ALBERT

Description: Aircraft engines can be effective actuators to help pilots avert or recover from emergency situations. Emergency control modes are being developed to enhance the engines performance to increase the probability of recovery under these circumstances. This paper discusses a proposed implementation of an architecture that requests emergency propulsion control modes, allowing the engines to deliver additional performance in emergency situations while still ensuring a specified safety level. In order to determine the appropriate level of engine performance enhancement, information regarding the current emergency scenario (including severity) and current engine health must be known. This enables the engine to operate beyond its nominal range while minimizing overall risk to the aircraft. In this architecture, the flight controller is responsible for determining the severity of the event and the level of engine risk that is acceptable, while the engine controller is responsible for delivering the desired performance within the specified risk range. A control mode selector specifies an appropriate situation-specific enhanced mode, which the engine controller then implements. The enhanced control modes described in this paper provide additional engine thrust or response capabilities through the modification of gains, limits, and the control algorithm, but increase the risk of engine failure. The modifications made to the engine controller to enable the use of the enhanced control modes are described, as are the interaction between the various subsystems and importantly, the interaction between the flight controller/pilot and the propulsion control system. Simulation results demonstrate how the system responds to requests for enhanced operation and the corresponding increase in performance.

Description: The anticipated development of the on-demand-mobility (ODM) market has accelerated the development of electric aircraft. Most proposed electric aircraft have propulsion systems that consist of fans directly driven by electric motors. The lower complexity of these propulsion systems opens the door to more custom propulsion system designs that are tailored to a given aircraft and its mission. This paper represents initial steps in the development of an electric propulsion system design code. A proof of concept version of the code is presented. The proof of concept version of the code is for the design of an axial flux rim driven propulsion system. NASA's all electric aircraft X-57, is used as a case study for this design code. The results of this case study are used to discuss the feasibility and potential benefits of using an axial flux rim driven propulsor on X-57. The final result of the case study shows a potential 4km increase in range over the current design.

Description: The physical design and operation of electric aircraft like NASA Maxwell X-57 are significantly different than conventionally fueled aircraft. Operational optimization will require close coupling of aerodynamics, propulsion, and power. To address the uncertainty of electric aircraft operation, a system level Mission Planning Tool is developed to simulate all aircraft trajectory phases: taxi, motor run-up, takeoff, climb, cruise, and descent. The Mission Planning Tool captures performance parameters at each point of the trajectory including battery state of charge, the temperatures of components in the electrical system, and propulsion system thrust. This work describes the modeling of each mission phase, and compares the results of simulating a user-specified trajectory, and using a collocated optimal control approach to determine an optimal trajectory. The results show that optimization of the mission show a significant increase in the final battery state of charge over the user- specified simulation strategy. These results will inform the operation of the NASA Maxwell X-57 test flights that will take place this year.

Description: Electric aircraft concepts enable advanced propulsion airframe integration approaches that promise increased efficiency as well as reduced emissions and noise. NASA's fully electric Maxwell X-57, developed under the SCEPTOR program, features distributed propulsion across a high aspect ratio wing. There are 14 propulsors in all: 12 high lift motor that are only active during take off and climb, and 2 larger motors positioned on the wingtips that operate over the entire mission. The power electronics involved in the wingtip propulsion are temperature sensitive and therefore require thermal management. This work focuses on the high and low fidelity heat transfer analysis methods performed to ensure that the wingtip motor inverters do not reach their temperature limits. It also explores different geometry configurations involved in the X-57 development and any thermal concerns. All analyses presented are performed at steady state under stressful operating conditions, therefore predicting temperatures which are considered the worst-case scenario to remain conservative.

Description: Electric aircraft pose a unique design challenge in that they lack a simple way to reject waste heat from the power train. While conventional aircraft reject most of their excess heat in the exhaust stream, for electric aircraft this is not an option. To examine the implications of this challenge on electric aircraft design and performance, we developed a model of the electric subsystems for the NASA X-57 electric testbed aircraft. We then coupled this model with a model of simple 2D aircraft dynamics and used a Legendre-Gauss-Lobatto collocation optimal control approach to find optimal trajectories for the aircraft with and without thermal constraints. The results show that the X-57 heat rejection systems are well designed for maximum-range and maximum-efficiency flight, without the need to deviate from an optimal trajectory. Stressing the thermal constraints by reducing the cooling capacity or requiring faster flight has a minimal impact on performance, as the trajectory optimization technique is able to find flight paths which honor the thermal constraints with relatively minor deviations from the nominal optimal trajectory.

Description: Urban air taxis, also known as urban air mobility (UAM) vehicles, are anticipated to be an area of significant market growth in the near future. These vehicles are typically vertical take-off and landing (VTOL) designs which are capable of carrying 1 to 30 passengers in an intra-urban environment with flights of less than 50 nautical miles. Development of UAM vehicles and their integration into the airspace will be enabled by advancements in a number of areas including electrified propulsion systems, structures, acoustics, automation, and controls. However, the strong multidisciplinary interactions for these unique vehicles presents a significant new design challenge. This work describes the development of a multidisciplinary analysis and optimization environment which can be used to support the conceptual design of these UAM vehicles, using efficient gradient based optimization with analytic derivatives. The tools included in this multidisciplinary analysis model the aircraft trajectory, vehicle aerodynamics, structures, and electrified propulsion system. The multidisciplinary environment created in this research is unique in that all the physics tools are tightly integrated together, with the trajectory model directly calling the aerodynamics, structures, and propulsion models. This multidisciplinary analysis environment is then demonstrated in the design optimization of a turboelectric tiltwing UAM vehicle concept.

Description: NASA's all-electric X-57 airplane will utilize 14 electric motors, of which 12 are exclusively for lift augmentation during takeoff and landing. This report covers the design and development process taken to create an open reference model representative of the 12 lift augmenting motors. A combined worst case scenario was used as the design point, which represents the simultaneously occurring worst case aspects of thermal, static stress, electromagnetic, and rotor dynamic conditions. This work also highlights the tightly coupled nature of aerospace electric motor design, requiring constant iteration between all disciplines involved. Further adding to the uniqueness is the cooling method, which is limited to nacelle skin forced convection cooling only, no internal air flow is permitted. The stator outer diameter limit of 156.45 mm greatly impacts the degree of coupling between the electromagnetic design with the thermal analysis. The permanent magnet synchronous motor developed here operates between 385 V and 538 V, at a peak current of 50 A. Detailed electromagnetic, thermal, static load, and rotordynamic analysis was completed for this electric motor; all of which are required for a full design. The rotordynamic analysis took into consideration the motor housing which is designed specifically for this motor. The final electric motor has a mass of 2.34 kg, produces 24.1 Nm of torque with a specific power of 5.56 kW/kg, and has an efficiency of 96.61% at the combined worst case design point.

Description: The experimental, fully electric X-57 Maxwell is designed to enable lower energy con-sumption at cruise compare to a fuel burning baseline. This is to be achieved using a sumof subsystem benefits incorporated in the electric, airframe, and propulsion systems. AMission Planning Tool captures the three stages of X-57 development in order to assess thedesign of each subsystem in the context of the whole aircraft. The Mission Planning Toolfor the fully electric X-57 Maxwell captures the aerodynamics, propulsion, heat transfer,and power system of the aircraft with trajectory optimization capabilities. It is able tomodel these subsystems through all phases of flight, from taxi to landing. Through thismultidisciplinary approach, we are able to predict the benefit of each subsystem and theeffect of key design assumptions and how the aircraft will react if they are not met or ex-ceeded. As the aircraft progresses and systems are tested, we can use the Mission PlanningTool to continue to predict performance. This paper details the continued development ofthe X-57 Mission Planning Tool and demonstrates its capabilities.

Description: Hyperloop is a new mode of transportation proposed as an alternative to California's high speed rail project, with the intended benefits of higher performance at lower overall costs. It consists of a passenger pod traveling through a tube under a light vacuum and suspended on air bearings. The pod travels up to transonic speeds resulting in a 35 minute travel time between the intended route from Los Angeles and San Francisco. Of the two variants outlined, the smaller system includes a 1.1 meter tall passenger capsule traveling through a 2.2 meter tube at 700 miles per hour. The passenger pod features water-based heat exchangers as well as an on-board compression system that reduces the aerodynamic drag as it moves through the tube. Although the original proposal looks very promising, it assumes that tube and pod dimensions are independently sizable without fully acknowledging the constraints of the compressor system on the pod geometry. This work focuses on the aerodynamic and thermodynamic interactions between the two largest systems; the tube and the pod. Using open-source toolsets, a new sizing method is developed based on one-dimensional thermodynamic relationships that accounts for the strong interactions between these sub-systems. These additional considerations require a tube nearly twice the size originally considered and limit the maximum pod travel speed to about 620 miles per hour. Although the results indicate that Hyperloop will need to be larger and slightly slower than originally intended, the estimated travel time only increases by approximately five minutes, so the overall performance is not dramatically affected. In addition, the proposed on-board heat exchanger is not an ideal solution to achieve reasonable equilibrium air temperatures within the tube. Removal of this subsystem represents a potential reduction in weight, energy requirements and complexity of the pod. In light of these finding, the core concept still remains a compelling possibility, although additional engineering and economic analyses are markedly necessary before a more complete design can be developed.

Description: As efficiency, emissions, and noise become increasingly prominent considerations in aircraft design, turning to an electric propulsion system is a desirable solution. Achieving the intended benefits of distributed electric propulsion (DEP) requires thermally demanding high power systems, presenting a different set of challenges compared to traditional aircraft propulsion. The embedded nature of these heat sources often preclude the use of traditional thermal management systems in order to maximize performance, with less opportunity to exhaust waste heat to the surrounding environment. This paper summarizes the thermal analyses of X-57 vehicle subsystems that don't employ externally air-cooled heat sinks. The high-power battery, wires, high-lift motors, and aircraft outer surface are subjected to heat loads with stringent thermal constraints. The temperature of these components are tracked transiently, since they never reach a steady-state equilibrium. Through analysis and testing, this report demonstrates that properly characterizing the material properties is key to accurately modeling peak temperature of these systems, with less concern for spatial thermal gradients. Experimentally validated results show the thermal profile of these systems can be sufficiently estimated using reduced order approximations.