Blade or wing
11273902 · 2022-03-15
Assignee
Inventors
Cpc classification
F03D1/0633
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T50/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B64C2003/445
PERFORMING OPERATIONS; TRANSPORTING
B64C2003/543
PERFORMING OPERATIONS; TRANSPORTING
F03D1/0675
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/72
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F05B2250/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2240/31
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01D5/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B64C3/48
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A blade or wing element includes a plurality of ribs (20) rotatable and/or slidable with respect to one another whereby to vary the aerodynamic configuration of the blade or wing element by causing a twist thereof. A blade or wing or blade or wing assembly, including such a blade or wing element is disclosed, as well as an aerodynamic apparatus such as an aircraft, or a wind turbine. A method of assembling a blade or wing element is also disclosed.
Claims
1. A blade or wing comprising a blade or wing element comprising: (a) many ribs slidable with respect to one another whereby to vary an aerodynamic configuration of said wing element by causing a twist thereof, wherein the leading edge and trailing edge of each rib are at said leading edge and trailing edge of said blade or wing; and wherein said ribs are adjacent and substantially without gaps between adjacent ribs whereby to provide a substantially smooth surface to said blade or wing element.
2. The blade or wing of claim 1 further comprising: (b) a plurality of actuators, each actuator of said plurality of actuators being coupled to an associated rib and each actuator being operable to rotate said respective associated rib.
3. The blade or wing of claim 2, wherein each said actuator is coupled to a main spar and is operable to rotate said respective rib with respect to said main spar.
4. The blade or wing of claim 3, wherein each actuator is coupled to the main spar via a lever arm.
5. The blade or wing of claim 4, wherein each actuator is operable to cause the respective lever arm to rotate about a pivot position in the main spar to cause a rotation of the respective rib.
6. The blade or wing of claim 2, wherein each actuator includes a servomotor.
7. The blade or wing of claim 1, wherein the ribs are coupled together by a linkage member configured to resist relative rotation of the ribs.
8. The blade or wing of claim 1, including at least one stiffening rod coupled to each of the ribs to resist relative rotation of the ribs.
9. The blade or wing of claim 1, wherein the ribs are uncovered.
10. The blade or wing of claim 1, wherein the ribs are compliant to deformation in width.
11. An aerodynamic apparatus including said blade or wing element according to claim 1.
12. The aerodynamic apparatus of claim 11, wherein said aerodynamic apparatus is an aircraft or a wind turbine.
13. The aerodynamic apparatus of claim 11, wherein said aerodynamic apparatus is a wind turbine.
14. The blade or wing of claim 1 wherein each rib comprises an elastomeric material and a rigid support.
15. The blade or wing of claim 1 wherein the wing element is over the complete wing span.
16. A method of assembling a blade or wing element wherein said blade or wing element comprises many ribs rotatable or slidable with respect to one another whereby to vary an aerodynamic configuration of said wing element by causing a twist thereof, wherein the leading edge and trailing edge of each rib are at said leading edge and trailing edge of said blade or wing; and wherein said ribs are adjacent and substantially without gaps between adjacent ribs whereby to provide a substantially smooth surface to said blade or wing element, said method comprising compressing said ribs before coupling an at least one stiffening rod.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENT(S)
(52) Some embodiments of the disclosure can be used for providing a wing section of an aircraft such as an aeroplane.
(53) As described below, a morphing wing section can be provided by a plurality of adjacent ribs which can slide and rotate slightly with respect to each other so as to create a smoothly changing twisting wing surface. In some embodiments, a control rod and at least one stiffening rod are coupled to the ribs, for example by passing through them, and are secured to an end element of the wing. By rotating the control rod, the end element is rotated, which causes the at least one stiffening rod to bend. The bending of the at least one stiffening rod causes each of the ribs to rotate, with the ribs rotating an increasing amount towards the end element, with each rib sliding slightly with respect to its adjacent rib. The result is a smooth but changeable and controllable twistable wing surface.
(54)
(55) As can be seen in
(56) The wing on each side of fuselage 16 has a longitudinal or spanwise dimension or direction 18 extending away from fuselage 16. As can be seen from
(57) The wing on each side of fuselage 16 also has a chord line which is an imaginary line from the leading edge of the wing to the trailing edge of the wing.
(58) As can be seen in
(59) Each of ribs 20 has a transverse cross section which corresponds to the transverse cross section of fixed wing section 12. In some preferred embodiments, the transverse cross section is in a plane parallel to the interface with an adjacent rib and perpendicular to the width of the rib. Having corresponding transverse cross sections means that an outer perimeter of the cross section of each rib 20 preferably corresponds to, and is preferably the same as, the outer perimeter of the cross section of fixed wing section 12.
(60) In some embodiments, the ribs are adjacent in a spanwise direction.
(61) In at least some embodiments, ribs have substantially no gaps between them, thereby providing a smooth surface to the morphing wing section.
(62) In some embodiments, ribs 20 are made of wood, although other materials can be used. In some embodiments, the surfaces of the ribs which are to form wing surfaces can be sanded and/or lacquered.
(63) In some embodiments, the ribs can comprise an elastomeric material such as rubber which is compliant to deformation in width to seal gaps between adjacent ribs and prevent, or at least reduce the chance of the ingress of foreign material. Such embodiments can also include a rigid metal support to provide rigidity. In some embodiments, across the width of a rib, the rib can comprise a metal rib element adjacent to an elastomeric rib element, and the ribs can be arranged so that the metal element of one rib is adjacent to the elastomeric element of an adjacent rib.
(64) As can be seen particularly in
(65) In the embodiment shown, first frame member 26 is at a top surface of the wing, and second frame member 28 is at a bottom surface of the wing.
(66) In some embodiments, rib 20 is substantially hollow between the first and second frame members. However, it is not excluded that the rib could be solid or contain some other filling or support between the frame members.
(67) In some embodiments, such as the one shown, the width of the rib is significantly less than the height of the rib.
(68) It is to be noted that although the frame is described as including first and second frame members, the frame can be a monolithic structure.
(69) In some embodiments, the frame further includes a plurality of bridging support members 34 which bridge from first frame member 26 to second frame member 28 and provide support for the cross-sectional shape of rib 20.
(70) In at least some of the embodiments, each of ribs 20 includes a plurality of rod coupling elements, including control rod coupling element 22 and a plurality of stiffness rod coupling elements 24. In some embodiments, at least some of the rod coupling elements are spaced, the spacing preferably providing separation at least along the rib line. In other words, at least some of the rod coupling elements are preferably spaced along but not necessary located directly on the rib line, although they can be located directly on the rib line in some embodiments. In the shown embodiment, the rod coupling elements are provided as holes to allow the rods to pass through ribs 20. The rod coupling elements are for coupling the ribs to control and stiffness rods to allow the ribs to rotate but provide a continuous surface as described below.
(71) In the embodiment of
(72) In the embodiment of
(73) In some embodiments, control rod 42 passes through control rod coupling element 22 of each of the ribs of morphing wing section 14. In some embodiments, control rod coupling element 22 of each rib 20 is configured to allow control rod 42 to rotate there within. In this example, control rod 42 is a steel shaft encased in a carbon tube. However, other materials can be used for control rod 42 and for a control rod sheath.
(74) In some embodiments, stiffening rods 44 are coupled to each rib 20 at each of the stiffening rod coupling elements 24. The size of the stiffening rod coupled to each stiffening rod coupling element 24 corresponds to the size of rod for which the stiffening rod coupling element is designed as described above. In some embodiments, stiffening rods have some flexibility but are generally stiff and are configured to limit the degree of rotation or sliding of each rib 20 with respect to its adjacent rib, thereby to ensure, or at least increase the likelihood, that morphing wing section 14 retains a smooth gradually changing surface when control rod 42 is actuated to provide rotation to ribs 20.
(75) In the example shown, stiffening rods 44 are carbon rods. However, other materials can also be used.
(76) In some embodiments, all of the rods extend parallel to the axis of rotation of the ribs and in the spanwise direction. However, in other embodiments, they could for example extend at an angle to the spanwise direction.
(77) In some embodiments, the ribs can be rotatable in a plane perpendicular to the axis of the control rod. However, in other embodiments, each rib can be rotatable in a plane that is at a non-perpendicular angle to the axis of the control rod.
(78) As shown in
(79) In some embodiments, control rod 42, and each of stiffening rods 44, of the morphing wing section, are secured to and terminate in the end element.
(80) In some embodiments, end element 46 can be rib 20 with a solid cross section. In some preferred embodiments, it is rounded in accordance with known practices since it is preferably at the end of the wing. In other embodiments, end element could be an end rib with a further section of wing beyond it.
(81) In at least some embodiments, each morphing wing section 14 has its own control rod and set of stiffness rods. In other words, one set of control and stiffness rods pass through each rib of a morphing wing section; but there can be a plurality of such sets of rods, each passing through a respective morphing wing section.
(82) In some embodiments, each morphing wing section 14 has an associated control unit 36. Control unit 36 for morphing wing section 14 can be seen clearly in
(83) As can be seen from
(84) Stiffening rods 44 can be securely coupled to the respective control unit 36, for example to substrate 40 thereof, as shown in
(85) When the control rod is in a non-actuated state, in which it is not providing rotation to any of ribs 20, the ribs are held by the control rod and stiffening rods so as to provide a continuous surface which is flush with the surface of fixed wing section 12.
(86) In at least some embodiments, when control unit 36 is operated to actuate control rod 42, the control rod causes rotation of end element 46, causing the angle of the chord line at end element 46 with respect to the chord line at fixed wing section 12 to change.
(87) In at least some embodiments, in the actuated state the servos also provide rigidity to the structure.
(88) In some embodiments, the rotation of end element 46 causes bending of the stiffening rods which is resisted by the stiffness of the stiffening rods owing to their being coupled in these examples to control unit 36. In some embodiments, the displacement of the stiffening rods from their unbent configuration is greatest adjacent to end element 46 and smallest adjacent to fixed wing section 12. In some embodiments, the bending of the stiffness rods causes the ribs to rotate owing to the separation of the stiffness rods from the axis of rotation of the ribs. Similarly to the degree of displacement of the stiffness rods, ribs 20 close to end element 46 rotate to a larger extent, though not quite as extensively as end element 46. In addition, in at least some embodiments, most, if not all, the ribs between end element 46 and fixed wing section 12 rotate but to a diminishing extent towards fixed wing section 12. The ribs therefore align in a very smooth manner causing a very gradual change, or twist, in wing configuration from fixed wing section 12 to end element 46.
(89) Typically, when the wing twists, there is an axial load on the stiffening rods due to the very small increase in length required when twisting. In some embodiments, during assembly, the end element and ribs are compressed before the stiffening rods are coupled or secured to the assembly. In this way, the ribs and end element collectively act like a spring when twisted, and maintain a smooth, gap-free surface.
(90) Details of another embodiment are shown in
(91) It is to be noted that for a large wing, the rib thickness can be larger without large drag increases. With regard to the internal distribution, size, and material of the stiffening rods, the bigger they are and the more in number makes the structure less/more stiff. They also provide the means to align most, if not all, the ribs precisely to maintain a smooth overall surface.
(92) Another embodiment of the disclosure is shown in
(93)
(94) In place of the control rod of other embodiments, the embodiment of
(95) In the embodiment of
(96) In the embodiment of
(97) In some embodiments, each actuator 138 is connected to main spar 142 via respective lever arm 139. Each lever arm 139 is coupled to main spar 142 at a respective lever arm junction 141. Each lever arm junction 141 provides a pivot position for the respective lever arm 139, which allows the respective lever arm the ability to rotate about the axis of the main spar, as well as to translate in and out of the body of main spar 142.
(98) Each actuator 138 is operable to rotate the respective associated rib(s) about main spar 142.
(99) As discussed above, there are provided a plurality of actuators 138 coupled to main spar 142 and to respective associated ribs along the span-wise direction of the morphing wing section. Actuators 138 are spaced several ribs apart in the span-wise direction.
(100) In some embodiments, each actuator 138 is coupled to a common control unit (not shown).
(101) In some embodiments, the control unit is operable to operate each of the actuators independently of each other. When actuated, each servomotor 138 imparts a rotation that causes lever arm 139 to rotate about the pivot position in main spar 142. Lever arm 139 being effectively anchored by main spar 142 causes an adjustable and local rotation capability about the axis of the main spar, rotating the respective associated rib(s) about main spar 142.
(102) In addition, owing to the presence of stiffening rods 44 discussed above, ribs adjacent to the respective associated rib(s) receive a force urging them to rotate in a similar manner, thereby maintaining a smooth wing surface.
(103) In at least some embodiments, if different servomotors 138 are rotated to different degrees along the span-wise direction of the morphing wing section, the stiffening rods are caused to bend between these different servomotors 138. The bending of the stiffening rods causes ribs between the different servomotors to rotate to different degrees, causing a gradual change in rotation degree for ribs between the different servomotors. This provides a very smooth gradual change or twist in wing configuration between the different servomotors. In this way, wing twist can be adjusted locally to provide adaptive wing twist distributions that allow maximum efficiency of wing loadings as required.
(104) Although some of the above embodiments include a fixed wing section, this is not necessary in all embodiments. The fixed wing section does not need to be fixed with respect to the fuselage. In addition, the components of the fixed wing section can for example be provided in the fuselage itself.
(105) In some embodiments, the morphing element can be over the complete wing span, not only a portion.
(106) Furthermore, the above described embodiment relates to a morphing wing section. However, in other embodiments, the morphing section can also be applied to a winglet of an aircraft, to a helicopter blade, or to a blade of other aerodynamic apparatuses, such as a wind turbine. In such embodiments, there would be provided blade sections rather than wing sections, and instead of a fuselage they can be coupled to a blade hub. The blade of a wind turbine is made up of an aerodynamically shaped profile that produces both lift and drag. The blade can be constructed as a plurality of ribs being actuated as described herein. For this example, a section of (or complete) blade can be comprised of many ribs mounted one-after the other along the span of the blade and allowed to slide relative to one-another to enact a change in twist along the blade span. This behaviour would be synonymous with the application for an aircraft's wing.
(107) Some embodiments include multiple ribs with each rib assembled with multiple carbon rods. As is known for morphing concepts challenges such as surface deformation and the strength under aerodynamic load are the main issues. Therefore, in at least some embodiments, these carbon rods are used at the origin of the wing chord to provide stiffness for the structure and to offer an aerodynamically smooth surface finish while allowing the wing twist. The main Carbon tube is also placed at the quarter chord of the model to provide actuator torque. This also provides durability to the wing structure and alignment together with the other morphing elements.
(108) In an example embodiment, the morphing elements were made of thin wood materials. The thickness size was determined from initial structural analysis, with the surface smoothness a main consideration to decide the right size for the morphing elements. Following that, the weight of the morphing elements was reduced to increase twist angle and reduce friction effects, hence low actuation energy was required to achieve twist. In assembly, significant attention was needed for the interface between the ribs and rods, consequently they were tightly fitted to reduce, if not eliminate, wrinkling and separation on the surface. This helped to achieve the similar drag profile relative the baseline fixed wing configurations. In addition, due to wood's rough surface, morphing elements were sanded and lacquered to receive the full benefits of the morphing twist system. A servo actuator was used with a servo-driven mechanism to actuate the twist. To enact twist deformation on the structure, moment (3.43 Nm) was applied to the main carbon tube. This moment was estimated through the torsion equation with desired twist change (minimum ±6°). Although, the friction effects were negligible in this model due to small surface area between each rib and the interface between the ribs and rods, additional torque was also estimated and the servo actuator was chosen based on high torque requirements. To allow the actuator tube to rotate the entire model, an end section was designed and placed at the tip of the structure with rods a fixed. When servo torque was applied to the carbon tube, the end support enacted twist by rotating all morphing elements correspondingly. This co-ordination was controlled by the carbon rods and the end-section.
(109) One of the important benefits of this design is the ability to maintain a skin with a low drag (smooth surface finish) while twist deformation is in action. Moreover, the structure is lightweight and strong enough to carry aerodynamic loads. Comparing with current mechanisms, this mechanism largely overcomes most, if not all the morphing wing challenges.
(110) Further details of an experimental example are provided below.
(111) A design of an active wing twist with adaptive skin for morphing aircraft control and performance is provided below. The design includes a pair of active morphing elements which was designed to overcome skin problem as well to actively adjust wing twist angle using servo-driven mechanism. Preliminary design and Finite element analysis were carried out in ANSYS Mechanical and CATIA V5. Also, Athena Vortex Lattice (AVL) used as a CFD tool to analyse aerodynamic response of wing twist. Subsequent to numerical study, wind tunnel model was built and tested. To compare the effect of morphing mechanism with full baseline wing was used. Moreover, aileron configurations were also built and tested in the wind tunnel to investigate achieved roll rate. Afterwards, flight testing was performed with an Extra 300 78 inch remote controller aircraft with the results being compared against existing fixed wing configurations. Results presented below show the design does provide evidence for aerodynamic efficiency with smooth surface finish. Furthermore, it gives a good indication for controlling of an aircraft which was validated through flight testing with similar roll authority achieved compared to traditional aileron configuration.
(112) The motivation for this study was to explore novel concepts of active wing concepts for morphing aircraft control and performance. The primary variables investigated involved changing the twist angle with the main aim being to identify degrees of movement both experimentally and numerically. ANSYS Mechanical and Athena Vortex Lattice software packages were used to obtain the numerical results and also for rib (skin) optimization. Principle aim was then to assess and demonstrate the developed concept within both the wind tunnel and flight test environment. This investigation also aimed to develop an alternative approach for a morphing skin.
(113) Numerical Analysis
(114) As a first step of the adaptive skin development and to ease the manufacturing difficulty, the straight wing was initially considered and created in AVL to provide aerodynamic data for ANSYS FEA tests. Obtained FEA data was used to compare with a wind tunnel model. Following that the analysis tool for the flight testing model mechanism and structural analysis setups are also described. Both adaptive skin and twist system were analysed in ANSYS and data used for comparison.
(115) Aerodynamic Load Prediction
(116) The aerodynamic modelling and numerical computations were carried out using Athena Vortex Lattice (AVL) software. Athena Vortex Lattice is a simulation package that determines the solutions to a linear aerodynamic flow model. For all simulations, modelling was performed from a set of wing panels along the wing span and chord axes (computational model of wing/winglet structure is shown in
(117) For all simulations, the free-stream velocity was set to 30 m/s and 40 m/s and all results were calculated without the influence of compressibility. In order to be computationally efficient, a grid refinement study was performed on the baseline configuration prior to widespread use of the developed model.
(118) Finite Element Model Analysis
(119) The Finite Element Modelling (FEM) was carried out using ANSYS Mechanical and CATIA V5 software packages. The wing structure was modelled in CATIA V5 design software and then imported to the ANSYS software structurally and, together with AVL results, investigated further the aerodynamic and structural relationship. The FEM structural model of the wing was also used to assess the magnitude of the wing-twist deformation magnitudes for the concept. In order to achieve this, external AVL of aerodynamic loads were applied to this morphing concept.
(120) Table 1 shows the material properties of the wing components. Laser ply (for wind tunnel model) and Balsa (for flight test prototype) were used for ribs, and carbon materials were used for rods and tube to provide strength of the model. To provide twist movement, end-bit part was manufactured which was made of Raku-Tool WB-1700 (for wind tunnel model) and P400 ABS Plastic (for flight test prototype).
(121) TABLE-US-00001 TABLE 1 Summary of Material Properties Tensile Strength, Materials MPa Raku-Tool WB-1700 85.00 Laser Plywood Sheets 70.93 Balsa Wood 30.00 P400 ABS Plastic 56.58 Carbon Fibre 600.00
(122) Once the geometry and the materials had been applied, the assembled ribs began to constraint.
(123) Experimental Setup and Apparatus
(124) The experimental testing was carried out at Brunel University, in a 0.46 m×0.46 m open circuit low speed wind tunnel, giving a maximum operating free stream velocity of 40 m/s. Three different configurations were used with fixed baseline wing, morphing wing, and wing with an aileron components. For flight testing, the flying site used for this study was Playing Fields. In total four circuits were completed. Two of them were with a fixed wing configuration and the other two were with the morphing configuration. Flight data were recorded for each circuit and then analysed to investigate flight performance.
(125) Morphing Wing Geometry and Twist Mechanism
(126) The model choosing for this twist demonstration study and its twist parameters are shown in
(127) The morphing actuation mechanism was critical for the concept to work adequately. It also had to be integrated into the model seamlessly to minimise drag. Once the mechanism is working, the vibration should be minimal in order to achieve accurate system performance. To accommodate this system, a part of the bottom section of the wing was removed and an internal mechanism installed inside the wing. Some support parts were used to provide adequate housing support for the mechanism as is shown in
(128) The morphing mechanism was placed inside the wing profile. The twist mechanism encompassed one Hitec HS-7950 TH high voltage torque servo, which was a titanium gear coreless servo. It is rated at 3.43 N-m torque at 7.4 Volts, and was retrofitted with a belt drive system operating with a 1:1 gear ratio to rotate the shaft, which was positioned at the quarter chord of the overall wing. When the servo torque was applied to this shaft to end-support would enact twist. A belt tensioning system was also set up inside the wing profile to allow belt tension adjustment. The system consisted of the ABS plastic boxes, which were glued to the bottom side of the wing and the top side of the system was free to slide and tension the belt. On this top surface, a bearing was used with a servo shaft connected to provide alignment and support structural bending. Once the belt system was tensioned, the top surface (plate) was screwed to the bottom side to maintain the aerodynamic shape. Space was also left inside the wing section for the servo cable to exit the wind tunnel support and connect to the driving electronics. Additionally, in order to reduce vibration, additional support boxes were also fastened and glued to the inside of the wing profile to further support the servo as well as the gears.
(129) For the morphing section each of the 239 ribs were made from 0.6 mm thick laser plywood sheet. For the combined morphing structure, CAD designs were imported into ANSYS to analyse structural performance to ensure it could withstand the required aerodynamic loads. Several rib designs and configurations were tested. After these exploratory investigations (mentioned in result section), it was decided that 2 carbon rods and one carbon tube would provide satisfactory stiffness to the concept. These lightweight and strong carbon fibre rods were both glued and screwed to the main wing. The torsion tube, which was a 10 mm diameter pultruded carbon fibre tube, was also glued to the wing. The parts were then assembled and the end-section was mounted and screwed with nuts and grub screws. Cavities were filled and sanded to create an aerodynamically smooth surface finish. After assembly, the top and bottom sections of the rib surfaces were also sanded in situ to ensure a smooth, aerodynamically clear surface. The completed wing internal mechanism is indicated in
(130) To attach the wing model to the wind tunnel, a 10 mm diameter steel tube was also fastened and glued with epoxy resin at the quarter chord point of the wing model. The servo motor cable was then passed from the steel tube and pulled out from the holes created for this purpose on the steel tube. An aluminium cover was also designed to enclose the top of the mechanism. To reduce undue aerodynamic flow behaviour, the exposed part of the cover was trimmed and sanded back to the main wing surface creating an aerodynamic smooth surface finish. To compare the results of morphing concept, a full wing baselined-fixed was separately manufactured (shown in
(131) In order to make a direct comparison and further validate the morphing concept and a traditional aileron system for roll control, six different ailerons (±10°, ±20° and ±30°) was designed and manufactured (as shown in
(132) The decision was also based on the calculated twisted wing roll rate as discussed in ESDU, “Rolling Moment Derivative, L ξ for Plain Ailerons at Subsonic Speeds,” (August 1988).
(133) Each aileron was made from a combination of 6 mm thick elements in a combined linear array.
(134) The final model is shown in
(135) Flight Test Mode
(136) The model chosen for this study was an Extreme flight Extra 300 with a 78-inch wingspan. The baseline wing configuration comprised a symmetrical airfoil section and a 2.5° leading edge sweep angle, a 1.980 m wing span, a 0.5 m root chord, and a 0.27 m tip chord, with aspect and tip ratios of 5.45 and 0.54 respectively. The fuselage part was 1.930 m long and the maximum thickness was 0.215 m. In this study two wing sets (left and right wing) were used (the schematic view of the plane is shown in
(137) For the twist mechanism, due to the weight requirements for an actual flight environment, balsa wood sheets were used as the main material for the ribs and the inside of the rib sections. The number of stiffening rods selected was based on the achievable twist displacement. The final model consists of 365 balsa wood ribs, which were cut using a Laser Cutter machine. The active wing model also had eight small carbon rods (each with a 0.5 mm diameter) that were distributed along the wing span. These rods produced an aerodynamic smooth surface while morphing as well as making the structure able to resist aerodynamic load. Additionally, two 1.5 mm diameter carbon rods were used at the origin of the wing chord. These also aimed to provide durability to the wing structure. Furthermore, the main carbon tube (10 mm outer-diameter) was used to align the ribs as well as to accommodate the internal shaft to rotate the end-section. The internal mechanism is also shown in
(138) Additional parts were needed to increase the strength of the edge of the fixed wing structure. Therefore 15 mm ribs consisting of 1 piece of plywood (6 mm thick) and 3 pieces of balsa wood (3 mm thick) were glued to the end of the wing structure. Additionally, a carbon tube was used to increase the strength of the wing tip for both wings. This was important due to the morphing element creating additional load when the twist was rotated. The carbon rod tube was then glued to the main wing with the ribs able to rotate with the twist action.
(139) The actuator mechanism for the twist movement consisted of a Hitec HS-7950 TH high voltage torque servo (which is a titanium gear coreless servo, 3.43 N-m maximum Torque at 7.4 Volt), a steel shaft, an attachment pin, bearings, a washer, nuts, and the ABS plastic made end-section. The steel shaft was positioned at the quarter chord of the wing over the span of the structure.
(140) The manufactured servo coupling held the connection between the servo motor and the steel shaft. The other side of the steel rod was connected to the end-section using a fitted attachment pin as well as additional nuts. Activating the servo rotated the end-section where all of the interconnection carbon rods were bonded. To align the steel rod with a carbon tube and to reduce any misalignment inside the carbon tube, four bearings were positioned and fixed to the steel rod. A 3 mm plywood cut and was also glued to the required position inside the wing to support the servo (
(141) After installing all servo mechanisms, shafts and electrical connections, baseline and morphing concept were compared to investigate any differences between these two wing configurations and the baseline wing was found to be lighter (54 gram less) than the morphing wing.
(142) A Futaba R617FS 2.4 GHz FASST 7-Channel receiver was used as the main controlling device. Servo cables, which provide wing twist, pitch, yaw and thrust, were connected to the receiver. These control surfaces were controlled by the transmitter (Futuba T10CG 2.4 GHz 10-Channel T-FHSS radio system). An Eagle Tree data flight recorder was used with a Seagull wireless data transmitter that used a static pressure/pitot tube/transducer combination for flight speed and pressure altitude, a magnetic RPM sensor for motor RPM, a thermocouple for temperature and a two axis accelerometer for g-forces in the rolling axis. Note that the G-force device was positioned on the plane's cg. The Eagle tree recorder also recorded the servo positions and control inputs from the radio. Data were recorded at 10 Hz and saved on an on-board computer. Velocity, altitude and signal strength were continuously transmitted to a ground station. The data recorder utilises a USB cord to communicate with the Eagletree software loaded on a laptop computer. RC Logger Video Telemetry and Orientation G-Force Module was also used to measure pitch angle, roll angle, direction, linear acceleration, angular position, and velocity during flight.
(143) The Wind Tunnel Measurement Environment
(144) The models as shown in
(145) The force and moment balance used to measure the performance of the wind tunnel models was an AMTI MC3A-500. To support the load cell on the wind tunnel, an aluminium balance support frame was manufactured and fixed to the tunnel wall. A spirit level and inclinometer were used to ensure that the load cell was level. The model support sting was then mounted to the active plate of the AMTI MC3A-500. To prevent contact between the support sting and the tunnel wall, a clearance hole was cut out of the tunnel lid. A symmetrical airfoil shaped fairing was manufactured and bonded to the boundary layer. Calibration of the load cell was completed before testing and derivation was found to be less the ±2.5% of full scale output. Force and balance data were measured before each section to compensate of the final test results. No wind tunnel blockage corrections and artificial mechanism were used.
(146) A Futaba R617FS 2.4 GHz FASST 7-Channel receiver and Futuba T10CG 2.4 GHz 10-Channel T-FHSS radio system (transmitter) were used to control the servo motor of the morphing wing. The Hitec Servo within the model was connected to the receiver and a 6V NiMh battery was utilised as the power source. The model would twist ϕ=±6° (
(147) To adjust the angle of attack of the wing configurations, a manual rotation stage was designed and attached to a support bar. This manual rotation stage was also mounted directly onto the force and moment balance, which was connected to the support frame fixed to the outside test-section wall. Using additional bolts, the wing support sting could be adjusted in accordance with the oncoming flow. A digital inclinometer was used to calibrate the angle of attack mechanism (position error ±0.5°). To obtain turbulence intensity, a Streamline CTA Module signal conditioners A/D boar NI e-series, miniature X wire Probe (Dantec 55P61) was used with a 55H24 probe support bar and an A1863 cable. The hot-wire voltage output was measured and averaged with the Stream Wire software. The nominal flow speed was chosen for this study V=30 m/s and V=40 m/s (±0.25 m/s), and turbulent intensity level was measured 0.35%.
(148) Results and Discussion
(149) The results were divided into three sections. First is the Finite Element Analysis (FEA) of the wing twist structures. Following that, wind tunnel results including aerodynamic force and moment results are discussed, as are comparisons to a traditional wing-aileron system to ascertain any performance enhancements. Final section shows the flight test results with comparing fixed baseline aileron configuration and morphing element.
(150) Experimental and Numerical Analysis of Wind Tunnel Model
(151) The results taken from ANSYS for the FEA model was compared directly to results from the experimental model under no-wind condition (shown in
(152) With wash-in (positive twist) deflection
(153) Comparison Between the Morphing Concept and Baseline Fixed Wing
(154) Drag coefficient results play a significant role in obtaining the aerodynamic performance of the aircraft. To illustrate the effects of morphing wing, initial test were conducted and compared to the baseline fixed wing. The drag coefficient results versus angle of attack for the morphing concept and the baseline fixed wing is shown in
(155) Static Forces and Moments
(156) The static force and moment results produced through wing twist between −6°<ϕ<6° versus angle of attack are shown from
(157)
(158) Considering further with increasing angle of attack, overall drag increases can also be seen in
(159)
(160) Further comparisons between the full span baseline wing and the ϕ=0° twist configurations are shown in
(161) For side force coefficients, there is a linear trend with an augmented side force coefficient with varying angle of attack and twist angle to a maximum (both positive and negative side
(162) The influence of twist on the rolling moment coefficient for both positive and negative twist is presented in
(163) As can be seen from
(164) The yaw moment coefficient with different twist cases versus angle of attack is presented in
(165) Influence of Reynold Number on Aerodynamic Response of Wing Twist
(166) With the decision to introduce no artificial boundary layer tripping to the model, a study of the influence of the Reynolds number on the static force and moment characteristics was conducted to investigate changes in the results in this transitional flow regime.
(167) Similar to C.sub.L, there is a reasonably coherent influence of Reynolds number with general magnitudes increasing with increasing Re.sub.n. It can be seen from
(168) Similar circumstances are discussed for Re.sub.n=3.85×10.sup.5, here for Re.sub.n=5.14×10.sup.5, considering the results for ϕ<0° as shown in
(169)
(170) For C.sub.Y, the influence of Re.sub.n is the increased effectiveness to produce side force as clear deviation is seen in C.sub.l as well. It can be seen from
(171)
(172) For C.sub.n, results show a similar trend as discussed for lift, pitching moment, and rolling moment coefficients for α<12° (
(173) Comparison Between Standard Aileron and Morphing Concept
(174)
(175) For negative angles, the lift becomes lower for reducing angle to γ=−30° and ϕ=−6°. This would be expected as reducing the effective incidence angle of the surface to decrease the lift force. Contrary to positive angles, variation between the negative twisted morphing concept and aileron configurations are slightly less and twisted concept was found to produce more lift than aileron deflections with ΔC.sub.L=0.03 (4.5%) at ϕ=−6°(α=9°) compare to γ=−30°. Reducing the angle of twist and aileron deflection angle, similar characteristics were seen with ΔC.sub.L is 0.05 (5%) and 0.01 (1%) for ϕ=−4° and ϕ=−2° respectively compare to γ=−20° and γ=−10°.
(176) For drag coefficient, there is a clear difference between the aileron and morphing concept model at large deflection angles. For the twisted morphing configuration at ϕ=6°, same the highest drag coefficients were measured only to be supposed by the aileron configuration at γ=30°. It can also be seen from
(177) Considering the results for γ<0° and ϕ<0° as shown in
(178)
(179) For the side force coefficient, a similar trend was observed for both the aileron and morphing configurations with possible exception of ϕ=2° and ϕ=−4°. It can be seen from
(180)
(181) Comparing C.sub.n results between the ailerons and morphing configurations, there appears to be much more variation compared to the other aerodynamic coefficients already discussed. It can be seen from
(182) The combined effects of lift and drag can be usefully combined by plotting the lift to drag ratio versus angle of attack (aerodynamic efficiency). To further discuss the advantage of the morphing system compared to a traditional aileron system C.sub.L/C.sub.D will be used. This is shown in
(183) To further quantify this improvement and through comparing positive and negative deflection for both aileron and morphing configurations, there is a significant improvement in terms of efficiency. For ϕ=−6° configuration, best (C.sub.L/C.sub.D) is obtained as 24.3 at α=8° and C.sub.L/C.sub.D shows 18.3% improvement over aileron configuration (γ=−30°). This rate was 22% contrary to full baseline wing model. This reduces by reducing twist angle to −4° with the efficiency reducing to 23.16 (4.7%). However, it is also promising the advantage over the aileron configuration of γ=−20°. Overall 22.66% improvements achieved at α=8° and with further increase in angle of attack to α=10°, as expected improvement rate is reduced to 17.84%, which is still high. Interestingly, the γ=−20° configuration performed similarly to a full span (zero-twist) wing profile due to low lift coefficient. As mentioned previously for a small positive angle of deflection (γ=10°) and twist ϕ=2° have minor effect on aerodynamic performance, but in here, for negative angle configurations, 10.5% improvement was seen at ϕ=−2° (α=8°) compare to full baseline wing model. Comparing ϕ=−2° with γ=−10°, 12% improvement was achieved. Thus, this smooth and continuous morphing concept appears to be more aerodynamic efficiency than the use of a standard aileron design.
(184) Lastly, to compare the effectiveness of the two concepts, the roll/drag coefficient ratio is shown in
(185) Considering the positive angle deflection in aileron and twist configurations, it can be seen from
(186) Structural Comparison Between FEA and Prototype Morphing Wing
(187) The structural deformation magnitudes without aero-load cases are shown in
(188) Rolling Rate Comparison Between the Traditional Wing Structure and Prototype Morphing Wing Concept
(189) Actual flight testing of the concept was performed to demonstrate the viability of the design. Both full wing with aileron (unmodified baseline wing) modified wings (morphing concept) were tested and compared.
(190) The altitude and flight paths adapted shown in
(191)
(192) Load factors for both the baseline (aileron) and morphing (twist) configurations are presented in
(193) In order to measure the efficiency of the morphing concept at rolling, the velocity was measured during the flight. This would provide some insight into relation drag increase in the turn. The velocity plot for both the morphing and baseline configurations is shown in
(194) According to the Pilot (Dr Alvin Gatto): “Both configurations were able to achieve the basic maneuvering. However, it was noticeable that the morphing wing enhanced performance without losing excessive velocity profile in the turn”.
(195) In at least some embodiments, it is important that skin remain smooth.
(196) A design of variable twist wings and adaptive skin concepts were described. According to results, the implemented and investigated morphing concept showed adequate aerodynamic efficiency as well as control moment for aircrafts. Moreover, the split rib design illustrates good agreement with numerical analysis (ANSYS). Finally, a morphing design also provided shape changing performance with smooth aerodynamic surface finish. Leading to the design being a viable skin for morphing application.
(197) All optional and preferred features and modifications of the described embodiments and dependent claims are usable in all aspects of the invention taught herein. Furthermore, the individual features of the dependent claims, as well as all optional and preferred features and modifications of the described embodiments are combinable and interchangeable with one another.