hyperion global aiaa-asm-final

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!

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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

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Motivation: Reduce Noise

-Motivation-

Image credit: NASA

[1]

AIAA-ASM 2012

Fuel Problem:

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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]

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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

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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

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Global Team

- Purpose -

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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

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Schedule

-Global Collaboration-

PDR CDR Start Flight

Testing

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Aerodynamics & Structures

-Technology Overview-

½ Scale Wind Tunnel Model Internal Structure Center Body/Integration

Aerodynamic Validation

CFD Validation

Wing Integration/Assembly

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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

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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

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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

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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

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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

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• 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

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System Testing

Flight Test

AIAA-ASM 2012

Pain: Efficiency in Global Industry Collaborations: needs improvement

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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-

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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

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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

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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

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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

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Current Development

- Current -

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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

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Michael Johnson Eric Kenney Jeremy Klammer Lydia Mcdowell Boris Papazov Taylor Petersen Robert Whitehill

Questions? Contact: jean.koster@colorado.edu

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Budget

- Budget-

Sponsors