Engineering topics

Borer, Nicholas K.

Publications and source records attributed to Borer, Nicholas K..

17 records

NASA NTRS2019

Flight Performance Maneuver Planning for NASA’s X-57 “Maxwell” Flight Demonstrator – Part 1: Power-Off Glides

Distributed Electric Propulsion technology is expected to yield up to a fivefold increase in high-speed cruise efficiency for NASA’s X-57 “Maxwell” flight demonstrator when compared to a combustion-powered general aviation baseline. A portion of this increased efficiency is due to beneficial aero-propulsive interaction inherent to the distributed propulsion architecture. The measure of the relative increase in efficiency between a conventional and distributed propulsion wing will be extracted from comparisons between flight test data from the electrically powered X-57 Mod II configuration with a conventional wing, and from the electrically powered X-57 Mod III/IV configuration with a distributed propulsion wing. Flight test maneuvers that accommodate errors in instrumentation and the flight test environment are developed to establish the power-off drag characteristics for all X-57 configurations. Analysis of these maneuvers with typical errors, including pilot-in-the-loop simulation data that incorporates simulated atmospheric turbulence effects, shows that the proposed power-off flight maneuvers can generate accurate power-off drag predictions for the X-57. These predictions show that the power-off differences in aerodynamic performance between the conventional and distributed propulsion configurations can be accurately measured from flight test data in the presence of typical data error sources.

Borer, Nicholas K.↗

NASA NTRS2019

A Study on the Use of Solid-Oxide Fuel Cells for Increased Power Generation on Small Aircraft

A growing demand for higher-power electrical equipment on aircraft is driving the exploration of alternative electrical power generation devices. “Hybrid-electric” aircraft architectures that leverage multiple or alternative power sources are also becoming more popular with rising concerns over efficiency. Fuel cells are particularly interesting as auxiliary or secondary electrical power generation devices, due to their relative efficiency and longevity, and could be used as a “power pod” for vehicles without enough on-board electrical generation capability. This paper examines the feasibility and potential value of using an externally-mounted, hybridelectric, solid-oxide fuel cell (SOFC) power system on a Class IV unmanned aerial vehicle (UAV) for the purpose of power generation in excess of the baseline electrical load. Moreover, the paper will demonstrate that a SOFC auxiliary power unit (APU) provides significant value to an aircraft by producing a relatively large amount of additional electrical power for a relatively low initial investment when compared to producing additional power by scaling the engine.

Litherland, Brandon L.↗

NASA NTRS2018

FUELEAP Model-Based System Safety Analysis

NASA researchers, in a partnership with Boeing, are investigating a fuel-cell powered variant of the X-57 “Maxwell” Mod-II electric propulsion aircraft, which is itself derived from a stock Tecnam P2006T. The “Fostering Ultra-Efficient Low-Emitting Aviation Power” (FUELEAP) project will replace the X-57 power subsystem with a hybrid Solid-Oxide Fuel Cell (SOFC) system to increase the potential range of the electric-propulsion aircraft while dramatically improving efficiency and emissions over stock internal-combustion engines. Our FUELEAP safety analysis faces two primary challenges. First, the Part 23 certificated Tecnam P2006T is undergoing significant modifications to host the hybrid electric-propulsion system, and the challenge is to assure that the safety inherent in the stock aircraft (and subsequently in X-57 Mod-II) is not compromised by changes in avionics, aircraft structural loading, weight and balance, or other considerations. Secondly, because the SOFC power system has little (if any) relevant in-service precedent, our challenge is to assure that we identify and mitigate all reasonably plausible hazards introduced by unique FUELEAP equipage. We are investigating and utilizing Model-Based Safety Analysis (MBSA) methods to help us address these FUELEAP safety challenges. We captured aircraft-level system hazard conditions using instances of a SysML hazard block via aircraft-level Functional Hazard Analysis (FHA). Then, using SysML models of the FUELEAP architecture, we related the hazard conditions to initiating system events and possible mitigations, such as design architecture modifications or operational constraints. We are continuing to define our approach to MBSA by developing a component-by-component inventory of local failure modes and tracing their possible contribution to hazard conditions. Finally, we are applying an argument-based approach to FUELEAP assurance. Through a FUELEAP “safety case,” we are providing an explicit argument for FUELEAP safety by associating assurance evidence with overarching safety claims through a structured argument.

Woodham, Kurt P.↗

NASA NTRS2018

Catalyzing Disruptive Mobility Opportunities Through Transformational Aviation Power

Lightweight, efficient power production has been a pacing technology for aviation. Advances in airborne electric propulsion technology have enabled new aviation concepts in markets that previously were not dominated by aviation systems, largely because electric propulsion allows for efficient, integrated propulsion/aerodynamic/control solutions that were previously not practical with combustion-based power architectures. These new markets include automated package delivery, urban air mobility, and short-haul transportation. As these markets evolve, the impact of using electricity for airborne propulsion on an expanding mission set, as well as the sheer amount of energy consumed, will begin to challenge the energy harvesting and distribution paradigm as it exists today. Left unaddressed, these challenges could stymie the evolution of these new markets and mobility options. This paper identifies some of the potential systemic issues associated with the expanded use of electric propulsion and explores the requirements associated with alternate aviation power architectures. The recommended path includes the development of a new hybrid-electric aviation power architecture that can be used in conjunction with a portfolio of evolving battery-electric and combustion-based systems.

Borer, Nicholas K.↗

NASA NTRS2018

Design and Performance of a Hybrid-Electric Fuel Cell Flight Demonstration Concept

As electric powertrain and propulsion-airframe integration technologies advance, airborne electric propulsion concepts appear to be on the cusp of disrupting or transforming aviation markets. One of the many challenges to this transformation lies within the onboard energy storage and generation technologies. State-of-the-art battery technology is heavy and lacks support infrastructure; purely combustion-based solutions to electrical power generation suffer from increased inefficiency as compared to a traditional combustion powertrain. This paper explores another alternative: a hybrid-electric, solid oxide fuel cell power system. This power system reforms traditional fuels to feed fuel cells that generate electrical power for the aircraft electric powertrain. A representative power system is designed based on the requirements for NASA’s X-57 Mod II electric flight demonstrator platform, and is shown to exceed system feasibility goals of 300 W/kg and 60% efficiency in at least one configuration. The hybrid-electric fuel cell power system is shown to be competitive with the range performance of a combustion-based power architecture and comparable in mission energy cost to a battery-electric power system.

Borer, Nicholas K.↗

NASA NTRS2018

Development of a Multi-Phase Mission Planning Tool for NASA X-57 Maxwell

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.

Schnulo, Sydney L.↗

NASA NTRS2017

Approach Considerations in Aircraft with High-Lift Propeller Systems

NASA's research into distributed electric propulsion (DEP) includes the design and development of the X-57 Maxwell aircraft. This aircraft has two distinct types of DEP: wingtip propellers and high-lift propellers. This paper focuses on the unique opportunities and challenges that the high-lift propellers--i.e., the small diameter propellers distributed upstream of the wing leading edge to augment lift at low speeds--bring to the aircraft performance in approach conditions. Recent changes to the regulations related to certifying small aircraft (14 CFR x23) and these new regulations' implications on the certification of aircraft with high-lift propellers are discussed. Recommendations about control systems for high-lift propeller systems are made, and performance estimates for the X-57 aircraft with high-lift propellers operating are presented.

Patterson, Michael D.↗

NASA NTRS2017

Development of a New Departure Aversion Standard for Light Aircraft

The Federal Aviation Administration (FAA) and European Aviation Safety Agency (EASA) have recently established new light aircraft certification rules that introduce significant changes to the current regulations. The changes include moving from prescriptive design requirements to performance-based standards, transferring many of the acceptable means of compliance out of the rules and into consensus standards. In addition, the FAA/EASA rules change the performance requirements associated with some of the more salient safety issues regarding light aircraft. One significant change is the elimination of spin recovery demonstration. The new rules now call for enhanced stall warning and aircraft handling characteristics that demonstrate resistance to inadvertent departure from controlled flight. The means of compliance with these changes in a safe, cost-effective manner is a challenging problem. This paper discusses existing approaches to reducing the likelihood of departure from controlled flight and introduces a new approach, dubbed Departure Aversion, which allows applicants to tailor the amount of departure resistance, stall warning, and enhanced safety equipment to meet the new proposed rules. The Departure Aversion approach gives applicants the freedom to select the most cost-effective portfolio for their design, while meeting the safety intent of the new rules, by ensuring that any combination of the selected approaches will be at a higher equivalent level of safety than today's status quo.

Borer, Nicholas K.↗

NASA NTRS2017

A Method for Designing Conforming Folding Propellers

As the aviation vehicle design environment expands due to the in flux of new technologies, new methods of conceptual design and modeling are required in order to meet the customer's needs. In the case of distributed electric propulsion (DEP), the use of high-lift propellers upstream of the wing leading edge augments lift at low speeds enabling smaller wings with sufficient takeoff and landing performance. During cruise, however, these devices would normally contribute significant drag if left in a fixed or windmilling arrangement. Therefore, a design that stows the propeller blades is desirable. In this paper, we present a method for designing folding-blade configurations that conform to the nacelle surface when stowed. These folded designs maintain performance nearly identical to their straight, non-folding blade counterparts.

Litherland, Brandon L.↗

NASA NTRS2017

Comparison of Aero-Propulsive Performance Predictions for Distributed Propulsion Configurations

NASA's X-57 "Maxwell" flight demonstrator incorporates distributed electric propulsion technologies in a design that will achieve a significant reduction in energy used in cruise flight. A substantial portion of these energy savings come from beneficial aerodynamic-propulsion interaction. Previous research has shown the benefits of particular instantiations of distributed propulsion, such as the use of wingtip-mounted cruise propellers and leading edge high-lift propellers. However, these benefits have not been reduced to a generalized design or analysis approach suitable for large-scale design exploration. This paper discusses the rapid, "design-order" toolchains developed to investigate the large, complex tradespace of candidate geometries for the X-57. Due to the lack of an appropriate, rigorous set of validation data, the results of these tools were compared to three different computational flow solvers for selected wing and propulsion geometries. The comparisons were conducted using a common input geometry, but otherwise different input grids and, when appropriate, different flow assumptions to bound the comparisons. The results of these studies showed that the X-57 distributed propulsion wing should be able to meet the as-designed performance in cruise flight, while also meeting or exceeding targets for high-lift generation in low-speed flight.

Borer, Nicholas K.↗

NASA NTRS2016

Design of an Electric Propulsion System for SCEPTOR

The rise of electric propulsion systems has pushed aircraft designers towards new and potentially transformative concepts. As part of this effort, NASA is leading the SCEPTOR program which aims at designing a fully electric distributed propulsion general aviation aircraft. This article highlights critical aspects of the design of SCEPTOR's propulsion system conceived at Joby Aviation in partnership with NASA, including motor electromagnetic design and optimization as well as cooling system integration. The motor is designed with a finite element based multi-objective optimization approach. This provides insight into important design tradeoffs such as mass versus efficiency, and enables a detailed quantitative comparison between different motor topologies. Secondly, a complete design and Computational Fluid Dynamics analysis of the air breathing cooling system is presented. The cooling system is fully integrated into the nacelle, contains little to no moving parts and only incurs a small drag penalty. Several concepts are considered and compared over a range of operating conditions. The study presents trade-offs between various parameters such as cooling efficiency, drag, mechanical simplicity and robustness.

SCEPTOR↗

NASA NTRS2016

High-Lift Propeller System Configuration Selection for NASA's SCEPTOR Distributed Electric Propulsion Flight Demonstrator

Although the primary function of propellers is typically to produce thrust, aircraft equipped with distributed electric propulsion (DEP) may utilize propellers whose main purpose is to act as a form of high-lift device. These \high-lift propellers" can be placed upstream of wing such that, when the higher-velocity ow in the propellers' slipstreams interacts with the wing, the lift is increased. This technique is a main design feature of a new NASA advanced design project called Scalable Convergent Electric Propulsion Technology Operations Research (SCEPTOR). The goal of the SCEPTOR project is design, build, and y a DEP aircraft to demonstrate that such an aircraft can be much more ecient than conventional designs. This paper provides details into the high-lift propeller system con guration selection for the SCEPTOR ight demonstrator. The methods used in the high-lift propeller system conceptual design and the tradeo s considered in selecting the number of propellers are discussed.

Patterson, Michael D.↗

NASA NTRS2016

Design and Performance of the NASA SCEPTOR Distributed Electric Propulsion Flight Demonstrator

Distributed Electric Propulsion (DEP) technology uses multiple propulsors driven by electric motors distributed about the airframe to yield beneficial aerodynamic-propulsion interaction. The NASA SCEPTOR flight demonstration project will retrofit an existing internal combustion engine-powered light aircraft with two types of DEP: small "high-lift" propellers distributed along the leading edge of the wing which accelerate the flow over the wing at low speeds, and larger cruise propellers co-located with each wingtip for primary propulsive power. The updated high-lift system enables a 2.5x reduction in wing area as compared to the original aircraft, reducing drag at cruise and shifting the velocity for maximum lift-to-drag ratio to a higher speed, while maintaining low-speed performance. The wingtip-mounted cruise propellers interact with the wingtip vortex, enabling a further efficiency increase that can reduce propulsive power by 10%. A tradespace exploration approach is developed that enables rapid identification of salient trades, and subsequent creation of SCEPTOR demonstrator geometries. These candidates were scrutinized by subject matter experts to identify design preferences that were not modeled during configuration exploration. This exploration and design approach is used to create an aircraft that consumes an estimated 4.8x less energy at the selected cruise point when compared to the original aircraft.

Borer, Nicholas K.↗

NASA NTRS2016

Overcoming the Adoption Barrier to Electric Flight

Electrically-powered aircraft can enable dramatic increases in efficiency and reliability, reduced emissions, and reduced noise as compared to today's combustion-powered aircraft. This paper describes a novel flight demonstration concept that will enable the benefits of electric propulsion, while keeping the extraordinary convenience and utility of common fuels available at today's airports. A critical gap in airborne electric propulsion research is addressed by accommodating adoption at the integrated aircraft-airport systems level, using a confluence of innovative but proven concepts and technologies in power generation and electricity storage that need to reside only on the airframe. Technical discriminators of this demonstrator concept include (1) a novel, high-efficiency power system that utilizes advanced solid oxide fuel cells originally developed for ultra-long-endurance aircraft, coupled with (2) a high-efficiency, high-power electric propulsion system selected from mature products to reduce technical risk, assembled into (3) a modern, high-performance demonstration platform to provide useful and compelling data, both for the targeted early adopters and the eventual commercial market.

Borer, Nicholas K.↗

NASA NTRS2014

Tradespace Exploration of Distributed Propulsors for Advanced On-Demand Mobility Concepts

Combustion-based sources of shaft power tend to significantly penalize distributed propulsion concepts, but electric motors represent an opportunity to advance the use of integrated distributed propulsion on an aircraft. This enables use of propellers in nontraditional, non-thrust-centric applications, including wing lift augmentation, through propeller slipstream acceleration from distributed leading edge propellers, as well as wingtip cruise propulsors. Developing propellers for these applications challenges long-held constraints within propeller design, such as the notion of optimizing for maximum propulsive efficiency, or the use of constant-speed propellers for high-performance aircraft. This paper explores the design space of fixed-pitch propellers for use as (1) lift augmentation when distributed about a wing's leading edge, and (2) as fixed-pitch cruise propellers with significant thrust at reduced tip speeds for takeoff. A methodology is developed for evaluating the high-level trades for these types of propellers and is applied to the exploration of a NASA Distributed Electric Propulsion concept. The results show that the leading edge propellers have very high solidity and pitch well outside of the empirical database, and that the cruise propellers can be operated over a wide RPM range to ensure that thrust can still be produced at takeoff without the need for a pitch change mechanism. To minimize noise exposure to observers on the ground, both the leading edge and cruise propellers are designed for low tip-speed operation during takeoff, climb, and approach.

Borer, Nicholas K.↗

NASA NTRS2014

Drag Reduction Through Distributed Electric Propulsion

One promising application of recent advances in electric aircraft propulsion technologies is a blown wing realized through the placement of a number of electric motors driving individual tractor propellers spaced along each wing. This configuration increases the maximum lift coefficient by providing substantially increased dynamic pressure across the wing at low speeds. This allows for a wing sized near the ideal area for maximum range at cruise conditions, imparting the cruise drag and ride quality benefits of this smaller wing size without decreasing takeoff and landing performance. A reference four-seat general aviation aircraft was chosen as an exemplary application case. Idealized momentum theory relations were derived to investigate tradeoffs in various design variables. Navier-Stokes aeropropulsive simulations were performed with various wing and propeller configurations at takeoff and landing conditions to provide insight into the effect of different wing and propeller designs on the realizable effective maximum lift coefficient. Similar analyses were performed at the cruise condition to ensure that drag targets are attainable. Results indicate that this configuration shows great promise to drastically improve the efficiency of small aircraft.

Stoll, Alex M.↗

NASA NTRS2005

Decomposition-Based Decision Making for Aerospace Vehicle Design

Most practical engineering systems design problems have multiple and conflicting objectives. Furthermore, the satisfactory attainment level for each objective ( requirement ) is likely uncertain early in the design process. Systems with long design cycle times will exhibit more of this uncertainty throughout the design process. This is further complicated if the system is expected to perform for a relatively long period of time, as now it will need to grow as new requirements are identified and new technologies are introduced. These points identify a need for a systems design technique that enables decision making amongst multiple objectives in the presence of uncertainty. Traditional design techniques deal with a single objective or a small number of objectives that are often aggregates of the overarching goals sought through the generation of a new system. Other requirements, although uncertain, are viewed as static constraints to this single or multiple objective optimization problem. With either of these formulations, enabling tradeoffs between the requirements, objectives, or combinations thereof is a slow, serial process that becomes increasingly complex as more criteria are added. This research proposal outlines a technique that attempts to address these and other idiosyncrasies associated with modern aerospace systems design. The proposed formulation first recasts systems design into a multiple criteria decision making problem. The now multiple objectives are decomposed to discover the critical characteristics of the objective space. Tradeoffs between the objectives are considered amongst these critical characteristics by comparison to a probabilistic ideal tradeoff solution. The proposed formulation represents a radical departure from traditional methods. A pitfall of this technique is in the validation of the solution: in a multi-objective sense, how can a decision maker justify a choice between non-dominated alternatives? A series of examples help the reader to observe how this technique can be applied to aerospace systems design and compare the results of this so-called Decomposition-Based Decision Making to more traditional design approaches.

Borer, Nicholas K.↗