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Electric VTOL Aircraft

Subscale Prototyping Overview

Francesco Giannini
fgiannini@aurora.aero
1 08 June 8th, 2017 ©2017 AURORA FLIGHT SCIENCES
Contents

• Intro to Aurora
• Motivation & approach for the full-scale vehicle
• Technical challenges
• Design and building the subscale models
• Lessons learned

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Aurora has been developing autonomous
aircraft systems for 28 years
ELECTRIC AIRFRAME
AUTONOMY AURORA BY THE NUMBERS
PROPULSION DESIGN
Heritage Locations

28 8
Years in Business Worldwide

UAS Design Hours

30+ 80
Built and Flown Endurance Record

Patents Feet

100+ 103K
Issued & Pending Highest Altitude Flown

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Three principles used in concept design

LARGE NUMBER OF USE THREE DESIGN PRINCIPLES


REQUIREMENTS TO CONSIDER

1 Keep it simple

2 Design for efficient cruise

3 Base design on existing


technology

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Detailed Concept Modelling and Selection

Traditional and novel promising


configurations were modeled and analyzed
before selecting a lift + cruise configuration

https://vertipedia.vtol.org/vstol/wheel.htm
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Aurora – BCG DV concept:
All-Electric VTOL Aircraft Design

Optionally piloted – can be flown


fully autonomously or piloted Takeoff noise comparable
to road traffic Inaudible in
cruise flight

Eliminates mechanical complexity –


Direct drive, fixed pitch rotors/prop

No safety critical
single points of failure

Light-weight, rigid structure >3x as efficient as a


avoids induced vibrations multi-copter in cruise
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Video at: https://www.youtube.com/watch?v=BSFVvhQP7ws&t=6s

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Design challenges: Need to look out for negative wing-
rotor interactions during transition
HOVER TRANSITION
Rotor lift Rotor lift
(reduced due to wing
interaction)
Wing
lift

v Download
from rotor
wash

• As aircraft gains forward speed,


rotor wash impinges on the wing to
create a download
• Rotor-wing interaction reduces lift
generated by the rotor, requiring
Rotors placed so that
rotor wash does not
rotor to increase power output
impinge on the wing

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Three main test objectives for the sub-scale model
Limited experience in industry with low disc loading vs. high wing loading design.
Need to verify rotor-wing interactions are manageable.

Prove that configuration is able to


1
perform the full mission

Verify power consumption and


2 controllability throughout mission is as
expected, particularly transition

Determine suitable sequence of reducing


3 rotor thrust to support low-power
transitions

Furthermore, flight testing helps us identify any unknown “unknowns” early

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Sizing the Subscale Vehicle
For data obtained from scale-model to be representative of full-scale
aircraft, need to observe “similitude requirements” and scaling
relationships for both the aircraft and test conditions:
Full-scale Sub-scale
Scale Factor
Linear dimension n 1/4 span = 8 m span = 2 m
Relative density (m/ρl3 ) 1
Froude number (V2 /lg) 1
Angle of attack 1
Linear acceleration 1
Weight, mass n^3 /σ (1/4)^3 = 1/64 M = 800 kg M = 12.5 kg
Moment of inertia n^5 /σ
Linear velocity n^1/2 (1/4)^(1/2) = 1/2 v = 180 km/h v = 90 km/h
Angular velocity 1/ (n^1/2)
Time n^1/2
Reynolds number (Vl/ν) n^1.5 * (ν/ν0)

Note: For rigid, free-flight models where compressibility and Mach number effects not of concern

Chambers, J. Modeling Flight: The Role of Dynamically Scaled Free-Flight Models in Support of NASA’s
Aerospace Programs NASA SP 2009-575

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Subscale Vehicle Design
2.0 m

2.0 m

Mass, kg 12.5
Span, m 2.0
Rotor diameter, cm 35.5
Cruise prop diameter, cm 30.5
Cruise motor, max, kW 2.0
Lift motors (max/cont), W 600/300
Max Speed, km/h 90
Hover time, min. 7.0

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10% subscale design

• The aerodynamics of the three-


lifting surface configuration were
analyzed using a Vortex-lattice
method.

• However, much uncertainty


remained regarding the extent of
the de-stabilizing effect of the
fuselage, as well as the desired cg
location

• A 10% scale model was built and


flown with and without the
fuselage, providing useful
information on cg position and
desired engine thrust line

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Subscale Materials and Construction
Flying surfaces : CNC Foam Electronics: COTS RC batteries, servos , motors, propellers,
core/balsa skin/Ultracote ESCs, autopilot boards and software, computer for
telemetry and logging

COTS carbon tube

COTS RC landing gear

100+ 3D printed parts


(High Temperature PLA with carbon fiber fill)

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Lessons Learned
• A properly-sized subscale model is a very good
development tool
• Brings to light “unknown unknowns”
• Even very small subscale models can represent
substantial “bang for the buck” value
• Adjustable features on the model prevent time-
consuming rebuilds
• Have high-def video of all flights for post-flight review
• Size controllers, motors, servos, with ample margin
• Next-day shipping and in-house AM capability
compressed our schedule

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Questions?

15

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