Active Turbulence Suppression System for Electric Vertical Take-Off and Landing (eVTOL) vehicles

While previous eVTOLs often require a near 90° wing tilt to position propellers in an optimal location to generate vertical force for takeoff, NASA has taken a very different approach. NASA's design instead uses a slight wing angle and large flaps designed to deflect slipstream generated by the propellers to create a net positive force in the vertical direction, all while preventing forward movement. This unique configuration allows for takeoff and landing operations without the need for near 90° wing tilt angles. After takeoff, the transition to forward flight only requires a slight change in attitude of the vehicle and retraction of the flaps. Similar solutions require large changes in attitude to accomplish this transition which is often undesirable, especially for air taxi operations that involve passengers. Given the effectiveness of this configuration for generating upward force, the requirement for wing angle tilt has been reduced from near 90° to approximately 15° during takeoff. Further iterations may reduce this requirement even further to 0°. By eliminating the need for near 90° wing tilt, NASA's eVTOL design removes the need for mechanisms to perform active tilting of the wings or rotors, reducing system mass and thereby improving performance. Flaps represent the only components that require actuation for takeoff and landing operations. Innovators at NASA leveraged the Langley Aerodrome 8 (LA-8), a modular testbed vehicle that allows for rapid prototyping and testing of eVTOLs with various configurations, to design and test this novel concept.

RAM-C interfaces with computational software to provide test logic and manage a unique process that implements three main bodies of theory: (a) aircraft system identification (SID), (b) design of experiment (DOE), and (c) CFD. SID defines any number of alternative estimation methods that can be used effectively under the RAM-C process (e.g., machine learning techniques, regression, neural nets, fuzzy modeling, etc.). DOE provides a statistically rigorous, sequential approach that defines the test points required for a given model complexity. Typical DOE test points are optimized to reduce either estimation error or prediction error. CFD provides a large range of fidelity for estimating aircraft aerodynamic responses. In initial implementations, NASA researchers “wrapped” RAM-C around OVERFLOW, a NASA-developed high-fidelity CFD flow solver. Alternative computational software requiring less time and computational resources could be also utilized. RAM-C generates reduced-order aerodynamic models of aircraft. The software process begins with the user entering a desired level of fidelity and a test configuration defined in terms appropriate for the computational code in use. One can think of the computational code (e.g., high-fidelity CFD flow solver) as the “test facility” with which RAM-C communicates with to guide the modeling process. RAM-C logic determines where data needs to be collected, when the mathematical model structure needs to increase in order, and when the models satisfy the desired level of fidelity. RAM-C is an efficient, statistically rigorous, automated testing process that only collects data required to identify models that achieve user-defined levels of fidelity – streamlining the modeling process and saving computational resources and time. At NASA, the same Rapid Aero Modeling (RAM) concept has also been applied to other “test facilities” (e.g., wind tunnel test facilities in lieu of CFD software).

The thrust actuating device includes several innovations in the aerodynamically stable tilt actuation of propellers, propeller pylons, jets, wings, and fuselages, collectively called propulsors. The propulsors rotate between hover and forward flight mode for a tilt-wing or tilt-rotor aircraft. A vehicle designed using this technology can transition from a hovering flight condition to a wing born flight condition with no mechanical actuation and can do so without complex control systems. This results in a reduction in system weight and complexity and produces a robust and naturally stable hovering aircraft with efficient forward flight modes.

The novel approach for optimizing airspeed for both actual and predicted wind conditions in electric Vertical Takeoff and Landing (eVTOL) aircraft with Distributed Electric Propulsion (DEP) systems includes the process of creating a lookup table for wind‐optimal airspeed as a function of wind magnitude, considering the direction of the wind relative to the cruise segment, considering the cruise altitude for an aircraft type, and incorporating the wind-optimal airspeed lookup table in the performance database for real‐time access by the Flight Management Systems (FMS) to predict wind-optimal airspeed at waypoints of the flight plan. The target wind‐optimal airspeed is updated in real-time throughout the cruise portion of a flight. In a test of the wind-optimal airspeed targeting technique using a multi-rotor aircraft model, results obtained show benefits of flying at the wind‐optimal cruise airspeed compared to the best‐range airspeed. In headwind conditions, energy consumption was reduced by up to 7.5%, and flight duration was reduced by up to 28%. Under uncertain wind magnitudes, flying at wind-optimal airspeed offered lower variability and higher predictability in energy consumption than flying at best‐range airspeed.

Currently, as fuel is burned, wing loading is reduced, thereby causing the wing shape to bend and twist. This wing-shape change causes the wings to be less aerodynamically efficient. This problem can be further exacerbated by modern high-aspect flexible wing design. Aircraft designers typically address the fuel efficiency goal by reducing aircraft weights, improving propulsion efficiency, and/or improving the aerodynamics of aircraft wings passively. In so doing, the potential drag penalty due to changes in the wing shapes still exists at off-design conditions. The unique or novel features of the new concepts are: 1. Variable camber flap provides the same lift capability for lower drag as compared to a conventional flap. The variable camber trailing edge flap (or leading edge slat) comprises multiple chord-wise segments (three or more) to form a cambered flap surface, and multiple span-wise segments to form a continuous trailing edge (or leading edge) curve with no gaps which could be prescribed by a mathematical function or the equivalent with boundary conditions enforced at the end points to minimize tip vortices 2. Continuous trailing edge flap (or leading edge slat) provides a continuously curved trailing edge (or leading edge) with no gaps to minimize vortices that can lead to an increase in drag. 3. The active wing-shaping control method utilizes the novel flap (or slat) concept described herein to change a wing shape to improve aerodynamic efficiency by optimizing span-wise aerodynamics. 4. An aeroelastic wing shaping method for analyzing wing deflection shape under aerodynamic loading is used in a wing-control algorithm to compute a desired command for the flap-actuation system to drive the present flap (or slat) system to the correct position for wing shaping.