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Aircraft power demands continue to increase with the increase in electrical subsystems. These subsystems directly affect the behavior of the power and propulsion systems and can no longer be neglected or assumed linear in system analyses. The complex models designed to integrate new capabilities have a high computational cost. This paper investigates the possibility of using a hardware-in-the-loop (HIL) analysis with real time integration. A representative electrical power system is removed from a turbine engine model simulation and replaced with the appropriate hardware attached to a 350 horsepower drive stand. In order to update the model to proper operating conditions, variables are passed between the hardware and the computer model. Using this method, a significant reduction in runtime is seen, and the turbine engine model is usable in a real time environment. Scaling is also investigated for simulations to be performed that exceed the operating parameters of the drive stand.

Advances in the past decade of the energy and power densities of lithium-ion based batteries for hybrid electric vehicles and various consumer applications have been substantial. Rechargeable high rate lithium-ion batteries are now exceeding 6 kW/kg for short discharge times (<15 seconds). Rechargeable lithium-ion polymer batteries, for applications such as remote-control aircraft, are achieving simultaneously high energy density and high power density (>160 Whr/kg at >1.0 kW/kg). Some preliminary test data on a rechargeable lithium-ion polymer battery is presented. The use of high rate rechargeable lithium-ion batteries as a function of onboard power, electric laser power level, laser duty cycle, and total mission time is presented. A number of thermal management system configurations were examined to determine system level weight impacts. Lightweight configurations would need a regenerative thermal energy storage subsystem.

Small remotely piloted aircraft (10-25 kg) powered by internal combustion engines typically operate on motor gasoline, which has an anti-knock index (AKI) of >80. To comply with the single-battlefield-fuel initiative in DoD Directive 4140.25, interest has been increasing in converting the 1-10 kW power plants in the aforementioned size class to run on lower AKI fuels such as diesel and JP-8, which have AKIs of ~20. It has been speculated that the higher losses (short-circuiting, incomplete combustion, heat transfer) that cause these engines to have lower efficiencies than their conventional-scale counterparts may also relax the fuel-AKI requirements of the engines. To investigate that idea, the fuel-AKI requirement of a 3W-55i engine was mapped and compared to that of the engine on the manufacturer-recommended 98 octane number (ON) fuel.

Two series of tests were conducted to investigate the performance of ejection seat cushions for safety and comfort, respectively. In the safety study, seven operational and prototype cushions were tested on the vertical deceleration tower, where the cushions were placed between the seat pan and the occupant (a 50th percentile Hybrid III manikin) and subjected to +Gz impact at 8, 10, and 12 g, respectively. In the comfort investigation, twenty volunteer subjects (12 females and 8 males) with a range of anthropometry were tested on four operational and prototype cushions over eight-hour durations. The safety performance of a cushion is evaluated by the impact transmissibility from the carriage acceleration to the peak lumbar load, whereas the sitting comfort performance is assessed in terms of the peak contact pressure and subjective survey data.

The interdependency between propulsion, power, and thermal subsystems on military aircraft such as the F-35 Joint Strike Fighter (JSF) and F-22 Raptor continues to increase as advanced war-fighting capabilities including solid-state radars, electronic attack, electric actuation, and Directed Energy Weaponry (DEW) expand to meet Air Force needs. Novel analysis and testing methodologies are required to predict these interdependencies and address adverse interactions prior to costly hardware prototyping. As a result, the Air Force Research Laboratory (AFRL) has established a dynamic hardware-in-the-loop (HIL) test-bed wherein transient simulations can be integrated through advanced real-time simulation with prototype hardware for integrated system studies and analysis. This paper details a test-bed configuration where a dynamic simulation of an aircraft turbine engine is utilized to control a dual-head electric drive stand.

This paper presents the concept of a dual latent heat sink for thermal management of pulse heat generating electronic systems. The focus of this work is to verify the effectiveness of the concept during charging through experimentation. Accordingly, custom components were built and a prototype version of the heat sink was fabricated. Experiments were performed to investigate the implementation feasibility and heat transfer performance. It is shown that this heat sink is practicable and helps in arresting the system temperature rise during charging (period of pulse heat load).

Aircraft power demands continue to increase with the increase in electrical subsystems. These subsystems directly affect the behavior of the power and propulsion systems and can no longer be neglected or assumed linear in system analyses. The complex models designed to integrate new capabilities have a high computational cost. Hardware-in-the-loop (HIL) is being used to investigate aircraft power systems by using a combination of hardware and simulations. This paper considers three different real-time simulators in the same HIL configuration. A representative electrical power system is removed from a turbine engine simulation and is replaced with the appropriate hardware attached to a 350 horsepower drive stand. Variables are passed between the hardware and the simulation in real-time to update model parameters and to synchronize the hardware with the model.

Rotating Heat Pipe (RHP) technolog y is being developed for high speed (>20 krpm) regimes of electric motor/generator cooling. The motivation for this research is the potential application of the high speed RHPs for the thermal management of advanced rotating electrical machines. The passive nature and relatively simple features of this device are attractive for the removal of waste heat from the rotors of electric machines. Interesting air-cooling experimental results of two high speed RHPs designed, fabricated and tested at AFRL are presented here. Emphasis is made on external heat removal concepts useful for cooling the RHP condenser in order to be successful in promoting this technology to real world problems.

Two compact intercoolers are designed for the Rotax 914 aircraft engine to increase engine power and avoid engine knock. A study is performed to investigate the effects of unsteady airflow on intercooler performance. Both intercoolers use air-to-liquid cross flow heat exchangers with staggered fins. The intercoolers are first tested by connecting the four air outlets of the intercooler to a common restricted exit creating a constant back pressure which allows for steady airflow. The intercoolers are then tested by connecting the four air outlets to a 2.4 liter, 4 cylinder engine head and varying the engine speed from 6000 to 1200 RPM corresponding to decreasing flow steadiness. The test is performed under average flight conditions with air entering the intercooler at 180°F and about 5 psig. Results from the experiment indicate that airflow unsteadiness has a significant effect on the intercooler's performance.

The two-phase flow modeling is done using the level set method to identify the interface of vapor and liquid. The modifications to the incompressible Navier-Stokes equations to consider surface tension, viscosity, gravity and phase change are discussed in detail. The governing equations are solved using finite difference method. In the present work, investigations on the effect of thermal conductivity and latent heat of vaporization of liquid on heat transfer in a 44 µm thick liquid film containing vapor bubble with droplet impact is investigated. The importance of thermal conductivity and latent heat of vaporization of liquid on heat transfer is identified. The variation of heat flux with thermal conductivity and latent heat is plotted. The computed liquid and vapor interface, velocity vector and temperature distributions at different time instants are also visualized for better understanding of the heat removal.

The Engine Supplier Base Initiative (ESBI) is a joint Air Force/Industry cooperative agreement aimed at achieving affordable precision investment cast airfoil and large structural components for man-rated gas turbine engines. The ESBI program will obtain these goals through the implementation of business and technology improvements with specific focus on increased product quality and reduced cycle time. This program has brought together competitors in the business to solve sector wide problems. This paper presents the framework of the teaming approach as well as results achieved in quality and cycle time improvements through technical and business process improvements.

Side-facing seats are present in a variety of aircraft. During impact, these seats load the occupants in a different manner than typical forward-facing seats, namely the occupants are exposed to a lateral impact. In order to minimize injury during a crash, it is necessary for the occupants to prepare themselves and be situated in a position for maximum protection. In an effort to understand occupant initial position in a side-facing seat, a 3-D rigid-body model was developed of a side-facing seat configuration with three occupants, using the Articulated Total Body (ATB) program. The occupants were seated side-by-side in webbed troop-style seats, and each occupant was restrained by a lap belt. Three different initial occupant positions were studied, and each of the three occupants in a given simulation were seated in the same position. A 10 G lateral pulse with an approximate duration of 200 ms was applied to the vehicle.

As technology for both military and civilian aviation systems mature into a new era, techniques to test and evaluate these systems have become of great interest. To achieve a general understanding as well as save time and cost, the use of computer modeling and simulation for component, subsystem or integrated system testing has become a central part of technology development programs. However, the evolving complexity of the systems being modeled leads to a tremendous increase in the complexity of the developed models. To gain confidence in these models there is a need to evaluate the risk in using those models for decision making. Statistical model validation techniques are used to assess the risk of using a given model in decision making exercises. In this paper, we formulate a transient model validation challenge problem for an air cycle machine (ACM) and present a hardware test bench used to generate experimental data relevant to the model.

As the cost and complexity of modern aircraft systems increases, emphasis has been placed on model-based design as a means for reducing development cost and optimizing performance. To facilitate this, an appropriate modeling environment is required that allows developers to rapidly explore a wider design space than can cost effectively be considered through hardware construction and testing. This wide design space can then yield solutions that are far more energy efficient than previous generation designs. In addition, non-intuitive cross-coupled subsystem behavior can also be explored to ensure integrated system stability prior to hardware fabrication and testing. In recent years, optimization of control strategies between coupled subsystems has necessitated the understanding of the integrated system dynamics.