2.evtol-Course Conceptual-Design Johnsonsilva May2018
2.evtol-Course Conceptual-Design Johnsonsilva May2018
Wayne Johnson
Christopher Silva
• Conceptual design
– Define aircraft to perform required mission
• Identify aircraft type, including propulsion system
• Size components and subsystems (weight, power, energy)
– Component design and optimization
• Estimate performance and cost
– Emphasis on breadth and speed of analysis
– Followed by preliminary design and detailed design
May 2018 2
Outline
• Introduction
• Design Tools
• NDARC – Conceptual Design Code
• Propulsion Systems
• Control, Trim, Power, Size
• Interesting and Important Factors
– Weights
– Performance, Loads, Structures
– Propulsion
• Sizing
• Requirements
• Design Metrics
May 2018 3
Conceptual Design Approaches
May 2018 4
NASA RVLT Conceptual Design Tool Suite
• Tool suite geared to design space
exploration and optimization
• https://software.nasa.gov
– NDARC: Design
– RCOTools: OpenMDAO
– ANOPP/ANOPP2: Noise
– NPSS (special access): Engines
• SIMPLI-FLYD: Handling qual/control
• CAMRAD II (Johnson): Aeromechanics
• IXGEN (M4): Blade stiffness
• OpenMDAO: Execute jobs, optimize
• OpenVSP: Initial geometry
– Rhino (McNeel): Final geometry
• Needs: Structures, Transient Thermal,
Cost/economics
May 2018 5
NASA Concept Vehicles for Air Taxi Operations
May 2018 6
Outline
• Introduction
• Design Tools
• NDARC – Conceptual Design Code
• Propulsion Systems
• Control, Trim, Power, Size
• Interesting and Important Factors
– Weights
– Performance, Loads, Structures
– Propulsion
• Sizing
• Requirements
• Design Metrics
May 2018 7
NDARC — NASA Design and Analysis of Rotorcraft
May 2018 9
NDARC Components to Construct Aircraft
Critical to achieving capability to model wide array of rotorcraft concepts is
decomposition of aircraft into set of fundamental components
rotors,
propellers,
ducted fans
connects
energy source:
rotating
burned,
components
renewed,
turbojet, turboshaft, fuel cell, or stored
turbofan, motor, solar cell
reaction drive generator,
May 2018 10
compressor
Digression on Language — NDARC terms
May 2018 12
Lots of Rotors
May 2018 13
Rotors and Wings
May 2018 14
Aircraft without Rotors
May 2018 15
Tilting and Swiveling and Stopping Things
May 2018 16
Outline
• Introduction
• Design Tools
• NDARC – Conceptual Design Code
• Propulsion Systems
• Control, Trim, Power, Size
• Interesting and Important Factors
– Weights
– Performance, Loads, Structures
– Propulsion
• Sizing
• Requirements
• Design Metrics
May 2018 17
Propulsion Architecture
• Turboshaft propulsion
– Mechanical drive train, connecting
engine groups and rotors
– Engine group, consisting of one or
more turboshaft engines
– Fuel tank system
• Weight changes as fuel used, fuel
is measured in weight
Mechanical Power
May 2018
Fuel or Energy 18
NDARC Propulsion — Turboshaft
May 2018 19
Reciprocating Engine
May 2018 20
Turbojet / Turbofan
May 2018 21
Fuel Cell
May 2018 22
Solar Cell
May 2018 23
Electric Motor
May 2018 24
Hybrid
May 2018 25
Turbo-Electric
May 2018 26
Outline
• Introduction
• Design Tools
• NDARC – Conceptual Design Code
• Propulsion Systems
• Control, Trim, Power, Size
• Interesting and Important Factors
– Weights
– Performance, Loads, Structures
– Propulsion
• Sizing
• Requirements
• Design Metrics
May 2018 27
Control, Trim, Power, Size
May 2018 28
Control, Trim, Power, Size
• Tiltrotor aircraft
– Control: two or more modes of operation
• Airplane mode: 4 pilot’s controls connected rotor collective, elevator,
aileron, rudder
May 2018 29
Aircraft Trim and Control
May 2018 30
Control with Many Lifting Rotors
• Control methods
– Collective pitch control
• Rotor speed fixed in flight state; can vary rotor speed for
performance optimization
• Actuator bandwidth sufficient for maneuvering and gust
alleviation
• Many options for drive train architecture
– Rotor speed control
• Rotor blade pitch fixed, no swashplate or pitch bearing
(collective change needed if tilt rotors)
• Independent rotor+motor subsystems
May 2018 31
Control, Trim, Power Required, Engine Size
May 2018 32
Control, Trim, Power, Size
May 2018 33
Control, Trim, Power, Size
• Turbo-electric propulsion
– Trim: add generator power = motor power
required
• Adjust generator power so zero energy flow
through battery
– Power required: turboshaft power =
generator power + trans loss + accessory
• Possibly direct drive
– Power required: motor power = rotor
power + trans loss + accessory
– Engine and Motor Size: power =
maximum required over all conditions
– Battery size: maximum energy required
over all missions
• Possibly no battery, just energy distribution
• Possibly turboshaft/generator out condition
(very large discharge rate)
May 2018 34
Outline
• Introduction
• Design Tools
• NDARC – Conceptual Design Code
• Propulsion Systems
• Control, Trim, Power, Size
• Interesting and Important Factors
– Weights
– Performance, Loads, Structures
– Propulsion
• Sizing
• Requirements
• Design Metrics
May 2018 35
Weights
May 2018 37
Parametric Component Weights
fuselage length and main rotor radius
• Aggregate accuracy ±5%
– Based on flying aircraft designed
for safe, cost-effective operation
• Domain of weights data base
disk loading
• Component weights:
– parametric weight model, with technology factor χ, plus input
increment
May 2018 39
Weight Technology Factors
• Tech factors at least account for Technology Factors for NASA Concept Designs
advanced materials and design rotor flight control
boosted controls 0.46 (0.30 coll only)
methods actuators 0.71 (0.50 coll only)
non-boosted controls 1.10 (0.90 coll only)
– sometimes >1 because of new fuselage
basic 0.76
requirements (e.g. fatigue life) crashworthiness 0.90
crash weight 6-15% basic
landing gear
basic 1.00
crash weight 15% basic
rotor
blade 0.92
hub 0.76
• To develop research targets, or propeller 1.40
show benefits of advanced fuel tank
tank 0.84
technology plumbing
drive system
0.66
May 2018 40
Contingency Weights
May 2018 41
Systems and Equipment
• Resources
– Equipment weights of existing aircraft
– New technology developments
• Introduction
• Design Tools
• NDARC – Conceptual Design Code
• Propulsion Systems
• Control, Trim, Power, Size
• Interesting and Important Factors
– Weights
– Performance, Loads, Structures
– Propulsion
• Sizing
• Requirements
• Design Metrics
May 2018 43
Performance
• Electric propulsion enabled by aerodynamic efficiency of the
aircraft, in both hover and cruise
• Aircraft optimization
– Disk loading: minimize aircraft weight,
power, energy
• Small aircraft with edgewise rotors optimize with low disk loading
May 2018 44
Rotor-Rotor Interactions
May 2018 45
Rotor-Rotor interactions
• The rotors act like a single wing, and induced drag varies as (W/btot)2
• You need analysis which captures wake interactions and aircraft system
effects to make the right design choices
– Outboard advancing is quite a bit better than outboard retreating
– Twist trades between hover and forward flight need system effects
– The supports/wings are sources of drag and weight, and maybe lift
Outboard retreating
Peak L/De ~ 9.4
Outboard advancing
Peak L/De ~ 10.5
Peak b/D ~ 0.85-0.9
January 2018 46
Performance — Aircraft Optimization
• Interesting trim characteristics of multi-rotor aircraft: collective control or
rotor speed control
May 2018 47
Rotor Design
• Example — Quadrotor
– Flapping rotor
• 4% hinge offset, with 45 deg pitch-flap coupling to minimize flapping relative shaft
– Hingeless rotor (more like a classic propeller)
• Higher blade and hub loads => higher rotor weight, larger weight for vibration control
• Resulting aircraft has 25% larger design gross weight
May 2018 48
Rotor Design Loads
May 2018 49
Outline
• Introduction
• Design Tools
• NDARC – Conceptual Design Code
• Propulsion Systems
• Control, Trim, Power, Size
• Interesting and Important Factors
– Weights
– Performance, Loads, Structures
– Propulsion
• Sizing
• Requirements
• Design Metrics
May 2018 50
Electric Motors
May 2018 51
Drives
• High speed motor + transmission almost always lighter than direct drive
• With weights of motor+trans based on parametric equations:
disk loading = 4
tip speed = 550
• Direct drive: requires light weight, low speed, high torque motor
– Operating with large mean and oscillatory loads from rotor on shaft
May 2018 52
Number of Rotors
weight = 5000
disk loading = 4
tip speed = 550
CT/σ = 0.10
flap freq = 1.25
effi
c
red iency
uct
(in ion
res terna
ista l
nce
)
capacity
reduction
May 2018 55
Impact of Battery Technology
• Need light-weight, high-power batteries
• Baseline designs: battery installed & useable specific energy = 400 Wh/kg
• State-of-the-art = 100-150 Wh/kg installed & useable
electric quadrotor
hybrid side-by-side
fuel
battery
payload
ba
tte
ry
operating weight
payload
operating weight
May 2018 56
Hover Discharge Current
need high discharge
current capability
electric side-by-side
current: I = xC
• Introduction
• Design Tools
• NDARC – Conceptual Design Code
• Propulsion Systems
• Control, Trim, Power, Size
• Interesting and Important Factors
– Weights
– Performance, Loads, Structures
– Propulsion
• Sizing
• Requirements
• Design Metrics
May 2018 58
Sizing
May 2018 59
Outline
• Introduction
• Design Tools
• NDARC – Conceptual Design Code
• Propulsion Systems
• Control, Trim, Power, Size
• Interesting and Important Factors
– Weights
– Performance, Loads, Structures
– Propulsion
• Sizing
• Requirements
• Design Metrics
May 2018 60
Design Missions and Conditions
• Flight conditions
– MTOW, SDGW, VROC, Vmax or Vcruise
– Motor failure(s) (determine control, trim, thrust, power)
May 2018 61
Simple Mission
Reserves
20 min @ VBE
or 10% Fuel
Altitude
Cruise @ VBR
5k/ISA+20oC Mission 1
Takeoff Landing
HOGE HOGE
2 min 2 min
SL/ISA+20oC Mission 2
Range
0 X nm
May 2018 62
Urban Air Mobility Mission
• Airworthiness approval means a document, issued by the FAA for an aircraft, which
certifies that the aircraft conforms to its approved design and is in a condition for
safe operation (14 CFR 21.1(b)(2))
• Crashworthiness
– Affects design of airframe structure, landing gear, passenger accommodation
and restraint
– Conceptual design: need impact on weights
May 2018 64
Outline
• Introduction
• Design Tools
• NDARC – Conceptual Design Code
• Propulsion Systems
• Control, Trim, Power, Size
• Interesting and Important Factors
– Weights
– Performance, Loads, Structures
– Propulsion
• Sizing
• Requirements
• Design Metrics
May 2018 65
Design Metrics
• Feasibility of concept
– Sensitivity to requirements and technology
• Weight, power, energy
– Principal drivers of cost
– Feasibility may require meeting threshold values
• Hover lb/hp, cruise L/De, battery C-rate
• Cost
– Development, purchase, maintenance, operating costs
• Emissions
– Accounting for grid emissions may be necessary
• Noise and annoyance
– FAA Depart, Flyover, Descent (dB)
– Annoyance is subject of active research with human subjects
• Passenger acceptance
– Vibration, handling qualities
May 2018 66
Feasibility of Concept
May 2018 67
Operational Effectiveness — Cost
fuel/energy cost flying design mission
• Purchase price
– Approximately (± 20% accuracy) driven by quadrotor
• Maintenance cost
– Data available for helicopter flying traditional
missions
– But not for unconventional aircraft, in air taxi
operations, with to-be-established side-by-side
maintenance concept
• Operating costs
– Fuel or energy is significant component
– Battery replacement costs important
May 2018 68
Noise and Annoyance
May 2018 70
References — NDARC
NDARC Development
Johnson, W. "NDARC. NASA Design and Analysis of Rotorcraft." NASA TP 2009-215402, December 2009; NASA TP 2015-218751, April 2015.
Johnson, W. "NDARC - NASA Design and Analysis of Rotorcraft. Theoretical Basis and Architecture." American Helicopter Society Specialists'
Conference on Aeromechanics, San Francisco, CA, January 2010.
Johnson, W. "NDARC - NASA Design and Analysis of Rotorcraft. Validation and Demonstration." American Helicopter Society Specialists' Conference
on Aeromechanics, San Francisco, CA, January 2010.
Johnson, W. "Propulsion System Models for Rotorcraft Conceptual Design." American Helicopter Society 5th Decennial Aeromechanics Specialists'
Conference, San Francisco, CA, January 2014.
Russell, C., and Johnson, W. "Application of Climate Impact Metrics to Civil Tiltrotor Design." AIAA Paper No. 2013-1087, January 2013.
Design Environment
Sinsay, J.D.; Hadka, D.M.; and Lego, S.E. "An Integrated Design Environment for NDARC." American Helicopter Society Specialists' Conference on
Aeromechanics Design for Vertical Lift, San Francisco, CA, January 2016.
Meyn, L.A. "Rotorcraft Optimization Tools: Incorporating Rotorcraft Design codes into Multi-Disciplinary Design, Analysis, and Optimization." American
Helicopter Society Technical Conference on Aeromechanics Design for Transformative Vertical Flight, San Francisco, CA, January 2018.
May 2018 71
References — NDARC
Electric Propulsion
Snyder, C.A. "Exploring Propoulsion System Requirements for More and All-Electric Helicopters." International Symposium on Air Breathing Engines,
Phoenix, AZ, October 2015.
Snyder, C.A. "Personal Rotorcraft Design and Performance with Electric Hybridization." American Helicopter Society 73rd Annual Forum, Fort Worth,
TX, May 2017.
May 2018 72
References — eVTOL Aircraft
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May 2018 73
References — eVTOL Aircraft
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