Actuated Electromagnetic System for Ice Removal

Transcription

1 University of Colorado at Boulder Actuated Electromagnetic System for Ice Removal Customers Ellis Langford, Ed Wen Advisor Joe Tanner University of Colorado Boulder Aerospace Engineering Sciences 1

2 Agenda 1. Project Background 2. Design Description 3. Design Verification and Validation 4. Conclusion University of Colorado Boulder Aerospace Engineering Sciences 2

3 Project Background University of Colorado Boulder Aerospace Engineering Sciences 3

4 Project Background Problem: Ice buildup on aircraft wings in flight Decreases Lift-to-Drag Ratio (L/D) Reduces mission capabilities In extreme cases can result in a crash Ice formation on wing. 1 Orion UAV 2 Application: ORION Aircraft 5 day continuous flight time 132 ft. wing span Cruising altitude of 20,000-30,000 ft. at 65 kias Requires: Low mass, low power deicing system to increase flight path possibilities without decreasing capabilities University of Colorado Boulder Aerospace Engineering Sciences 4

5 Problem Requirements Problem Statement: Design, build, and test a small-scale prototype of a deicing system for the Orion UAV. Functional Requirements 1. The full-scale system shall be integrable with the Orion UAV. 2. The prototype shall remove ice. 3. The full-scale system shall use less than 4kW-hr to deice the wing section. Orion UAV in flight 3 University of Colorado Boulder Aerospace Engineering Sciences 5

6 Design Overview University of Colorado Boulder Aerospace Engineering Sciences 6

7 Electromagnetic Solution Generate a force using electromagnetics- force impacts leading edge of wing and breaks ice Solenoid Changing Current Flow (Generated by Capacitor Discharge) 1 st Magnetic Field 2 nd Magnetic Field Eddy Currents Repulsive Force Metal Target Disk University of Colorado Boulder Aerospace Engineering Sciences 7

8 Solution Integration Integrated System Wing Section = + Housing Unit & Support Structure + Deicing Mechanism University of Colorado Boulder Aerospace Engineering Sciences 8

9 Design Verification and Validation University of Colorado Boulder Aerospace Engineering Sciences 9

10 Modeling Modeling Goals 1. Find force produced by designs 2. Find force required to break ice 3. Check that force does not damage material 4. Refine force, material, and ice values with testing Solenoid Force Model COMSOL- Calculate force based on solenoid and target disk parameters Flat Plate Model ANSYS- Calculate expected deflection of material under force Wing Section Model ANSYS- Calculate force required to break ice Model that no structural damage occurs with lifetime usage 0.01 in = max deflection University of Colorado Boulder Aerospace Engineering Sciences 10

11 High Level Test Overview TEST PURPOSE Ballistic Pendulum Test Verify Solenoid Force Model Gather experimental data on solenoids Laser Deflection Test (Flat Plate) Measure the deflection to verify material properties via Flat Plate Model Ice Breaking Test (Flat Plate & Wing Section) Verify force required to break ice Prove functionality while meeting power and integration requirements University of Colorado Boulder Aerospace Engineering Sciences 11

12 Ballistic Pendulum Testing Test Setup Results High Speed Camera In-House Encoder Oscilloscope Accelerometer Conclusion Model predicted impulse matches test results Modeling software limitations- based on experimental data trends, solenoid design was improved upon University of Colorado Boulder Aerospace Engineering Sciences 12

13 Flat Plate Testing Test Setup Results Conclusion Experimental deflection is less than modeled Adjustments to material values 4/25/16 Design Description Test Overview Test Results Systems Engineering Project Management University of Colorado Boulder Aerospace Engineering Sciences 13

14 Wing Section Testing Electric Leaf Blower (3) Test cage with viewing window Deicing Circuit Start After 1 Impulse After 2 Impulses After 3 Impulses Conclusion ANSYS model predicts requiring 40.5 lb. force to break ice with one impulse Required 3 impulses at 40.5 lb. force University of Colorado Boulder Aerospace Engineering Sciences 14

15 Ice Breaking Test University of Colorado Boulder Aerospace Engineering Sciences 15

16 Conclusion University of Colorado Boulder Aerospace Engineering Sciences 16

17 Conclusion of Testing 1. Solenoid Design - Verified force required to break ice can be produced - For given voltage, larger diameter creates larger impulse but possible size limited by wing shape and manufacturing 2. Materials - Carbon fiber deflects less then expected- less strain - Values used for ice adhesion have uncertainty 3. Functionality - Solution does break ice - Less deflection then predicted means more impulses required to completely clear wing University of Colorado Boulder Aerospace Engineering Sciences 17

18 Full Scale Integration From testing, 1 Solenoid clears 2 ft. section of ice off wing section For full-span, deicing requires 62 solenoids + Housing + Supporting Circuitry Total Mass Estimate = 200 lb. Orion UAV takeoff 4 Total Power Estimate = 310 W to recharge and fire at 5 minute intervals Note: requires further testing to account for extra rigidity of ORION wing ribs and further testing on ice crack and shed areas University of Colorado Boulder Aerospace Engineering Sciences 18

19 Ice Breaking Demo Come see a demo of breaking ice at 2:30 pm University of Colorado Boulder Aerospace Engineering Sciences 19

20 Sources [1] Aurora s Orion MALE UAV Aims For 120-hr. Flight, Aviation Week. Sept. 17, [2] Aurora Orion UAV Could Cut ISR Costs 80%, Aerospace. Nov. 30, [3] Aurora Flight Sciences. AFS website. Accessed April 13, 2016 [4] Orion Unmanned Aircraft World Record Confirmed, Aurora Flight Sciences. July 1, University of Colorado Boulder Aerospace Engineering Sciences 20