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8 Sizing and Integration of the UCAV Thrust Vectoring System

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8 Sizing and Integration of the UCAV Thrust Vectoring System Cranfield University Adrian James Clarke The Conceptual Design of Novel Future UAV’s Incorporating Advanced Technology Research Components School of Engineering Doctor of Philosophy (PhD) Thesis Cranfield University School of Engineering Doctor of Philosophy (PhD) Thesis 2011 Adrian James Clarke The Conceptual Design of Novel Future UAV’s Incorporating Advanced Technology Research Components Supervisor: Prof. J. P. Fielding Academic Year 2010 to 2011 This thesis is submitted in partial fulfilment of the requirements for the degree of Doctor of Philosophy (PhD) © Cranfield University, 2011. All rights reserved. No part of this publication may be reproduced without the written permission of the copyright holder. Abstract There is at present some uncertainty as to what the roles and requirements of the next generation of UAVs might be and the configurations that might be adopted. The incorporation of technological features on these designs is also a significant driving force in their configuration, efficiency, performance abilities and operational requirements. The objective of this project is thus to provide some insight into what the next generation of technologies might be and what their impact would be on the rest of the aircraft. This work involved the conceptual designs of two new relevant full-scale UAVs which were used to integrate a select number of these advanced technologies. The project was a CASE award which was linked to the Flaviir research programme for advanced UAV technologies. Thus, the technologies investigated during this study were selected with respect to the objectives of the Flaviir project. These were either relative to those already being developed as course of the Flaviir project or others from elsewhere. As course of this project, two technologies have been identified and evaluated which fit this criterion and show potential for use on future aircraft. Thus we have been able to make a contirubtion knowledge in two gaps in current aerospace technology. The first of these studies was to investigate the feasibility of using a low cost mechanical thrust vectoring system as used on the X-31, to replace conventional control surfaces. This is an alternative to the fluidic thrust vectoring devices being proposed by the Flaviir project for this task. The second study is to investigate the use of fuel reformer based fuel cell system to supply power to an all-electric power train which will be a means of primary propulsion. A number of different fuels were investigated for such a system with methanol showing the greatest promise and has been shown to have a number of distinct advantages over the traditional fuel for fuel cells (hydrogen). Each of these technologies was integrated onto the baseline conceptual design which was identified as that most suitable to each technology. A UCAV configuration was selected for the thrust vectoring system while a MALE configuration was selected for the fuel cell propulsion system. Each aircraft was a new design which was developed specifically for the needs of this project. Analysis of these baseline configurations with and without the technologies allowed an assessment to be made of the viability of these technologies. The benefits of the thrust vectoring system were evaluated at take-off, cruise and landing. It showed no benefit at take-off and landing which was due to its location on the very aft of the airframe. At cruise, its performance and efficiency was shown to be comparable to that of a conventional configuration utilizing elevons and expected to be comparable to the fluidic devices developed by the Flaviir project. This system does however offer a number of benefits over many other nozzle configurations of improved stealth due to significant exhaust nozzle shielding. i The fuel reformer based fuel cell system was evaluated in both all-electric and hybrid configurations. In the ell-electric configuration, the conventional turboprop engine was completely replaced with an all-electric powertrain. This system was shown to have an inferior fuel consumption compared to a turboprop engine and thus the hybrid system was conceived. In this system, the fuel cell is only used at loiter with the turboprop engine being retained for all other flight phases. For the same quantity of fuel, a reduction in loiter time of 24% was experienced (compared to the baseline turboprop) but such a system does have benefits of reduced emissions and IR signature. With further refinement, it is possible that the performance and efficiency of such a system could be further improved. In this project, two potential technologies were identified and thoroughly analysed. We are therefore able to say that the project objectives have been met and the project has proven worthwhile to the advancement of aerospace technology. Although these systems did not provide the desired results at this stage, they have shown the potential for improvement with further development. Keywords: Thrust vectoring, fuel cells, fuel processing, alternative fuels, aircraft performance ii Acknowledgements This thesis is dedicated to Frank Clarke. My great uncle, who worked in Woomera Australia as a designer of the Black Arrow Rocket and then worked on the subsequent missile projects. He has always been somebody to look up to and his work has been an inspiration for my own career. The author would like to thank the following people for their continual help and support during my studies, • Prof. Fielding (my supervisor) – For his continued support and advise, especially through the most difficult times. • My family – For their love, support and patience. • BAE Systems (Case Award sponsors) - For their financial support, without which this project would not have been possible. • The 2007-2008 Flaviir Team – Especially, Craig Lawson, Robert Jones and Andrew Mills. It was a very interesting and rewarding year and I was proud to be a key part of the original team which turned the project around and tuned it in to an ultimate success. • The library staff – Especially Tricia Fountain and Sharon Hinton for their warm welcome, help and for always being there when I really needed somebody to talk to. Additional thanks is also due for them always being kind enough to remove the continual bar on my library account (for never returning books on time). • Thanks also goes out to a special group of people who helped me through the darkest times. Any time, day or night, they were always there to turn to and always willing to give up hours of their time to listen to others and offer their comfort and support. I am glad to be part of the group and am now pleased to be able play an active part in helping others in the same situation. We are pressed on every side by troubles, but we are not crushed. We are perplexed, but not driven to despair. We are hunted down, but never abandoned by god. We get knocked down, but we are not destroyed. - 2 Corinthians 4:8 Fairy Tales are more than true; not because they tell us that dragons exist, but because they tell us that dragons can be beaten. - G. K. Chesterton iii Table of Contents Abstract.............................................................................................................................. i Acknowledgements ......................................................................................................... iii 1 Introduction .............................................................................................................. 1 1.1 Project objectives.............................................................................................. 1 1.2 Work on the Flaviir project .............................................................................. 2 1.3 Summary of work ............................................................................................. 2 1.4 Thesis structure................................................................................................. 3 2 Initial literature review............................................................................................. 4 2.1 A review of aircraft design methodologies....................................................... 4 2.1.1 An overview of the aircraft design process ..................................................... 4 2.1.2 A closer look at the conceptual design phase.................................................. 5 2.1.3 The aircraft design process applicable to UAV’s............................................ 6 2.2 Review of existing UAVs and down-selection of the baseline configurations 6 3 Baseline UAV design ............................................................................................... 7 3.1 Design requirements and design flight profiles................................................ 7 3.1.1 UCAV design requirements ............................................................................ 7 3.1.2 MALE design requirements ............................................................................ 8 3.2 The conceptual design of the baseline configurations...................................... 8 3.2.1 The conceptual design of the UCAV............................................................... 9 3.2.2 The conceptual design of the MALE............................................................. 10 3.3 Details of the final baseline configurations .................................................... 11 3.3.1 The UCAV configuration .............................................................................. 12 3.3.2 The MALE configuration
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