A review of variable-pitch propellers and their control strategies in aerospace systems

The relentless pursuit of aircraft flight efficiency has thrust variable-pitch propeller technology into the forefront of aviation innovation. This technology, rooted in the ancient power unit of propellers, has found renewed significance, particularly in the realms of unmanned aerial vehicles and urban air mobility. This underscores the profound interplay between visionary aviation concepts and the enduring utility of propellers. Variable-pitch propellers are poised to be pivotal in shaping the future of human aviation, offering benefits such as extended endurance, enhanced maneuverability, improved fuel economy, and prolonged engine life. However, with additional capabilities come new technical challenges. The development of an online adaptive control of variable-pitch propellers that does not depend on an accurate dynamic model stands as a critical imperative. Therefore, a comprehensive review and forward-looking analysis of this technology is warranted. This paper introduces the development background of variable-pitch aviation propeller technology, encompassing diverse pitch angle adjustment schemes and their integration with various engine types. It places a central focus on the latest research frontiers and emerging directions in pitch control strategies. Lastly, it delves into the research domain of constant speed pitch control, articulating the three main challenges confronting this technology: inadequacies in system modeling, the intricacies of propeller-engine compatibility, and the impact of external, time-varying factors. By shedding light on these multifaceted aspects of variable-pitch propeller technology, this paper serves as a resource for aviation professionals and researchers navigating the intricate landscape of future aircraft development

Peak-seeking control of propulsion systems

Propulsion systems like Turboprop engines are generally designed to operate at a narrow range of optimum steady state performance conditions. However, these conditions are likely to vary in an unpredictable manner according to factors such as components aging, structural damages or even the operating environment. Over time, inefficiencies could add up and can lead to expensive fuel consumption or faster component aging. This thesis presents a self-optimizing control scheme, referred as Peak-seeking control, applied to propulsion systems similar to Turboprop engines. Using an extended Kalman filter, the Peak-seeking method is able drive the system to an optimal condition based only on measurements. No prior knowledge of the engine dynamics is required which make the Peak-seeking technique easy to implement and also allow for modularity in the engine design. This study is performed on both a turboprop and a DC motor driving a variable pitch propeller and considers several performance functions to optimize.MSCommittee Chair: Eric Feron; Committee Member: Eric Johnson; Committee Member: Manuj Dhingr

Electric Power Systems and Components for Electric Aircraft

Electric aircraft have gained increasing attention in recent years due to their potential for environmental and economic benefits over conventional airplanes. In order to offer competitive flight times and payload capabilities, electric aircraft power systems (EAPS) must exhibit extremely high efficiencies and power densities. While advancements in enabling technologies have progressed the development of high performance EAPS, further research is required. One challenge in the design of EAPS is determining the best topology to be employed. This work proposes a new graph theory based method for the optimal design of EAPS. This method takes into account data surveyed from a large set of references on commonly seen components including electric machines, power electronics and jet engines. Thousands of design candidates are analyzed based on performance metrics such as end-to-end system efficiency, overall mass, and survivability. It is also shown that sensitivity analysis may be used to systematically evaluate the impact of components and their parameters on various aspects of the architecture design. Once an EAPS architecture has been selected, further, detailed, validation of the power system is required. In these EAPS, many subsystems exist with timescales varying from minutes to hours when considering the aerodynamics, to nanosecond dynamics in the power electronics. This dissertation presents a multiphysics co-simulation framework for the evaluation of EAPS with a unique decoupling method to reduce simulation time without sacrificing detail. The framework has been exemplified on a case study of a 500kW all-electric aircraft, including models for aerodynamics, energy storage, electric motors and power electronics. Electric machines for aviation propulsion must meet several performance requirements, including a constant power speed range (CPSR) of approximately thirty percent above rated speed. This operation is traditionally achieved through the flux weakening technique with an injection of negative d-axis current. However, the degree of CPSR achievable through flux weakening is a strong function of the back emf and d-axis inductance. This dissertation reviews alternative methods for CPSR operation in machines with low inductance. A new method of current weakening has been proposed to address this challenge, involving reducing the machine\u27s current inversely proportional to the operating speed, maintaining constant power through the extended speed range. One benefit of the proposed method is that all current is maintained in the q-axis, maintaining maximum torque per ampere operation. Coreless axial flux permanent magnet (AFPM) machines have recently gained significant attention due to their specific form factor, potentially higher power density and lower losses. Coreless machine designs promise high efficiency particularly at higher speeds, due to the absence of a ferromagnetic core. In this dissertation, coreless AFPM machines with PCB stators are investigated as candidates for propulsion in electric aircraft applications. Two PCB stator design variations are presented with both simulation and experimental results

A methodology for the validated design space exploration of fuel cell powered unmanned aerial vehicles

Unmanned Aerial Vehicles (UAVs) are the most dynamic growth sector of the aerospace industry today. The need to provide persistent intelligence, surveillance, and reconnaissance for military operations is driving the planned acquisition of over 5,000 UAVs over the next five years. The most pressing need is for quiet, small UAVs with endurance beyond what is capable with advanced batteries or small internal combustion propulsion systems. Fuel cell systems demonstrate high efficiency, high specific energy, low noise, low temperature operation, modularity, and rapid refuelability making them a promising enabler of the small, quiet, and persistent UAVs that military planners are seeking. Despite the perceived benefits, the actual near-term performance of fuel cell powered UAVs is unknown. Until the auto industry began spending billions of dollars in research, fuel cell systems were too heavy for useful flight applications. However, the last decade has seen rapid development with fuel cell gravimetric and volumetric power density nearly doubling every 2-3 years. As a result, a few design studies and demonstrator aircraft have appeared, but overall the design methodology and vehicles are still in their infancy. The design of fuel cell aircraft poses many challenges. Fuel cells differ fundamentally from combustion based propulsion in how they generate power and interact with other aircraft subsystems. As a result, traditional multidisciplinary analysis (MDA) codes are inappropriate. Building new MDAs is difficult since fuel cells are rapidly changing in design, and various competitive architectures exist for balance of plant, hydrogen storage, and all electric aircraft subsystems. In addition, fuel cell design and performance data is closely protected which makes validation difficult and uncertainty significant. Finally, low specific power and high volumes compared to traditional combustion based propulsion result in more highly constrained design spaces that are problematic for design space exploration. To begin addressing the current gaps in fuel cell aircraft development, a methodology has been developed to explore and characterize the near-term performance of fuel cell powered UAVs. The first step of the methodology is the development of a valid MDA. This is accomplished by using propagated uncertainty estimates to guide the decomposition of a MDA into key contributing analyses (CAs) that can be individually refined and validated to increase the overall accuracy of the MDA. To assist in MDA development, a flexible framework for simultaneously solving the CAs is specified. This enables the MDA to be easily adapted to changes in technology and the changes in data that occur throughout a design process. Various CAs that model a polymer electrolyte membrane fuel cell (PEMFC) UAV are developed, validated, and shown to be in agreement with hardware-in-the-loop simulations of a fully developed fuel cell propulsion system. After creating a valid MDA, the final step of the methodology is the synthesis of the MDA with an uncertainty propagation analysis, an optimization routine, and a chance constrained problem formulation. This synthesis allows an efficient calculation of the probabilistic constraint boundaries and Pareto frontiers that will govern the design space and influence design decisions relating to optimization and uncertainty mitigation. A key element of the methodology is uncertainty propagation. The methodology uses Systems Sensitivity Analysis (SSA) to estimate the uncertainty of key performance metrics due to uncertainties in design variables and uncertainties in the accuracy of the CAs. A summary of SSA is provided and key rules for properly decomposing a MDA for use with SSA are provided. Verification of SSA uncertainty estimates via Monte Carlo simulations is provided for both an example problem as well as a detailed MDA of a fuel cell UAV. Implementation of the methodology was performed on a small fuel cell UAV designed to carry a 2.2 kg payload with 24 hours of endurance. Uncertainty distributions for both design variables and the CAs were estimated based on experimental results and were found to dominate the design space. To reduce uncertainty and test the flexibility of the MDA framework, CAs were replaced with either empirical, or semi-empirical relationships during the optimization process. The final design was validated via a hardware-in-the loop simulation. Finally, the fuel cell UAV probabilistic design space was studied. A graphical representation of the design space was generated and the optima due to deterministic and probabilistic constraints were identified. The methodology was used to identify Pareto frontiers of the design space which were shown on contour plots of the design space. Unanticipated discontinuities of the Pareto fronts were observed as different constraints became active providing useful information on which to base design and development decisions.Ph.D.Committee Chair: Mavris, Dimitri; Committee Member: Nam, Taewoo; Committee Member: Parekh, David; Committee Member: Soban, Danielle; Committee Member: Volovoi, Vital

Design Decisions for a Powertrain Combination of Electric Motor and Propeller for an Electric Aircraft

For the sizing of an electric motor, the diameter and length of the installation space are important parameters that significantly influence and limit the characteristics of the electric motor. From an aerodynamic point of view, it is not technically advantageous to choose a propeller hub diameter that is larger than mechanically necessary. The hub diameter defines the installation space ans thus the outer diameter for the electric motor driving the propeller. The research question that arises is this: Is there an optimum diameter for the hub and thus the electric motor and how is it limited? The present work should help to establish a better understanding of the system combination of electric motor and propeller, especially the choice of the diameter and further geometrical parameters of the electric motor. A parameter study investigating aeromechanical and electromagnetic aspects has been performed and the results are combined to achieve the best solution in terms of efficiency and power density. The investigations show that an increase in the diameter causes little disadvantage from an aerodynamic point of view, but the improvements to the electric motor are significant only up to the point where the diameter-to-length ratio becomes too high and end-region effects become more significant. The installation space for the electric motor could be determined using a hub-to-tip ratio of 0.16 to 0.20, which is applicable to any propeller. In addition, it could be shown that a co-optimisation of the speed throughout a mission profile with regard to the efficiency is affected by the propeller alone

Increasing Safety in Ultralight Aviation with a Wankel-Based Series/Parallel Hybrid Electric Power System

none2The goal of this investigation is to propose a series/parallel hybrid electric power system for ultralight aviation designed to improve safety and, possibly, reduce fuel consumption. The power system consists of a Wankel engine, two electric machines, a battery, and a planetary gear set, all acquired from the automotive market. After a preliminary design based on takeoff power, the system is simulated over a typical flight mission and in case of engine failure for a first validation of the proposed powertrain. The investigation also shows a comparison in terms of performance and fuel consumption between the initial configuration (reciprocating piston engine), a non-hybrid Wankel arrangement, and the proposed hybrid electric configurations by using in-house simulation software. A heuristic energy management strategy is proposed as well. During a typical mission, the new powertrain works as a parallel hybrid during takeoff and climb, thus ensuring high performance and safety. During the cruise, the system behaves like a parallel hybrid with a continuously variable transmission that makes the engine work always at high efficiency. The battery is partially recharged during the descent by the extra power of the engine. The preliminary results reported in this work predict an improvement in fuel consumption by about 20% compared with the initial piston engine configuration and 28% compare with the non-hybrid Wankel powertrain, despite the larger takeoff weight.T. Donateo, D. CavaleraDonateo, T.; Cavalera, D

Multirotor Design Optimization: The Mechatronic Approach

Doktorgradsavhandling ved Fakultet for teknologi og realfag, Universitetet i Agder, 2015Multirotors such as the more famous quadcopter have been a favoured research object the last years. It is widely used as a flying platform for the hobby enthusiasts, but recently also used more and more by the industry. The multirotor has complex dynamics and requires sensors and a control system in order to fly. To get the desired flight characteristics batteries, motor and the propeller have to be chosen wisely as different combinations create different properties. The usual design approach is to test different combinations of motors and propellers, and based on experience select components that will be closest to the desired flight properties. This thesis presents an optimization method that calculates what hardware to use in order to get closest to the demanded properties. The method will only select from a given database, hence not returning a diameter and pitch of a propeller that are not available. A wide range of criteria can be optimized, examples are dynamics of the motor/propeller, flight dynamics, flight time, payload etc. The optimization routine will also calculate if the better choice is a quadcopter with four propellers, a hexacopter with six or an octocopter with eight propellers. The optimization is not trivial due to the non-linear characteristics of the propeller. A lot of experimental work was done to test the response of the propeller, both for acceleration and deceleration. Theory and experimental work show that the thrust response of the propeller can be more or less equal if the electronic speed controller controls the motor in a special mode. This mode also makes the response of the motor faster than normal. The new design is tested with a new approach for attitude estimation, and a controller operating directly with the result of the estimator. Most of the multirotors use a microcontroller with limited resources as the control system, hence the attitude and controller were designed specifically without time consuming trigonometric functions such as the sine and cosine. Overall, the methods and results presented in this thesis will aid the engineer when designing a multirotor system consisting of control system, mechanical frame, battery, actuators and propellers

Design and implementation of UAV performance validation system

Abstract. This thesis aims for design and implementation of a system for drone performance measurements, which can be used for validation of different drones for research projects accordingly. Additionally, the device should be able to be used as a part of a hardware-in-loop -system with simulators in drone research. The primary goal for this thesis is to build a system which helps to document different drone properties efficiently and safely. This is done with a system that consists of a robust frame, a force and torque measuring transducer, a drone stabilizing unit, a data logging system, and a remote-control power supply. For controlling the system, user interface was created to control the data stream, the drone stabilizing unit, and the power supply. This thesis includes a literature review of drone general classification properties and legal regulations. Short review of drone usage and selection criteria in industry and research is conducted, as well as in-depth review of the drone components and their relation to overall performance of the drone. The thesis also contains literature review of force and torque measuring theory, and other drone performance measuring units. The functionality of the designed unit is tested by building a drone from spare components, and valuating its performance based on e.g., lift generation, power consumption and visual behavior of the drone. Measured data is documented, and with the documents, drone’s suitability for future research projects can be assessed. According to the results, the unit can be used to evaluate drone’s performance, and groundwork for Hardware-in-loop simulator connection for drone research. The testing unit and the data recordings as well as the built testing drone stays within the research facility for further development.UAV testausjärjestelmän suunnittelu ja toteutus. Tiivistelmä. Tässä diplomityössä suunnitellaan ja valmistetaan droonien suorituskykyä mittaava tutkimuslaitteisto, jonka avulla voidaan arvioida erilaisten droonien soveltuvuutta tutkimusprojekteihin tapauskohtaisesti. Työssä tavoitellaan helppokäyttöistä järjestelmää, jonka avulla itse tehtyjen droonien ominaisuuksia voidaan dokumentoida turvallisesti ja tehokkaasti. Työssä perehdytään droonien luokitteluun tutustumalla voimassa oleviin säädöksiin, sekä droonin suorituskykyä kuvaaviin ominaisuuksiin. Työssä tarkastellaan droonien käyttöä eri aloilla arvioiden esiin nousseita droonin valintaperusteita ja ominaisuuksia. Tämän jälkeen tutustutaan droonien rakenteeseen ja ominaisuuksiin. Voiman mittauksen teoriaan sekä kehitettyihin mittausmenetelmiin tutustutaan tukemaan anturivalintaa. Suunniteltu järjestelmä koostuu tukevasta rungosta, voiman mittaukseen soveltuvasta anturista, droonin vakauttamisen kokonaisuudesta, datan keräysjärjestelmästä sekä etäohjattavasta virtalähteestä. Laitteiston ohjaukseen luotiin rajapinta, jonka kautta järjestelmää voidaan hallita. Järjestelmän toimivuus todettiin kahdella mittauskäyttöön soveltuvalla droonilla, joiden suorituskykyä arvioitiin droonien ominaisuuksien, sekä visuaalisen käyttäytymisen avulla. Mittauksien tulokset dokumentoitiin, ja dokumentaation perusteella voidaan arvioida sekä tutkimuslaitteiston toimivuutta, että mitattujen droonien soveltuvuutta tulevissa tutkimusprojekteissa. Mittausten perusteella voidaan todeta laitteen soveltuvan droonien suorituskyvyn mittaamiseen, sekä pohjatyöksi simulaattorikytkentään. Mittalaitteisto sekä mittaustulokset jäävät Biomimetiikka ja älykkäät järjestelmät -tutkimusyksikön käyttöön droonitutkimuksen tueksi