2011 Aerospace Engineering Design Symposium 24
  24. 24. Electronics & Control Ground Station Legend Human Pilot Radio Controller Power Signal Data Receiver Laptop PC Video Receiver Video Monitor Aircraft Data Acquisition System Control System GPS Data Transmitter Flight Computer Radio Receiver Power Supply Data Logger Flight Computer Propulsion Sensors Pitot Tube Servos Flight Computer First Person Vision System Sensors Control Surface OSD Overlay Video Transmitter Main Electronics Power Supply Camera - Electronics & Control- 2011 Aerospace Engineering Design Symposium 25
  25. 25. Electronics & Control Flight Computer Roll Rate Aileron Deflection Commands Pitch Rate Elevator Deflection PWM SignalsReceived from to Servos Pilot Yaw Rate Rudder Deflection [1] 3-Axis IMU Alpha/ Beta Probe Roll Rate AoA Pitch Rate Sideslip Angle Yaw Rate [2] [3] - Electronics & Control- Photo Credit: [1]National Instruments [2]Memsense [3]RCATS 2011 Aerospace Engineering Design Symposium 26
  26. 26. TestingDynamically (1/2) Scale ModelPrototypePurpose for ½ prototype testing: • Test aircraft capability and characteristics. • Identify unforeseen problems. • Pilot familiarization • Test: Taxi, takeoff, cruise, land • Test: Mass sensitivity, cg Moving Test-Bed • Test flight power system • Test landing gear stability - Integration & Testing- 2011 Aerospace Engineering Design Symposium 27
  27. 27. Global Integration Mitigation IDT (Interface Dimension Template) • Device used to ensure German center body matches USA wingsFlat 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 28
  28. 28. Integration & Test 29 Mission Operations Manual - Integration & Testing- 2011 Aerospace Engineering Design Symposium
  29. 29. Budget - Lessons Learned- 2011 Aerospace Engineering Design Symposium 30
  30. 30. 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 - Lessons Learned- 2011 Aerospace Engineering Design Symposium 31
  31. 31. Lessons Learned Operations 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 - Lessons Learned- 2011 Aerospace Engineering Design Symposium 32
  32. 32. AcknowledgementsA 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 -Acknowledgements- 2011 Aerospace Engineering Design Symposium 33
  33. 33. Questions?

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