AIAA-ASM 2013 Hyperion 2.1 Green Aircraft Project

AIAA-ASM 2013

Hyperion 2.1 Green Aircraft Project Jean Koster and Weston Willits

University of Colorado at Boulder

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Agenda

Hyperion 2012-13

Goals and Team

Manufacturing and FEA

Experiments / Results

System Configuration & Design

Hyperion Goal

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Conceive, design, implement, and operate (CDIO) an aerial vehicle for engineering academic experience. Investigate novel green technologies for improvements in aircraft capabilities and efficiencies.

Goal:

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Project Progress

Hyperion 2012-13

• AIAA-ASM 2011; Design of a Hybrid Propulsion System for Aircraft.

•The HYPERION 2 Green Aircraft Project

• HYPERION UAV: An International Collaboration

• ASME-IMECE 2011; Design of a Blended Wing Body UAS with Hybrid Propulsion

• ASME-IMECE 2011; Work Force Development for Global Aircraft Design

• AIAA- ASM 2012: SOLSTICE

See: AIAA-2012-1223

See: ASME-IMECE2011-62126

See: ASME-IMECE2011-62273

See: AIAA-2011-1011

See: AIAA-2012-0147 -1st Place at AIAA Region V Student Competition 2011

See: AIAA-2012-0878

Hyperion 2.1 Deliverables

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Studies and Deliverables:

Fly R/C with COTS EM

Fly R/C with Hybrid gas-electric Engine

Fly Autonomously with COTS EM

Stretch Goal - Fly Autonomously with Hybrid Engine

Collect efficiency data & analyze efficiency

Customer Dr. Koster

Inst. & Sci. Greg

PM Corrina

Testing Andrew G.

Zach Sys. E Gaurav

Adil O.

Prop. Pierce

GNC Kristen Haynes

Wings Wes

Hybrid Control

Ben

CAD Vibin

Prototypes Gaurav

R&D and CFD

Adil A.

EE Zach

V&V Corrina

Gaurav Adil O. Zach

Alex E. Alex N.

Ben Corrina

Adil A. Andrew G.

Vibin Alex E. Sean Casey

Gaurav Zach Kristen Zach

Haynes Andrew G

Casey

Raj Casey Adil A.

“Stuttgart”

Greg

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Hyperion 2.1 Team Flow Down

Hyperion 2012-13

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Agenda

Hyperion 2012-13

Goals and Team




System Configuration

Hybrid-Electric Engine

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BWB Carbon Fiber / Composite

Structure

Integrated Control System

𝑪𝑳𝒎𝒂𝒙 ~1

𝑳/𝑫𝒎𝒂𝒙 ~18

𝑽𝒔𝒕𝒂𝒍𝒍 13.2 m/s (29.5 mph)

𝑽𝑻𝑶 15.8 m/s (35.4 mph)

𝑽𝑪𝑹 30 m/s (67 mph)

𝑺 1.693 m2 (18.22 ft2)

𝒃 3.2 m (10.5 ft.)

𝑾 16 kg (35 lb)

𝑾/𝑺 9.45 kg/m2

ΛLE 35°

Aerodynamics

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Lift Distribution of Hyperion 2.1. Solid Line represents the lift per unit span. Dashed Line represents local lift coefficient CL.

Design demonstrates the key characteristics of a blended wing body in its lift distribution

S-5010 airfoils for the wings S-5016 airfoil for center body

2012 AIAA-ASM Nashville, TN 10

International Collaboration

-Technology Overview-

½ Scale Wind Tunnel Model Internal Structure Center Body/Integration

Aerodynamic Validation

CFD Validation

Wing Integration/Assembly

AIAA 2012-1223

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Agenda

Hyperion 2012-13

Goals and Team




Structures Overview

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Structure design based on minimizing aircraft weight

Composite center-body manufactured at Univ. of Stuttgart, Germany

Carbon Fiber wings manufactured in Boulder, CO

Internal support structure manufactured from composite materials

External Wing Molds made in 3D printer at EBS Carbon Inc. Internal Structure of center-body; Shipped to

Germany for composite skin layup

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Analysis of critical ribs

Structural Analysis of Critical Ribs

Rib 5 Rib 2

Why rib 2 and rib 5 ? • Our main concern –

structural stability the holes

1. Critical location of the holes

2. Holes are very close to the tip

3. Holes are very close to each other

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Wings WBS

Flight Ready Wings

Wing-tip design &

CAD

Wing-tip Manufacture

Wing-tip Foam &

Integration

Electronic and Pitot

holes

Control Surface

Fabrication

Trapdoors for access

Epoxy Internal Structure to

Skin

Control Surface

Integration

Center body Bracket Design Fabrication &

Integration

Vibin, Adil, Wes & Andrew G

Alex

Andrew G & Wes

Haynes

Zach

Zach, Greg & Andrew G

Vibin, Andrew G, Wes, Adil

Wes & Andrew G

Wes & Andrew G

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Wing Manufacturing

Hyperion 2012-13

The wings were manufactured in two sections

The internal structure • consists of carbon fiber spars & ribs and aluminum brackets

The external skin

• a distinct manufacturing process resulting in a carbon fiber shell

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Manufacturing – External Structure

Hyperion 2012-13

Wing Dissection Small pieces for 3D printer

3D Print Arrangement of pieces inside 3D printer

Mold Pieces 3D printer output Digital Cardboard layout for mold

integration

Stepwise procedure for 4 negative molds

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Hyperion 2012-13

• 24 pieces for each cradle • dxf file implemented into cutting

table software • Modified fabric cutting machine

Mold Layup Connecting mold pieces together

Cutting cardboard cradle

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Hyperion 2012-13

Plaster the mold with an inch thick layer of glue

Reinforcing with steel bars

• Steel sealed with mold strips of fiber glass

• Molds removed from cardboard cradle

• Resin applied to part side • Molds baked at 150°F for 6 hours

at atmospheric pressure

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Hyperion 2012-13

Sanding to level out surface

Repeated spraying/sanding to improve surface finish Buffing to obtain required surface

finish

Spraying part surface with mixture Duratec(100%)/MEKP(2%)/Acetone(25%)

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Hyperion 2012-13

Molds Ready for Carbon Fiber layup

Wing Molds Top and Bottom wing halves ready for vacuum sealing

Autoclave High temperature and pressure cures carbon fiber

Vacuum bagging & sealing the molds

• Curing done at 255 ̊F for 4 hours • Vacuum maintained inside airtight bags at -25 psi

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Hyperion 2012-13

Removed cooled carbon fiber wings from molds Cut out control surfaces, trap doors for

servo access and trimmed to exact wing dimensions

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Manufacturing – Internal Structure

Hyperion 2012-13

• Internal structure for each wing consists of: • 4 ribs and 1 wing-tip bracket • 1 C-spar consisting of 3 components • 2 servo mounts per wing • 2 center body integration brackets

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Hyperion 2012-13

Mastercam Mill software used to map components

Materials • Carbon fiber C70-40 Airex

foam core (Dragonplate) • 3M Scotch-Weld Epoxy

Adhesive 2216 Gray

CNC Processing to cut out each component

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Hyperion 2012-13

Epoxy of initial components

Wing-tip bracket must integrate structures and pivot rod

Wing-tip design to integrate all components

Epoxied wing-tip bracket on internal structure

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Manufacturing – Control Surfaces

Hyperion 2012-13

External Shell

Internal Support Rib

Control Arm

Front Half Cylinder

Pivot Rod

Materials • Carbon fiber C70-40 Airex foam core (Dragonplate) • 3M Scotch-Weld Epoxy Adhesive 2216 Gray • Carbon fiber half cylinder • Carbon fiber shell cut from external structure

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Manufacturing – Control Surfaces

Hyperion 2012-13

CNC mill outline on carbon fiber Control Surface Airfoils finished

Skeleton of control surfaces Epoxied using 3M Scotch-Weld Epoxy Adhesive

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Manufacturing – Integration

Hyperion 2012-13

Pivot rod for control surface integration Integrated control surfaces

Integrated center body brackets Modified control arm mounting design

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Wing Integration

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Agenda

Hyperion 2012-13

Goals and Team




Wind Tunnel Testing

- Scale 3D printed model

- Verify CFD analysis

Noise Testing

- Denver International Airport Noise Abatement Team

- Engine and aerodynamic noise

Flight Testing

- Fuel efficiency in flight

- Engine emission data

- Aerodynamic stability data

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Science

Hyperion 2012-13

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3-D Model Printing

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Goal: Find out if takeoff pitch-flip behavior is systematic, or a ½ scale proto manufacturing flaw

Method: 3D print scaled model wind tunnel tests 10” wingspan

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Pitching Moment

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Result 1: Pitching moment is unstable for low Angles of Attack (0-8 deg), then stable from (8-14 deg)

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Center of Gravity

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Method 2: Print a new model with CG moved forward in order to analyze the effects on pitching moment stability

First Model CG was at .0414 m (x12.5=.5175 m)

Second Model CG was at .0376 m (x12.5=.470 m)

Moved CG forward by 3.8 mm

CG for wind tunnel test model was defined by sting head location. Sting measurements and data processing assume sting head is at CG.

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CG impact

Hyperion 2012-13

Result 2: Pitching moment is marginally stable to stable (damping oscillatory behavior) for low Angles of Attack (0-8 deg), then stable from (8-14 deg)

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Flight Ready - EM

Terminator 30/8 EM ready for flight!

Bench test operations

Dynamometer testing (Torque and HP vs. RPM)

EM mounted in center body

Taxi tests performed with center body & Brakes

Arvada Flight Restrictions

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39°50'44.89"N 105°13'3.79"W

39°50'35.75"N105°13'5.96"W

39°50'25.87"N 105°12'23.21"W

39°50'34.40"N 105°12'19.76"W

0.68miles

FAA COA submitted

ICE Throttle

cmd

Throttle cmd

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HYCO – Status

EM Throttle

cmd

Throttle Commands

Labview

sbRIO

Futaba

Piccolo

Hybrid Engine

Propulsion: Terminator EM

- Power Testing

- Reliability Testing

- Taxi Operations with Flight

Propeller

- Endurance Testing

- Structural Integration

GNC: Futaba Control System

- Range Testing

- Integrated ground testing

- Operations Verification

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Flight Systems Status

EE & Instruments Science

- Electrical Power Systems (EPS)

- Electrical interfaces

- Flight Data Acquisition Systems

- Integrated Operations

Verification

Structures

- Wings: End Caps

- Control Surfaces

- Final Integration

- Final Structural Analysis

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Acknowledgements

Hyperion 2012-13

Thanks to…

Graduate Student Team members

• Corrina Gibson, PM

• Gauravdev Soin, SE

• Brandon Benjamin

• Weston Willits

• Vibin Sankaranarayanan

• Andrew Gilbert

• Andrew Haynes

• Greg Nelson

• Kristin Uhmeyer

• Pierce Martin

• Zach Dischner

• Adil Ali Mohammed

Undergraduates:

• Alex North

• Casey Myers

Univ. of Stuttgart:

• Benjamin Arnold

• Pascal Weihing

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Acknowledgements

Hyperion 2012-13

A special thanks to…

Advisors/Sponsors/Customers:

Dr. Jean Koster of CU

Joseph Tanner of CU

Dr. Brian Argrow of CU

Dr. Eric Frew of CU

Trudy Schwartz of CU

Matt Rhode of CU

Mike Kisska of Boeing

Frank Doerner of Boeing

Eric Strauss of EBS Carbon

Consultants:

James Mack (Pilot)

Joe Pirozzoli (R/C Pilot)

Stewart Garrett (R/C Pilot)

DIA Noise Abatement Office

University of Stuttgart: Prof. Claus-Dieter Munz

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The End

Hyperion 2012-13

Documents

AIAA-ASM 2013 Hyperion 2.1 Green Aircraft Project