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In addition to very high safety and reliability requirements, the design of internal combustion engines (ICE) in aviation focuses on economic efficiency. The objective must be to design the aircraft powertrain optimized for a specific flight mission with respect to fuel consumption and specific engine power. Against this background, expert tools provide valuable decision-making assistance for the customer. In this paper, a mathematical calculation model for the fuel consumption of aircraft ICE is presented. This model enables the derivation of fuel consumption maps for different engine configurations. Depending on the flight conditions and based on these maps, the current and the integrated fuel consumption for freely definable flight emissions is calculated. For that purpose, an interpolation method is used, that has been optimized for accuracy and calculation time. The mission boundary conditions flight altitude and power requirement of the ICE form the basis for this calculation. The mathematical fuel consumption model is embedded in a parent program. This parent program presents the simulated fuel consumption by means of an example flight mission for a representative airplane. The focus of the work is therefore on reproducing exact consumption data for flight operations. By use of the empirical approaches according to Gagg-Farrar [1] the power and fuel consumption as a function of the flight altitude are determined. To substantiate this approaches, a 1-D ICE model based on the multi-physical simulation tool GT-Suite® has been created. This 1-D engine model offers the possibility to analyze the filling and gas change processes, the internal combustion as well as heat and friction losses for an ICE under altitude environmental conditions. Performance measurements on a dynamometer at sea level for a naturally aspirated ICE with a displacement of 1211 ccm used in an aviation aircraft has been done to validate the 1-D ICE model. To check the plausibility of the empirical approaches with respect to the fuel consumption and performance adjustment for the flight altitude an analysis of the ICE efficiency chain of the 1-D engine model is done. In addition, a comparison of literature and manufacturer data with the simulation results is presented.
To meet the challenges of manufacturing smart products, the manufacturing plants have been radically changed to become smart factories underpinned by industry 4.0 technologies. The transformation is assisted by employment of machine learning techniques that can deal with modeling both big or limited data. This manuscript reviews these concepts and present a case study that demonstrates the use of a novel intelligent hybrid algorithms for Industry 4.0 applications with limited data. In particular, an intelligent algorithm is proposed for robust data modeling of nonlinear systems based on input-output data. In our approach, a novel hybrid data-driven combining the Group-Method of Data-Handling and Singular-Value Decomposition is adapted to find an offline deterministic model combined with Pareto multi-objective optimization to overcome the overfitting issue. An Unscented-Kalman-Filter is also incorporated to update the coefficient of the deterministic model and increase its robustness against data uncertainties. The effectiveness of the proposed method is examined on a set of real industrial measurements.
To meet the challenges of manufacturing smart products, the manufacturing plants have been radically changed to become smart factories underpinned by industry 4.0 technologies. The transformation is assisted by employment of machine learning techniques that can deal with modeling both big or limited data. This manuscript reviews these concepts and present a case study that demonstrates the use of a novel intelligent hybrid algorithms for Industry 4.0 applications with limited data. In particular, an intelligent algorithm is proposed for robust data modeling of nonlinear systems based on input-output data. In our approach, a novel hybrid data-driven combining the Group-Method of Data-Handling and Singular-Value Decomposition is adapted to find an offline deterministic model combined with Pareto multi-objective optimization to overcome the overfitting issue. An Unscented-Kalman-Filter is also incorporated to update the coefficient of the deterministic model and increase its robustness against data uncertainties. The effectiveness of the proposed method is examined on a set of real industrial measurements.
It is investigated whether a nonrotating lifting fan remaining uncovered during cruise flight, as opposed to being covered by a shutter system, can be realized with limited additional drag and loss of lift during cruise flight. A wind-tunnel study of a wing-embedded lifting fan has been conducted at the Side Wind Test Facility Göttingen of DLR, German Aerospace Center in Göttingen using force, pressure, and stereoscopic particle image velocimetry techniques. The study showed that a step on the lower side of the wing in front of the lifting fan duct increases the lift-to-drag ratio of the whole model by up to 25% for all positive angles of attack. Different sizes and inclinations of the step had limited influence on the surface pressure distribution. The data indicate that these parameters can be optimized to maximize the lift-to-drag ratio. A doubling of the curvature radius of the lifting fan duct inlet lip on the upper side of the wing affected the lift-to-drag ratio by less than 1%. The lifting fan duct inlet curvature can therefore be optimized to maximize the vertical fan thrust of the rotating lifting fan during hovering without affecting the cruise flight performance with a nonrotating fan.
This paper presents an approach for UAV propulsion system qualification and validation on the example of FH Aachen's 25 kg cargo UAV "PhoenAIX". Thrust and power consumption are the most important aspects of a propulsion system's layout. In the initial design phase, manufacturers' data has to be trusted, but the validation of components is an essential step in the design process. This process is presented in this paper. The vertical takeoff system is designed for efficient hover; therefore, performance under static conditions is paramount. Because an octo-copter layout with coaxial rotors is considered, the impact of this design choice is analyzed. Data on thrust, voltage stability, power consumption, rotational speed, and temperature development of motors and controllers are presented for different rotors. The fixed-wing propulsion system is designed for efficient cruise flight. At the same time, a certain static thrust has to be provided, as the aircraft needs to accelerate to cruise speed. As for the hover-system, data on different propellers is compared. The measurements were taken for static conditions, as well as for different inflow velocities, using the FH-Aachen's wind-tunnel.
The recently discovered first high velocity hyperbolic objects passing through the Solar System, 1I/'Oumuamua and 2I/Borisov, have raised the question about near term missions to Interstellar Objects. In situ spacecraft exploration of these objects will allow the direct determination of both their structure and their chemical and isotopic composition, enabling an entirely new way of studying small bodies from outside our solar system. In this paper, we map various Interstellar Object classes to mission types, demonstrating that missions to a range of Interstellar Object classes are feasible, using existing or near-term technology. We describe flyby, rendezvous and sample return missions to interstellar objects, showing various ways to explore these bodies characterizing their surface, dynamics, structure and composition. Interstellar objects likely formed very far from the solar system in both time and space; their direct exploration will constrain their formation and history, situating them within the dynamical and chemical evolution of the Galaxy. These mission types also provide the opportunity to explore solar system bodies and perform measurements in the far outer solar system.
The recovery of waste heat requires heat exchangers to extract it from a liquid or gaseous medium into another working medium, a refrigerant. In Organic Rankine Cycles (ORC) on Combustion Engines there are two major heat sources, the exhaust gas and the water/glycol fluid from the engine’s cooling circuit. A heat exchanger design must be adapted to the different requirements and conditions resulting from the heat sources, fluids, system configurations, geometric restrictions, and etcetera. The Stacked Shell Cooler (SSC) is a new and very specific design of a plate heat exchanger, created by AKG, which allows with a maximum degree of freedom the optimization of heat exchange rate and the reduction of the related pressure drop. This optimization in heat exchanger design for ORC systems is even more important, because it reduces the energy consumption of the system and therefore maximizes the increase in overall efficiency of the engine.
In the friction tests between honeycomb with film adhesive and prepreg, the relative displacement occurs between the film adhesive and the prepreg. The film adhesive does not shift relative to the honeycomb. This is consistent with the core crush behavior where the honeycomb moves together with the film adhesive, as can be seen in Figure 2(a). The pull-through forces of the friction measurements between honeycomb and prepreg at 1 mm deformation are plotted in Figure 17(a). While the friction at 100°C is similar to the friction at 120°C, it decreases significantly at 130°C and exhibits a minimum at 140°C. At 150°C, the friction rises again slightly and then sharply at 160°C. Since the viscosity of the M18/1 prepreg resin drops significantly before it cures [23], the minimum friction at 140°C could result from a minimum viscosity of the mixture of prepreg resin and film adhesive before the bond subsequently cures. Figure 17(b) shows the mean value curve of the friction measurements at 140°C. The error bars, which represent the standard deviation, reveal the good repeatability of the tests. The force curve is approximately horizontal between 1 mm and 2 mm. The friction then slightly rises. As with interlaminar friction measurements, this could be due to the fact that resin is removed by friction and the proportion of boundary lubrication increases. Figure 18 shows the surfaces after the friction measurement. The honeycomb cell walls are clearly visible in the film adhesive. There are areas where the film adhesive is completely removed and the carrier material of the film adhesive becomes visible. In addition, the viscosity of the resin changes as the curing progresses during the friction test. This can also affect the force-displacement curve.
This paper analyzes the drag characteristics of several landing gear and turret configurations that are representative of unmanned aircraft tricycle landing gears and sensor turrets. A variety of these components were constructed via 3D-printing and analyzed in a wind-tunnel measurement campaign. Both turrets and landing gears were attached to a modular fuselage that supported both isolated components and multiple components at a time. Selected cases were numerically investigated with a Reynolds-averaged Navier-Stokes approach that showed good accuracy when compared to wind-tunnel data. The drag of main gear struts could be significantly reduced via streamlining their cross-sectional shape and keeping load carrying capabilities similar. The attachment of wheels introduced interference effects that increased strut drag moderately but significantly increased wheel drag compared to isolated cases. Very similar behavior was identified for front landing gears. The drag of an electro-optical and infrared sensor turret was found to be much higher than compared to available data of a clean hemisphere-cylinder combination. This turret drag was merely influenced by geometrical features like sensor surfaces and the rotational mechanism. The new data of this study is used to develop simple drag estimation recommendations for main and front landing gear struts and wheels as well as sensor turrets. These recommendations take geometrical considerations and interference effects into account.
The paper presents an aerodynamic investigation of 70 different streamlined bodies with fineness ratios ranging from 2 to 10. The bodies are chosen to idealize both unmanned and small manned aircraft fuselages and feature cross-sectional shapes that vary from circular to quadratic. The study focuses on friction and pressure drag in dependency of the individual body’s fineness ratio and cross section. The drag forces are normalized with the respective body’s wetted area to comply with an empirical drag estimation procedure. Although the friction drag coefficient then stays rather constant for all bodies, their pressure drag coefficients decrease with an increase in fineness ratio. Referring the pressure drag coefficient to the bodies’ cross-sectional areas shows a distinct pressure drag minimum at a fineness ratio of about three. The pressure drag of bodies with a quadratic cross section is generally higher than for bodies of revolution. The results are used to derive an improved form factor that can be employed in a classic empirical drag estimation method. The improved formulation takes both the fineness ratio and cross-sectional shape into account. It shows superior accuracy in estimating streamlined body drag when compared with experimental data and other form factor formulations of the literature.