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Paper presented at AIAA-ASM Conference 2012, Nashville, TN
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AIAA-ASM 2012, Nashville, TN, January 12, 2012
Jean Koster, University of Colorado Boulder
Hyperion UAV: An International Collaboration
AIAA-ASM 2012
Jean Koster
– University of Colorado Boulder, USA
Claus-Dieter Munz, Ewald Kraemer
– University of Stuttgart, Germany
KC Wong, Dries Verstraete
– University of Sydney Australia
Collaboration
Collaboration
AIAA-ASM 2012
NASA’s ERA Goals
Reduce:
Aircraft fuel consumption
Emissions
Noise
…Simultaneously!
3
Motivation: Green Aviation
-Motivation-
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]
AIAA-ASM 2012
Airport Noise Challenge: Aircraft noise regarded most significant hindrance to National Airspace System
4
Motivation: Reduce Noise
-Motivation-
Image credit: NASA
[1]
AIAA-ASM 2012
Fuel Problem:
5
Motivation: Reduce Fuel Burn
-Motivation-
In 2008 U.S. Commercial air burned 19.7 Billion Gallons D.O.D. burned an additional 4.6 Billion Gallons
Goals
[1]
+
250,000,000… Tons of Carbon Dioxide (CO2)
Nitrogen Oxide (NOx)
Reduce NOx Emissions:
20% by 2015 50% by 2020
>50% beyond 2025 [1]
Reduce Fuel Burn:
33% by 2015 50% by 2020
>70% beyond 2025 [1]
AIAA-ASM 2012 6
Motivation: Blended Wing Body
-Motivation-
[2]
Image credit: NASA
AIAA-ASM 2012
WHY HYPERION?
• Society/ industry needs:
– Aerodynamically & energy efficient aircraft
– 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
-Purpose-
Image credit: NASA
AIAA-ASM 2012
• 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
8
Global Project
-Purpose-
Why a global project?
AIAA-ASM 2012
“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.”
G.B. Shaw said:
GBS
AIAA-ASM 2012 10
Global Team
- Purpose -
AIAA-ASM 2012 11
Goals
-Project Overview-
1. Investigate new technologies for improved capabilities and efficiencies
2. Practice international collaboration in education
1. Conceive, design, build, and test a 2nd generation hybrid propulsion system to be integrated into the Hyperion
Boulder + Stuttgart + Sydney
Undergraduate CU Team
Thank you to our sponsors!
AIAA-ASM 2012 12
System Configuration
-Project Overview-
•Hybrid-Electric Engine to explore quiet take-off and landings, quiet loitering, and improved efficiencies (CONOPS dependent)
• Aerodynamic design started by Sydney team
• Raked wingtips & vertical stabilizers designed by Stuttgart team
• Management, electronics, internal structure design & systems integration by CU
See: AIAA-2012-0878
AIAA-ASM 2012
Subsystem Design
-Technology Overview-
Manufacturing
Electronics
Aerodynamics
Materials/Structures
Weights
AIAA-ASM 2012 14
Schedule
-Global Collaboration-
PDR CDR Start Flight
Testing
AIAA-ASM 2012 15
Aerodynamics & Structures
-Technology Overview-
½ Scale Wind Tunnel Model Internal Structure Center Body/Integration
Aerodynamic Validation
CFD Validation
Wing Integration/Assembly
AIAA-ASM 2012 16
Aerodynamic Analysis
-Technology Overview-
L/D greater than 20 Statically stable Stall velocity less than 15 m/s Span efficiency (e) greater than 0.8 Wing loading less than 15 kg/m²
Aerodynamic Requirements: Aerodynamic testing was performed using multiple methods CFD 1/2 scale wind tunnel testing
AIAA-ASM 2012 17
Manufacturing: Center Body
-Technology Overview-
Project Goal and Objectives Distributed Manufacturing
• Negative molds milled from CAD-data
• Fiberglass-foam-core skin laminated by hand
• Integration of internal structure from University of Colorado
AIAA-ASM 2012 18
Global Integration Manufacturing
-Integration-
IDT (Interface Dimension
Template)
• Device used to ensure German center body matches USA wings
Similar ideas used for wing manufacturing
Winglet Wing
Delocalized manufacturing increases integration risk!
Risk
Mitigation
AIAA-ASM 2012 19
Global Integration
-Global Collaboration-
“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
Need: Electronics integration into plane Problem: Plane center body in Germany!
Solution
Image credit: NASA
Cubesat Broken Down Flat Layout Electronics
AIAA-ASM 2012
FTS Example
-Global Collaboration-
Colorado Team • Changes structure component • Does it meet Requirements? • What does this mean for manufacturing
and aerodynamics?
Sydney Team • Evaluates Structural Implications on
Aerodynamic Design • Proposes design changes • Provides aerodynamic feedback
Stuttgart Team • Evaluates Manufacturing implications on
aerodynamic and structural designs • Proposes design changes • Provides manufacturing feedback
8 Hours
8 Hours
8 Hours
AIAA-ASM 2012 21
Hybrid Gas-Electric Engine
-Technology Overview-
Project Goal and Objectives Design, build and test a hybrid propulsion system to be integrated into the aircraft
Offset drive
No control system
Focus: Efficiency, proof of
concept
Coaxial drive
Multiple flight mode control
Focus: Reliability, operations
Objective:
See: AIAA-2012-0147
AIAA-ASM 2012 22
• Test aircraft capability and characteristics.
• Identify unforeseen problems.
• Pilot familiarization
• Test: Taxi, takeoff, cruise, land
• Test: Mass sensitivity, cg
• Test: International analysis of data
Testing
-Technology Overview-
Dynamically (1/2) Scaled Prototype
AIAA-ASM 2012
• Electric propulsion
– Hybrid Engine fully bench tested, but not flight tested (maturity)
• R/C Piloted – Successful takeoff, cruise, and landing
23
System Testing
Flight Test
AIAA-ASM 2012
Pain: Efficiency in Global Industry Collaborations: needs improvement
24
FTS Collaboration Experiment
-Global Collaboration-
Concept 3 Teams, distributed 8 hours apart relay work daily.
Follow-the-Sun (FTS), produces 3 work-days in one 24 hour period
Results • 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
AIAA-ASM 2012
Internet Communication and Cloud File Sharing
Best Practices
-Global Collaboration-
12
IT Plan
- Integration & Testing -
Detail IT Plan
Concept of Operations
Integration
Manufacturing
Develop and define mission phases
Project Requirements
Determine verification method and develop tests
System Architecture
Identify subsystem interfaces and risks
Project Decomposition
Time
Testing
Operation
Verification andValidation
Implement IT Plan
Systems Engineering
AIAA-ASM 2012 26
Lessons Learned
-Global Collaboration-
Language and Cultural Barriers Although everyone speaks Englineerish….
Encodes/Writes Message
Decodes/Misinterprets Message
Cloud Noise Filter Can Cause: -Loss of Tone
-Loss of Intent -Misinterpretation
Encodes Counter Productive Feedback Message
Decodes Message
AIAA-ASM 2012 27
Lessons Learned
-Global Collaboration-
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.
AIAA-ASM 2012
• 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
28
Lessons Learned
- Global Collaboration-
AIAA-ASM 2012
• 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
Conclusion
AIAA-ASM 2012
• 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
30
Current Development
- Current -
AIAA-ASM 2012 31
Acknowledgements
-Acknowledgements-
A special thanks to… Mike Kisska of Boeing 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
Skip Miller of Skip Miller Models
James Mack of LASP (Pilot)
AIAA-ASM 2012
Student Global Team
-Team-
Michaela Cui Tyler Drake Arthur Kreuter Gavin Kuti l Brett Mi l ler Corey Packard Marcus Rahimpour Gauravdev Soin
Mart in Arenz Holger Kurz David Pfei f fer Matthias Seitz Bar is Tunal i Jonas Schwengler
Kai Lehmkuehler Matthew Anderson Joshua Barnes Byron Wi lson Andrew McCloskey
Derek Nasso Jul ie Price Er ic Serani Tom Wiley
Richard Zhao Kr isten Brenner Corr ina Gibson
Nathan Jastram
32
Michael Johnson Eric Kenney Jeremy Klammer Lydia Mcdowell Boris Papazov Taylor Petersen Robert Whitehill
Questions? Contact: [email protected]
AIAA-ASM 2012 34
Budget
- Budget-
Sponsors