Hybrid Electric Integrated

Optimized System (HELIOS)

Design of a Hybrid Propulsion System for Aircraft

Jean Koster, Cody Humbargar, Eric Serani, Alec Velazco, Derek Hillery,
Dan Larrabee, Tom Wormer, Josh Marshman, Eric Petersen, Dan Gaide
University of Colorado, Boulder, Aerospace Engineering Sciences,
Boulder, CO 80309

Les Makepeace
*TIGON EnerTec Inc., Louisville, CO 80027

AIAA ASM, January 5, 2011

 Overview/
HELIOS Concept Background

Develop the capability of a Dual-Torque (Hybrid)

Propulsion Technology for Aircraft
↓Team HELIOS: Capstone Senior Design Project,
7 students (ASEN 4018/4028)
↓ Need an aircraft!

2/9/2012 2
 Overview/
Program History Background

Project Formation
Tri–Team Development
1) University of Colorado (UCB)
– Propulsion System
2) Daniel Webster College (DWC)
3) University of Massachusetts (UML)
– Specialized Experimental Airframe

Funding
NASA CDIO Grant NNX09AF65G
Conceiving
Designing
Implementing
Operating
Why Not All Electric?

All
All Gas Hybrid
Electric
Detectable
Signatures

Energy Density

Versatility

Product Cost

Adaptable
Con Ops
 Overview/
Goals of the Program Background

 Study feasibility of hybrid power plant for aircraft

 Effectively reduce fuel consumption
 Stretch goal: replace Avgas with Biodiesel
 Collaboratively combine 4 components into a UAV
 Internal Combustion Engine
 Electric Motor
 Batteries
 Photovoltaic Cells
Teach global engineering skills: delocalized teams

5
 Overview/
Safety & Reliability Background

44% of GA Accidents Involve ICE related Failures in

Flight
– Dual Torque provides Redundancy & Added Safety
– Loss of 1 engine still lands aircraft safely
– “By Far, Personal Safety is the Highest Concern
Among Buyers of $1M Aircraft.”
Debbie Halevi, ATI

Simplicity of System and Components

reduces Maintenance and Improves Reliability

2/9/2012 6
 Overview/
Major Market UAS/UAV Background

 US Mil-UAV $62B over 2010-2015; CAGR = 10% (1)

 UAV Market World: $80B over 10 years (2)
 UAV Market to top $13B by 2014 (3)
 2016: expected FAA approval for commercial UAV (4)

“Of all the platform technologies

in UAVs, the engines or power
plants remain the most sought
after and least investigated”.
~Frost & Sullivan

1) Market Research Media 4/9/2010: http://www.marketresearchmedia.com/2010/04/09/unmanned-aerial-

vehicles-uav-market/
2) Teal Group Corporation
3) Larry Dickerson, Forecast International 4/15.2008 7
4) “2010 Market Profile and Forecast.” Teal Group Corporation. 23 Feb. 2010
 Overview/
Targeting the UAV Market Background

Reasons for Targeting the UAV Market:

 Hybrid prototype was tested with small RC aircraft (S = 11ft)

 Small aircraft offer excellent test-bed for technology
 System lends itself to design modularity
o Flexible Power Optimization
o User-control over aircraft parameters
o Endurance available
o Quiet operation mode
 Hybrid Mission Profile Overview/
Background

20% Fuel Savings

Start Destination

15-20% More Range ~400 miles

Start New Destinations

EM only
Quiet Loitering

Start Destination
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 Major Requirements HELIOS

Requirement Description Verification Method

0.PRJ.1 Increase fuel efficiency of a Compare baseline and HPS
gas powered propulsion power requirements via
system of an RC aircraft bench testing

0.PRJ.2 The hybrid system shall Power sensors confirm output

consist of PV cells, an ICE, an from all components
electric motor and batteries.

0.PRJ.3 The HPS shall provide power Timed endurance bench

for a minimum of 30 minutes testing followed by possible
to keep an RC aircraft aloft. flight test

0.SYS.1 The components of the Power sensors confirm output

hybrid system shall run from all components
collaboratively.
The Model HELIOS

Main Requirement:
• Reduce the Baseline (BL) ICE power by 25%

How much power does the BL need?

What governs/defines the BL?
Requirements Bounding the BL:
•PV Cells produce 2-5% of BL power
•Sufficient battery power for 30 min
•Wing loading less than 2 lb/ft2

Iterative Subsystem studies

Cost and inefficiencies in Cost and performance of Wing loading dictates that
PV cells require at least current battery technology the total wing area must be
1300 in2 of static wing area requires W/lb to be less ≥ 1500 in2 to achieve less
to achieve 2-5% than 30 than 2 lb/ft2

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System Flow Diagram HELIOS

Controls Airframe - DWC

Antenna Receiver Servos Tail

Control Fuselage
Throttle
Surfaces
ESC Wing

Propulsion Electric

EM
Propeller Gearbox Batteries PV Cells
ICE

ESC: Electronic Control System

Electrical Connection EM: Electric Motor
Mechanical Connection ICE: Internal Combustion Engine
DWC Project PV: Photo Voltaic
12
CU-DWC Collaboration HELIOS

HELIOS – DWC–
Propulsion System Specialized Airframe

HPS Pre-Flight Check Wing Spar Development

13
Alternative Designs HELIOS

Electrically Additive System Mech-Elect Configuration

ICE power converted to electrical power ICE power partially converted to

Overall efficiency: 68% electrical power, the rest remains
mechanical power
Overall efficiency: 68%  85%
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System Design Selection HELIOS
HELIOS

ICE/Fuel
85 – 90%

GB/
Propeller
Mechanical
80% Device

EM
95 – 98% 85% System Efficiency

Batts
Connection Efficiency
90 – 95%
Component
PV Cells
15
 FAB/
Constructed Product Integration

UCB HPS Final Design (HPMAS) DWC Airframe Final Design

PV cells not shown Hand Launch / Belly landing

Subsystem Component Selection Subsystem Design

Batteries Max Amp 22.2V - Construction Carbon Fiber /
10Ahr Balsa
EM Axi 4120/20 465 Kv Propeller 14” x 8”
ICE 0.46 O.S. LA Tail Low Conventional
PV Cells PowerFilm MP3-75 Wings 11’ Span / 13”
16
Chord
Risks / Tall Poles: HELIOS

Original Risk Matrix

Design Phase Risk Matrix
Gearbox manufacturing  Experience
High RPM  Redesigned GB gearing
Battery Failure  Digital Balancer

Revised Risk Matrix

Testing Phase Risk Matrix

ICE Start  Damaged GB bearings

17
Testing Results HELIOS

Gearbox (GB) Test flow after manufacturing:

 Electric Motor Shaft*
 Spin?
 500 RPM
Gearbox
 1000RPM
 5,000 RPM
 10,000 RPM Gearbox 2.0
 ICE Shaft*
 Spin?
Gearbox 3.5
 500 RPM
 5,000 RPM
 Extended Time Test * The opposite shaft was
 Achieve 10 min held at zero RPM.
 Achieve 15 min
 Load Test
 12x6 Prop
 14x8 Prop
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Electrical Subsystem HELIOS

Electric Motor Li-Po Batteries

Motor Specifications Battery Specifications

Max Power: 1100W Capacity: 10,000 mAh
Kv Rating: 465 rpm/V Voltage: 22.2 V
Max Efficiency: 87% Max Discharge: 200 A
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Electrical Subsystem HELIOS

To battery

PowerFilm MP3-75 Series Connection

Parallel Connection
# of Cells 72 cells
Volts: 4V
Amps: 0.1 A
Weight: 0.5 lb
Power Supplied: 29.7 W Model Layout

PowerFilm | Home. Web. 08 Oct. 2009. <http://www.powerfilmsolar.com/>. 20

Component Results (Electrical) HELIOS

PV Cells Batteries
 Three panels, 24 cells each
 High-Amperage discharge test
 Used MPPT to limit losses
 Battery Supplies 215 Whr at 10Amps
 Designed to get 27.8 W
 Meets Requirements
 With MPPT: Actual Power was 6.5 W

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Mechanical Subsystem HELIOS

Internal Combustion Engine Gearbox

Engine Specifications: GB Specifications:
– Max Power: 1.2 Hp – Efficiency: 85 % (+/- 7%)
– Weight: 14 oz – Weight: 1.1 lb
Diesel Conversion Capable Simultaneous Power Input

O.S. 0.46 LA Engine

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Gearbox Design HELIOS
Gear Box

Ring Current Planetary Design:

Electric Motor Gear Ratio
Planet Constant 434 W
0.5 Sun/Ring
Prop
Arm TO: 1024 W @ 9K RPM
Cruise: 512W @ 8K RPM
Sun ICE
TO: 655W @ 8K RPM
Cruise: 153W @ 5K RPM

Propeller Choice:
For: L/D = 10 1.5lb Thrust @ Cruise

Aeronaut 14” by 8 foldable prop

Max Static Thrust of 7 lbs
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Hybrid bench testing HELIOS

• Original test showing collaborative work

• ICE at 3x rpm due to gear ratio
 Component Conclusions HELIOS

Predicted Performance Actual Performance

EM 80% Efficient 79.9% ± 1.1% Efficient
525 W input power 525 W input power

Battery 80% Depth of 83% Depth of

Discharge 440 Whr Discharge 430 Whr

ICE 152 W @ 5k RPM 150 W @ 5.5 k RPM

1 fl oz/min 0.18 fl oz/min (glow)

PV Cells MPPT:0.38 W/panel MPPT: 0.09 W/panel

Alone: 0.26 W/panel Alone: 0.14 W/panel

Max RPM: 12,000 Max RPM: > 12,000

Gearbox
Efficiency: 85% Efficiency: 85% ± 7%
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Project Goals Airframe DWC

 Support in proof of concept hybrid propulsion system prototype

 Remotely control electric motor powered aircraft for 15 minutes

 Design and optimize airframe for endurance flight mission

 Construct 6 lb airframe

Airplane Picture

26
 Aircraft Components DWC

Fuselage
1.1 lbs
Skid Landing System Tail
Bulkhead/Carbon Fiber Build-up 1.0 lbs
Conventional
Foam/Fiberglass
Wing Build-up
2.97 lbs
1600 in2 Wing Area
Rib/Spar Build-up
Electric Power Plant
5.8 lbs
Scorpion 4020-12 BL Motor
LiPo 22.2V Batteries
Foldable Propeller 27
DWC

28
DWC students visited for HELIOS

flight testing
 HELIOS
Flight-Test Video
 AWARDS for HELIOS
• AIAA Region NE-1 Student Paper: First Prize
– HELIOS collaborator team from Daniel Webster College received
the 1st Prize at the AIAA Regional North East Student Paper
Competition, April 2010.
• “MOST COMPLEX BUILD” Award
– Given by the Project Advisory Board of the Department of
Aerospace Engineering at the University of Colorado, May 7,
2010.
• NSIC 3rd Place and $1,000 cash prize
– 4th Annual National Security Innovation Competition (NSIC),
Department of Homeland Security, Colorado Springs, CO, May 7,
2010.
• CDIO Academy: 2nd Prize and $1,500 cash prize
– 6th International CDIO Conference, Montreal, Canada, June 15-
17, 2010
2/9/2012 31
 Hyperion Graduate Proj. Hyperion

• Fall semester 2010

• The Hyperion Blended Wing Body (BWB) aircraft is an
unmanned aerial vehicle (UAV) system operated as an R/C
aircraft.
• The design explores new aircraft design ideas (BWB, flying
wing), aerodynamic efficiency, hybrid gas-electric propulsion,
fly-by-wire controls, and improved acoustics.
Hyperion Graduate Proj. Hyperion

Purpose:
• The BWB/flying wing is considered a green aircraft technology.
• X48B BWB design expected to reduce the fuel consumption by more than 20%
• Integrate hybrid power propulsion system
• Project teaches essential systems engineering skills
 Long-distance design collaboration

•GOALS:
 6 ft Model wingspan
 Aerodynamics
 Navigation and Control
 Composite fabrication
Funding by:
 Further improve hybrid propulsion system
 Follow-The-Sun design operation

33
 Hyperion Graduate Proj.
Hyperion

• Global Team:
 12 graduate: University
of Colorado
 8 undergrad: University
of Colorado
 4 grad: University of
Stuttgart, Germany
 1 grad + 8 undergrad:
University of Sydney,
Australia
 Hyperion Graduate Proj. Hyperion

Follow-The-Sun (FTS) work organization

Scott Balaban Michaela Cui

Kai Lehmkuehler BE Martin Arenz Andrew Brewer Tyler Drake
Chelsea Goodman Arthur Kreuter
Joshua Barnes Holger Kurz
Derek Hillery Gavin Kutil
Sudarsh Bharaduaj David Pfeiffer Brett Miller
Cody Humbargar
Mitchell Knox Matthias Seitz Corey Packard
Mark Johnson
Andrew McCloskey Marcus Rahimpour
Julie Price
Maya Mirzaei Poueinag Gauravdev Spin
Derek Nasso
Matthew New-Tolley Eric Serani
Nathan Wallace Alec Velazco
Byron Wilson Tom Wiley
Richard Zhao
 Hyperion Graduate Proj. Hyperion

Schedule Budget Technical Staffing

Business
Controls
Propulsion
Weights
Electronics
Structures
Aero
CAD
I&T

Back to Agenda Green Yellow Red

On schedule, no Non-critical problems, Critical Problem!
problems mitigation in place Needs help now
Hyperion Graduate Proj. Hyperion

• Geometry
– 3.0 meter wing span
– 1.25 meter max chord
• Airfoils
– Body
• S5016
– Wing
• S5010
• Wing Endings
– Raked Wing Tips
• Rudders
– H-Tail
Integration Plan
Manufacture Ship Assemble Ship Integration
CU
Winglets
Internal Structure
Components
½ Scale Prototype Stuttgart
Wings w/ Ailerons Integration of Internal
Structure Components
with Center Body Skin CU
Stuttgart
Center Body Skin Combine Center Body with
Wings
Vertical Stabilizers
Integrate Electronics
Elevator
Integrate Propulsion

Shipping of Components Minimized

All manufacturing complete by March 1st, Integration by April 1st, 2011

Critical Design Review 38

Hyperion CONOPS Hyperion
Hyperion Graduate Proj. Hyperion
 Overview/
HELIOS Concept and Synergy Background

Develop the capability of a Dual-Torque (Hybrid)

Propulsion Technology for Aircraft
↓Team HELIOS: Senior Design Project,
7 students (ASEN 4018/4028)
↓ Entrepreneurial Business Plan
 6 students (ESBM 4830)
↓Market Assessment Team
5 students + 2 senior members
 TIGON EnerTec, Inc.
4 grad. students + 2 senior members

2/9/2012 41
 Tigon EnerTec, Inc. TIGON

Problem: Inefficient/noisy IC engines, poor flight optimization,

limited commercial Unmanned Aerial Systems (UAS) development
Pain: Rising fuel costs; negative environmental impact of Avgas;
pilot safety; opportunity for optimized concepts of operations;
endurance combined with optional quietness; airport noise.

We seek to capitalize on cutting-edge market and industry trends

Federally directed increases in Biofuel/diesel usage
Increased military focus on UAS
Shifting national focus to aeronautic advancements
Increasing UAS usage outside of the Department of Defense
Higher reliability and safety for GA

http://tigonenertec.com
42
Boulder Innovation Center
Thank you!

The Helios Team

and the Tigon Team
43