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An Exploration Into the Potential of Microturbine Based Propulsion Systems for Civil Unmanned Aerial Vehicles

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An Exploration Into the Potential of Microturbine Based Propulsion Systems for Civil Unmanned Aerial Vehicles Master of Science Thesis An exploration into the potential of microturbine based propulsion systems for civil Unmanned Aerial Vehicles Anna Marcellan 13 May 2015 Faculty of Aerospace Engineering · Delft University of Technology An exploration into the potential of microturbine based propulsion systems for civil Unmanned Aerial Vehicles Master of Science Thesis For obtaining the degree of Master of Science in Aerospace Engineering at Delft University of Technology Anna Marcellan 13 May 2015 Thesis number = 030#15#MT#FPP Faculty of Aerospace Engineering · Delft University of Technology Copyright c Anna Marcellan All rights reserved. Delft University Of Technology Department Of Flight Performance and Propulsion The undersigned hereby certify that they have read and recommend to the Faculty of Aerospace Engineering for acceptance a thesis entitled \An exploration into the po- tential of microturbine based propulsion systems for civil Unmanned Aerial Vehicles" by Anna Marcellan in partial fulfillment of the requirements for the degree of Master of Science. Dated: 13 May 2015 Head of department: Prof. Dr. Ir. P. Colonna Supervisor: Dr. Ir. W. P. J. Visser Reader: Dr. Ir. M. Voskuijl Reader: Dr. Ir. R. Pecnick Summary A Master Thesis Research has been undertaken with the goal of investigating the po- tential of micro gas turbines as propulsion system of choice for small Unmanned Aerial Vehicle (UAV) used in civil applications. An Exploration Study is performed both in the fields of UAV technology and of Micro Gas Turbine technology. These two areas are covered in order to understand the possible advantages and limitations of micro gas turbine engines compared to alternative propul- sion concepts (e.g. electric and reciprocating engines) when used for a specific application. After the identification of a significant Case Study, a conceptual design of a high-potential UAV micro gas turbine based propulsion system is performed. Prediction of scale effects is important within the framework of turbine conceptual design where the power output is varied in order to optimize the mission performance in which the turbine is integrated. To this end, engine cycle optimization using Gas turbine Simulation Program (GSP) is carried out. Furthermore, an "Aircraft Study" is performed in a correlated Master Thesis Project in which the aerodynamic and flight performance model of a baseline UAV is developed. After the model validation, results from the micro gas turbine model are integrated and the performance of the new UAV configuration is investigated. v vi Summary Acknowledgements Foremost, I would like to express my gratitude to my supervisor Wilfried Visser for his availability and support, for his motivation, enthusiasm, and great knowledge. Besides my supervisor, I would like to thank my thesis committee, Prof. Piero Colonna for his kind approval and guidance during the structuring of the project and for providing arguments and encouragement during this research, Mark Voskuijl, for his support and invaluably constructive criticism and advice during the project work, and Rene Pecnik for taking the time to asses my thesis work. I would like to thank Sander Beuselinck for being part of this venture, I enjoyed collabo- rating and discussing with him both our work and many other topics during the months that passed. My sincere thanks also goes to Adam J. Head for his constant support and help in uncountable things during the development of this thesis, and to the other PhD candidates of the Department of Flight Performance and Propulsion for their kind sup- port and guiding. I also want to extend my gratitude to my friends, who are my source of energy and inspi- ration, for being there when it was most needed and for creating a wonderful environment for me to grow as a person and as an engineer. I thank my fellow course mates for the stimulating discussions, for the sleepless nights we were working together before deadlines, and for all the fun we have had in the last two years. I also want to place on record my sense of gratitude to all the persons, who directly or indirectly, have lent their hand for the successful completion of this report. Last but not the least, I would like to thank my family: my parents Massimo and Carla, for supporting me with love throughout my life; my brother Marco, for reminding me to always follow my dreams and fight for my beliefs; and my sister Elena, whose courage and kindness I will always admire. With gratefulness, Delft, The Netherlands Anna Marcellan 13 May 2015 vii viii Acknowledgements Contents Summary v Acknowledgements vii List of Figures xi List of Tables xiii 1 Introduction1 1.1 Project Rationale................................2 1.2 Research question, aims and objectives....................2 2 Exploration Study5 2.1 UAV Overview.................................5 2.1.1 Definition and Classifications.....................5 2.1.2 Market and Development Trends...................7 2.1.3 Regulations and Certifications.................... 10 2.1.4 Civil Applications........................... 11 2.1.5 Existing UAVs............................. 12 2.2 Propulsion Systems............................... 15 2.2.1 Electric Motors............................. 16 2.2.2 Reciprocating Engines......................... 18 2.2.3 Gas Turbine Engines.......................... 19 2.2.4 Propulsion Systems Comparison................... 22 2.3 Micro Gas Turbines.............................. 23 2.3.1 Downscaling Effects.......................... 24 3 Methodology 27 ix x Contents 4 Case Study 31 4.1 Application................................... 31 4.1.1 Selection Procedure.......................... 31 4.1.2 Mission Requirements Definition................... 34 4.2 Reference UAV................................. 37 4.3 Reference Gas Turbine Engine........................ 38 5 Model Development 41 5.1 Micro Gas Turbine Performance Model.................... 41 5.1.1 Downscaling Approach......................... 42 5.1.2 Components Efficiency Calculation.................. 43 5.1.3 Technology Levels........................... 45 5.1.4 Weight Estimation........................... 46 5.1.5 GSP Implementation.......................... 47 5.1.6 Propeller Model............................ 50 5.2 Models Coupling................................ 57 5.3 Aircraft Performance Model.......................... 58 6 Analysis 59 6.1 Technology Level Effects............................ 59 6.2 Size Effects................................... 62 6.3 Components Efficiency Effects......................... 63 6.4 Mission Results................................. 67 7 Conceptual Engine Design 71 8 Results and Discussion 73 9 Conclusion 77 9.1 Recommendations for future work...................... 78 9.2 Reflection.................................... 78 BIBLIOGRAPHY 80 Appendix A Turboprop Thermodynamic Cycle 85 Appendix B Compressor and Turbine Efficiency 89 Appendix C Ideal Propeller Theory 93 Appendix D Analysed existing UAVs 99 Appendix E Thrust Management Tables 101 List of Figures 2.1 Top 10 UAVs manufacturing Countries according to the 2013 Worldwide UAV Roundup done by the American Institute of Aeronautics and Astro- nautics...................................... 14 2.2 Existing UAVs status according to the 2013 Worldwide UAV Roundup done by the American Institute of Aeronautics and Astronautics [1]... 14 2.3 Propulsion systems employed by existing UAVs according to the 2013 Worldwide UAV Roundup done by the American Institute of Aeronautics and Astronautics................................ 14 2.4 Vertical take-off and landing (VTOL) and hover capability of existing UAVs according to the 2013 Worldwide UAV Roundup done by the American Institute of Aeronautics and Astronautics.................. 15 3.1 Research Process Layout............................ 29 4.1 Selection process elements and relations layout............... 32 4.2 Applications divided according to most suitable Gas turbine engine type. 33 4.3 UAV civil applications versus UAV types versus gas turbine engine types. 34 4.4 Design and system performance trends evaluation of existing UAVs.... 37 4.5 EADS Harfang UAV views, from [2]..................... 38 5.1 GSP model of the MGT............................ 49 5.2 Design Point Equation Scheduler for Inlet air mass flow.......... 50 5.3 Design Point Equation Scheduler for Compressor Design Efficiency.... 51 5.4 Loop Case Control input series for DP analysis............... 54 5.5 Flight Envelope for the Off-Design Simulations............... 55 5.6 Thrust Management Tables structure..................... 58 6.1 Carpet Plot for a Scaling Factor of 0.47 with power output and specific fuel consumption variations for different technology levels (pressure ratio effects on components efficiency not included)................ 60 xi xii List of Figures 6.2 Carpet Plot for a Scaling Factor of 0.47 with power output and thrust specific fuel consumption (TSFC) variations for different technology levels (pressure ratio effects on components efficiency not included)........ 61 6.3 Variation of TSFC with compressor pressure ratio for different TIT at DP. 61 6.4 Carpets trend (SFC over Power) with engine size reduction. Green plot refers to a scaling factor of 0.33, blue plot to SF=0.39, and black plot to a SF=0.47..................................... 62 6.5 Carpets trend (TSFC over FN) with engine size reduction. Green plot refers to a scaling factor of 0.33, blue plot to SF=0.39, and black plot to a SF=0.47..................................... 63 6.6 TSFC trend for different engine sizes with flight Mach
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