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Aerospace Science and Technology 53 (2016) 207–219

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Aerospace Science and Technology


www.elsevier.com/locate/aescte

Conceptual design of a hybrid solar MALE UAV


P. Panagiotou, I. Tsavlidis, K. Yakinthos ∗
Laboratory of Fluid Mechanics and Turbomachinery, Department of Mechanical Engineering, Aristotle University of Thessaloniki, 54124 Thessaloniki, Greece

a r t i c l e i n f o a b s t r a c t

Article history: This study presents the conceptual design of a hybrid solar Medium-Altitude-Long-Endurance Unmanned-
Received 2 July 2015 Aerial-Vehicle (MALE UAV) designed to perform surveillance-related missions, such as border patrolling,
Received in revised form 18 March 2016 wildfires monitoring, atmospheric data recording, search and rescue missions and telecommunications.
Accepted 26 March 2016
For this purpose, a conceptual design methodology was also developed, focusing on the energy
Available online 1 April 2016
management of the aerial platform. Specifically, the presizing calculations are presented, including
Keywords: the methods for estimating weight, aerodynamic and performance parameters. In order to perform a
Aerodynamic design complete aerodynamic study and accurately estimate the aerodynamic coefficients, theoretical analytical
UAV methods were employed, along with Computational Fluid Dynamics (CFD) analysis. A refined weight
CFD sizing methodology is presented in detail, including a solar power estimation technique, which allows
Solar energy for a balanced selection between fuel amount, panel area and battery size. The conceptualization of the
power system, the selection of appropriate solar panels and the sizing of the batteries are also discussed.
Finally, the results of the conceptual design procedure are presented and appropriate conclusions are
drawn.
© 2016 Elsevier Masson SAS. All rights reserved.

1. Introduction 21st century. Various studies present the aerodynamic design pro-
cedure of solar aircraft. For example, a conceptual design method
Modern Unmanned Aerial Vehicles (UAVs), ranging from micro- for solar powered aircraft is presented in Hajianmaleki [3]. Young-
scaled vehicles to large-scale aerial platforms, comprise intelligent blood and Talay [4] and Reinhardt et al. [5] carried-out design
autonomous systems capable of carrying-out multiple tasks and studies of unmanned solar-powered platforms. Furthermore, a sig-
missions, such as forest monitoring and fires detection, board pa- nificant progress on the field of unmanned solar aircraft has been
trolling, weather monitoring for research purposes and search and carried-out by the research group working on the HELIPLAT project
rescue missions [1]. The main advantages of UAVs arise from the [6–8], including aerodynamic, structural, construction and testing
lack of crew, and are the reduced operational cost, the ability to considerations.
operate under hazardous conditions and their improved endurance. The operation of a so-called “solar aircraft” is based on a rather
Considering the latter, the flight endurance is essentially limited simple procedure. Solar panels installed on the external surfaces of
from the available fuel onboard, which up to this day is the basic the aerial vehicle collect the power from the sun during daylight
source of energy of both manned and unmanned aerial vehicles. It and transfer it to the aircraft’s batteries, which in turn power the
therefore follows that the utilization of alternative energy sources, propulsion systems and the electro-optical equipment of the air-
and specifically renewable energy sources, could aid a long way in craft. The panels and the batteries have to be appropriately sized,
increasing the flight time. in order to ensure that there is enough energy surplus available to
The transition from fossil fuels to renewable energy sources power the vehicle during the night i.e. when the sunlight is absent.
is an ambition not just at the field of flight though. In the last Therefore, it follows that the use of solar energy can help to
decades, a considerable effort concentration towards that direc- dramatically increase flight endurance, and even unlock the poten-
tion has led to an evolution of the renewable energy resources tiality of “eternal flight” [9], thus adding to the aforementioned
technologies [2]. Therefore, specifically at the field of aeronautics, advantages of UAVs. As mentioned in Jashnani et al. [10], addi-
utilizing alternative energy sources, and mainly solar energy, for tional benefits of solar aircraft are the reduced pollutant emis-
flight applications is becoming more feasible and realistic in the sions, the reduced operational and maintenance cost and the abil-
ity for the UAV to operate at higher flight altitudes. On the other
hand though, solar aerial vehicles also have several disadvantages.
* Corresponding author. The collected power depends highly on weather conditions (e.g.
E-mail address: kyak@auth.gr (K. Yakinthos). cloud density) and operational latitude, whereas the solar radiation

http://dx.doi.org/10.1016/j.ast.2016.03.023
1270-9638/© 2016 Elsevier Masson SAS. All rights reserved.
208 P. Panagiotou et al. / Aerospace Science and Technology 53 (2016) 207–219

Nomenclature

English symbols W weight


E energy Greek symbols
H solar hour angle
I power per unit area α angle of attack
P power η efficiency ratio
V flight speed ρ air density

varies largely between different times of the year, thus affecting solar aircraft, which mainly refer to the absence of stored fuel
the performance of the aircraft. Furthermore, it should be men- and to some unique structural features, such as solar panels
tioned that there are few aircraft systems manufacturers able to and batteries. Therefore, different weight estimation methods
deliver products capable of working under severe environmental have to be used.
conditions, as the ones found above 15 km, due to the fact that • The performance characteristics of a solar aircraft vary from
only few aerial vehicles have been designed to operate in such al- that of a conventional UAV as well, with the operational flight
titudes [11]. speed being a typical example. Specifically, since the wing area
In the present study, the conceptualization of an aircraft that of a solar aerial vehicle is considerably larger, the cruising, loi-
will utilize both solar and conventional energy sources is at- ter and stall speeds are lower.
tempted. Thus, the benefits of solar-powered flight are exploited,
As a first step, and in order to overcome the disadvantages of
while the conventional power source provides the system with in-
solar aircraft as presented above, e.g. dependence on weather con-
creased reliability and versatility, being for example less dependent
ditions, day of year and latitude and lack of know-how, it was
on weather conditions. At first, three different concepts for the
decided to design a hybrid unmanned aerial vehicle, which will
hybrid propulsion system are proposed, and the selection proce-
utilize both conventional and renewable energy sources. Thus, the
dure of the solar panels and batteries is discussed. A custom sizing
conceptual design process that will be explained below is based on
methodology is presented in detail, including a solar power esti-
the conventional presizing methods as described in [12,13,16], but
mation method that allows for the estimation of the collected solar
at the same time it incorporates the key elements of solar aircraft
power in respect to the time of the year. A detailed aerodynamic
design.
study is also made, including CFD computations. Finally, an initial
concept is developed, answering the basic design aspects, and its
characteristics are presented and discussed. 2.1. Solar cells and energy storage systems

2. Design methodology In this section, the basic aspects of the solar cells and batteries
selection procedure are presented and an initial selection is made.
It should be noted though, that since this work focuses on the
When it comes to sizing a traditional aircraft, there is a detailed
conceptual design stage, the analysis is kept at low detail.
documentation considering all aspects of the design procedure,
Solar cell selection is a crucial aspect of solar aircraft design.
including presizing methods, stability estimation methods and sys-
Considering the efficiency, solar cells technologies are experienc-
tems design [12–16], following almost a century of experience and
ing a continuous growth with a gradual improvement [21]. How-
dozens of concepts in several aircraft categories. Especially in the
ever, several other parameters have to be taken into account, such
case of unmanned aerial vehicles, the design process is simplified
as the relation between efficiency and weight, i.e. good collective
due to the lack of on-board human passengers [17,18].
efficiency at the lower possible weight, and the cells’ structural
However, the design procedure of a solar aerial vehicle varies
strength, in order to sustain the loads that are applied i) during
considerably from that of a conventional design. Taking into ac-
their installation on the wing, due to the curvature of the upper
count that solar flight is a relatively new field in aeronautics, and
side, and ii) during flight, due to the aerodynamic loads.
that there are only a few existing concepts and prototypes, limited
For the conceptualization of the hybrid UAV, monocrystalline
to experimental applications and research purposes, it follows that
silicon (monoSi) cells were selected, such as the ones that have
dedicated presizing methods for solar aircraft are limited as well.
been used in previous applications [22]. The monoSi cells that are
Due to the aforementioned advantages of solar aircraft though, the
currently available in the market reach efficiencies up to 22.5%,
field of solar flight is a much promising technological field, and nu-
at 20 ◦ C [23], a ratio that rises as the temperature decreases [11].
merous researchers have attempted to develop sizing methods and
The solar cells are heated during their operation, but at the same
describe the design process of a solar aerial vehicle [3–6,9–11,19,
time the low ambient temperature (−30 ◦ C) at the operating flight
20]. The most notable variations between the design of a solar and
altitude (7 km, as stated in the mission requirements paragraph
a conventional aircraft are listed below:
of Section 2.3) aids in their cooling. A detailed cooling study is
• When sizing a conventional aircraft, the main wing area (S) is required in order to calculate the temperature at the surface of
defined by the performance parameters. The wing area must the cells, and consequently the efficiency ratio. However, as such
be large enough to ensure that the aerial vehicle can achieve a study is not to be made at this early design phase, the value of
certain performance requirements, such as minimum (stall) 22.5% was employed for the calculations. Furthermore, the monoSi
speed and landing distance. In the case of a solar aircraft cells are relatively light and have good structural characteristics,
though, the main wing hosts the majority of the solar panels. whereas the fact that they are being used in similar applications
Therefore, the sizing of the main wing is defined by the re- adds in their reliability. Finally, the weight estimation of the solar
quired panel area, and consequently the energy requirements cells was based on the methodology used in [10], and was carried-
of the flight. out by using the density of silicon (ρsilicon = 2329 kg/m3 ), adding
• When it comes to weight sizing, there are several considera- a percentage for coating and accessories. The solar cell thickness,
tions that have to be taken into account in the special case of a or t cell was estimated at 135 μm based on similar applications [22].
P. Panagiotou et al. / Aerospace Science and Technology 53 (2016) 207–219 209

Fig. 1. Examples of the hybrid propulsion system configuration. Independent operation (a), Serial (b), and Series/Parallel (c).

Thus, by combining the above, the weight of the solar cells, or W sc , Table 1
[kg] is equal to Efficiency ratios for the various parts of the propulsion system.

Solar components Propulsion components


W sc = 0.377 · S c (1)
Component Efficiency % Component Efficiency %
where S c [m2 ] is the area covered by solar cells. Solar cells 22.5% Engine block (+ generator) 17.0%
Considering the selection of the batteries, the most important MPPT 97.0% Electric motor 85.0%
parameter is their energy density. A good example of state-of-the- Batteries charge 95.0% Gearbox 97.0%
Batteries discharge 95.0% Motor controller 95.0%
art rechargeable batteries, are the ones that have been installed
Power control unit 95.0% Propeller 85.0%
on Zephyr, which have a density of 350 Wh/kg [3]. A proper siz-
ing of the power system ensures that the energy surplus which is
collected during daylight, and especially during midday when radi- An important parameter in selecting one of the proposed con-
ation level is higher, is stored at the batteries of the aerial vehicle. figurations is the stability of the aerial vehicle, as each of the above
The aerial system concept has been designed to operate all year configurations has a different combination of components, and
long, and as the maximum energy surplus is generated during the consequently a different effect in the center of gravity. This obser-
summer (summer solstice – 20th June), the batteries sizing was vation should be evaluated in the preliminary design phase, where
conducted based on that power load, in order to ensure that all of the detailed calculations considering the stability and trimming of
the available energy is stored. Concluding, the battery weight, or the aerial vehicle are to be carried out. Furthermore, additional pa-
W batteries [kg], is given by rameters in selecting one of the above configurations are the cost
and complexibility of each of the three systems. To define these
W batteries = 10.286 · ( E solar, stored )max,per day (2) parameters, a more detailed analysis has to be carried-out, also
where E solar, stored [J] is the maximum amount of solar energy including electronics and structural studies, which is beyond the
stored in the batteries during a day of operation. scope of this study as well. Hence, as no conclusion considering
the selection of the three configurations could be made, a worst
2.2. Hybrid propulsion system case scenario was employed, which corresponds to a total effi-
ciency ratio of 12.5%.
In order for the UAV to utilize both fuel and solar energy, a
hybrid propulsion system was conceptualized as well, that com- 2.3. Solar irradiation estimation methodology
bines an electric motor and an internal combustion engine (ICE).
The three proposed configuration suggestions are described below For the purposes of this study, a detailed research was carried-
and presented in Fig. 1: out regarding the available solar irradiation with respect to the
flight level, latitude, day of year and time of day. In order to es-
a) Two electric motors and one internal combustion engine will timate the collected solar power, the model of Bailey and Bower
operate independently. The ICE will be located on the fuse- [24] was employed. It should be noted that altitude is an impor-
lage and power a center propeller, whereas the electric motors tant factor that affects the amount of available solar irradiation at
along with their respective propellers will be mounted on the a defined position in the atmosphere, primarily due to the pres-
wing nacelles. ence of clouds, which are mostly located at the lower layers of the
b) The electric motor is connected directly to the propeller, while troposphere. In order to employ this specific solar power estima-
the ICE is used for the production of electric current i.e. charg- tion technique though, it has to be assumed that solar irradiation
is not blocked by cloud presence, therefore the model of Bailey
ing the batteries through an electric generator (Serial Hybrid
and Bower can be applied at flight altitudes higher than 2.5 km, or
System).
about 8000 ft.
c) An ICE and an electric motor are combined to supply a single
The power produced by a photovoltaic system of arbitrary ori-
propeller with the required power, with a use of a power-split
entation is calculated as:
device (Series/Parallel Hybrid System).
P produced = I b ηsc S c cos(i ) (3)
An estimation considering the efficiency ratio of each compo-
nent of the propulsion system was made as well. The efficiency of 2
where I b [W/m ] is the power of solar irradiation per unit area,
the solar panels was set at 22.5%, as mentioned in section 2.1, and ηsc is the efficiency of the photovoltaic system, S c [m2 ] is the sur-
typical values where selected for the rest of the parts [9]. Table 1 face covered by photovoltaic cells, and i is the angle of incidence
presents the efficiency ratios of each component of the power sys- of the solar rays over the surface of the cells i.e. the angle between
tem. Therefore, using Table 1, the total efficiency ratio of each of the solar rays and the normal to the panel surface. Solar incidence
the proposed propulsion system concepts can be estimated. angle is a function of the solar panel inclination angle B (Beta), the
210 P. Panagiotou et al. / Aerospace Science and Technology 53 (2016) 207–219

Fig. 2. Key parameters of the solar power estimation methodology (Bailey and Bower
[24]).

wall azimuth angle α w and the solar azimuth angle αs (Fig. 2). In
the case where the solar cells are installed on the wing of an aerial
vehicle, it can be assumed that the surface of the solar cells is hor-
izontal, because the largest part of the aerial vehicle’s mission will
involve cruise and loiter segments, which take place at steady level
flight conditions. In other words, it can be assumed that B = 0◦ ,
which leads to cos(i ) = sin(Alpha) [24], and consequently eq. (2)
can be rewritten as:

P produced = I b ηsc S c sin( A ) (4)

where A (Alpha) is the solar altitude angle (Fig. 2), and

sin( A ) = cos( D ) cos( H ) cos( L ) + sin( L ) sin( D ) (5)

Note that D [deg] is the declination angle and is calculated using


eq. (6):
  ◦
d
D = 23.5 sin 360 (6)
365
where d is the difference in days from the vernal equinox (March
20th), L [deg] is the latitude and H [deg] is the solar hour angle.
Note that H = (t /24) · 360 where t is the time difference between
the time of interest and 12 p.m. (e.g. if time of interest is 10 p.m. Fig. 3. Total, available on horizontal plane and collected solar power per unit area
then t = 2). at vernal equinox (a), at summer solstice (b) and at winter solstice (c), at 42◦ North
latitude. (For interpretation of the references to color in this figure, the reader is
In order to estimate the available solar power per unit area, de-
referred to the web version of this article.)
termining the atmospheric transmittance is necessary. Atmospheric
transmittance represents the amount of the radiation that is fil- whereas, given the atmospheric pressure p ( z), the value of m( z, A )
tered by the atmosphere, and is the radiation that reaches to the can be calculated at any altitude using:
point of interest I b , divided by the radiation outside the atmo-  
sphere. That is:
p ( z)
m( z, A ) = m(0, A ) (10)
p (0)
Ib
T atm = ⇐⇒ I b = T atm I o (7) By employing eqs. (5) to (10), eq. (4) can now be solved to
Io
yield the solar power per unit area, for a specific day of the year.
where I o = 1353 [W/m2 ] is the mean solar radiation outside the Thus, by integrating it through the hours of the day, the daily solar
atmosphere. power per unit area can be calculated.
For the atmospheric transmittance, the following equation also This integration takes place from sunrise to sunset. The respec-
applies: tive values can be calculated by employing eq. (11):
 
  | H sr | = | H ss | = cos−1 − tan( L ) tan( D ) (11)
T atm = 0.5 e −0.65m(z, A ) + e −0.095m(z, A ) (8)
where the subscripts sr and ss correspond to sunrise and sunset
The value m( z, A ) refers to the air mass at a specific altitude z respectively.
and is the air mass that has to be “penetrated” in order for the Consequently, charts like Fig. 3 can be drawn, which show the
solar radiation to reach a specific point. At sea level, this value is per-unit-area-available and collected solar power at a given flight
calculated by eq. (9): altitude. Blue line depicts the available solar power at the time and
 point of interest I b (eq. (7)), while the green line is the solar power
 2
m ( z = 0, A ) = 1229 + 614 sin( A ) − 614 sin( A ) (9) that would have been gathered at the horizontal plane (eq. (4)), in
P. Panagiotou et al. / Aerospace Science and Technology 53 (2016) 207–219 211

Fig. 4. Conceptual design flow chart of the hybrid solar UAV.

the case of an ideal solar system i.e. 100% efficiency. Finally, the at a conceptual level. An innovative methodology was developed,
red line corresponds to the power that is actually collected by the which combines the methods used in conventional aircraft sizing
system, by also taking the efficiency ratio into account (eq. (4)). In with the key aspects of solar aircraft design. A custom presizing
the current figure, an efficiency ratio of 12.5% was employed, as tool that has been developed in the Laboratory of Fluid Mechan-
mentioned in section 2.2. ics and Turbomachinery, in Aristotle University of Thessaloniki, for
Considering the conceptual design of the hybrid solar UAV, the previous design studies [18], was properly modified in order to fa-
solar power calculations were conducted for the 20th of March, i.e. cilitate the presizing calculations of the hybrid solar aerial vehicle.
the vernal equinox, when the available solar power is at its mean The corresponding conceptual design methodology (Fig. 4) is pre-
annual level. It should be noted though, that based on the calcu- sented below.
lations, the solar power varies considerably throughout the year
(Fig. 3). Hence, it follows that either the endurance of the hybrid 2.4.1. Mission requirements
solar UAV will vary throughout the year, reaching larger values in Coastal areas and borders monitoring for safety purposes, and
summer and smaller values during winter, or the fuel quantity has wildlife surveillance for environmental purposes were defined as
to be adjusted at each flight period in order to maintain a constant the main missions that the aerial platform should be able to
flight endurance. These considerations can be quantified during the carry-out. The mission requirements refer to a payload weight of
“refined weight sizing” and “final weight estimation” stages of the 50 kg, flight endurance of 48 hours and flight altitude at 23,000 ft
conceptual design procedure that is analyzed in the following sec- (7,000 m). Specifically, 50 kg is a typical weight of electro-optical
tion. payload for a MALE UAV, whereas the 48 hours is a compromise
between the typical endurance values of conventional and solar
2.4. Conceptual design aircraft. What is more, the 7,000 m were set as the operating flight
altitude, where the scarce cloud presence allows for higher val-
In the field of aeronautical engineering, the aircraft design is di- ues of solar power to be collected and the lower density of the
vided into three stages i.e. the conceptual, preliminary and detail air yields lower drag values. Furthermore, the latitude was set at
stages [12]. The first step is to determine the mission require- 42◦ N, which corresponds to a typical southern European country,
ments that the aerial vehicle should fulfill. Then, based on those such as Greece.
requirements, the configuration layout of the aircraft is determined A comment about the jet-streams must be made at this point,
and the basic weight, performance, geometric and aerodynamic as they can affect the sizing of an aerial vehicle operating at such
parameters are either estimated or defined by the designer. This high altitudes [6]. Their characteristics depend on both latitude
is essentially the conceptual design stage. During the preliminary and altitude, and detailed measurements have to be taken at a
and detail design phases the aircraft is analyzed in detail including specific geographical location, in order to accurately estimate their
aerodynamics, structures, control and optics, the technical draw- magnitude. Indicatively, studies from [6] and [25] show that a peak
ings are drawn and the production line is designed. These two value in jet-stream velocity appears at 10,000 m, however the ve-
latter phases of the design are not a part of this study though. locities at higher and lower altitudes vary between the two papers.
The primary objective of this study was to develop hybrid-solar- Regarding the current work, no such measurements were carried-
aircraft presizing tools, focusing on the energy sizing aspects, and out at this early point of the design, and no further conclusions
to examine the feasibility of a hybrid solar Medium-Altitude-Long- can be extracted. Hence, this issue remains to be addressed dur-
Endurance unmanned aerial platform, with the analysis being kept ing the preliminary design phase, where more detailed studies are
212 P. Panagiotou et al. / Aerospace Science and Technology 53 (2016) 207–219

Fig. 7. Aerodynamic efficiency vs. angle of attack for six different airfoils, for a
Reynolds number equal to 1 · 106 [27]. The FX63-137 was eventually selected, which
Fig. 5. Empty weight fraction trends as a function of takeoff weight (Sóbester et al. corresponds to the gray dashed curve.
[26]).

estimate for the W 0 . It should be noted that, up to this point, the


made considering the propulsion system and the operation of the solar aspects of the design are ignored.
aerial vehicle.
2.4.3. Aerodynamic and performance parameters
2.4.2. First weight estimation Subsequently, the basic aerodynamic parameters of the aerial
The first step is an initial estimation of UAV’s weight. Gross vehicle are specified i.e. the airfoil characteristics and the geomet-
takeoff weight (GTOW or W 0 ) is generally defined as the aircraft’s ric parameters of the wing. For the selection of these parameters,
maximum weight at the beginning of its mission i.e. its weight be- the trends and constraints that apply to the design of solar aircraft
fore take-off. In the case of an unmanned platform, W 0 can be were also taken into account.
calculated by summing up the payload, the fuel and the empty Considering the wing design, it was decided for the needs of
(structural) weight. That is: the conceptual design stage to choose an already existing airfoil
profile that will be common for the entire main wing, for sim-
W0 = W p + We + W f (12)
plicity purposes. Fig. 7 indicatively presents the Lift-to-Drag ratios
Payload weight refers to weight of all the equipment that the from −6 to 12 deg of angle of attack, for various airfoils which
aerial vehicle must have on-board in order to carry-out its mission were examined [27], at a Reynolds number of 1 · 106 , which is
(e.g. computers, cameras etc.) and is essentially defined by the re- a rough estimation of Reynolds number that corresponds to the
quirements. Empty weight is the net weight of the aircraft, e.g. cruise/loiter flight conditions. The Wortmann FX 63-137 [28] air-
structural and engine weight. During the first design steps it is es- foil was eventually selected, as it combines a low upper surface
timated using statistical data (Fig. 5) from existing aircraft [13,26]. (suction side) curvature with good aerodynamic efficiency, i.e. large
In order to calculate the fuel weight, the mission is divided into Lift-to-Drag ratios, for a wide range of angles of attack. It should
segments (Fig. 6) and the amount of required fuel is calculated be noted that the former was an important parameter in the airfoil
separately. For some segments, such as the warmup & take-off seg- selection process, as it affects the installation of the solar cells.
ment, statistical data are used, whereas for the remaining ones, In order to select the taper and aspect ratios, a trade-off was
analytical methods such as the ones described in Anderson [12] made between optimum aerodynamic performance and maximum
and Raymer [13] are employed. Eq. (13) is a typical equation in solar panel installation area. Specifically, the taper ratio was at first
aeronautics that yields the required amount of fuel during a cruise set at 0.4, in order to minimize the induced drag component and
mission segment: increase aerodynamic efficiency [29]. However, as the chord at the
tip had to increase in order to provide enough space for the instal-
W i   lation of the solar panels, a value of 0.5 was eventually selected,
V CL dW
R= (13) thus satisfying both of the aforementioned objectives. Considering
c CD W the aspect ratio, typical values in solar aircraft range from 12 to
W i +1
31 [3,7,24] with the higher ones yielding better aerodynamic ef-
where V is the freestream velocity [m/s], c the specific fuel con- ficiency and the smaller ones being less demanding in structural
sumption [lbs/lbs/h], and (C L /C D ) the Lift-to-Drag ratio. The pay- strength. Hence, for the current concept, a value of 19 was se-
load, empty, and fuel weight values are then added, yielding a first lected, to satisfy both sides.

Fig. 6. Mission profile of the hybrid solar UAV concept.


P. Panagiotou et al. / Aerospace Science and Technology 53 (2016) 207–219 213

Fig. 8. Fuselage design of the hybrid solar UAV. The airfoil rails are presented in
blue. (For interpretation of the references to color in this figure legend, the reader
is referred to the web version of this article.)

The next step is the calculation of the two most important per-
formance parameters, namely the wing reference area (S) and the
engine horsepower (hp). Horsepower is estimated using the power
loading ratio (hp/W ), by taking the appropriate considerations that
Fig. 9. Configuration layout of the hybrid solar concept. Red, cyan, yellow and black
arise from flight requirements into account. Concerning the wing represent possible locations (hardpoints) for the engines/motors, payload, batteries
reference area, for a conventional, fuel-powered aerial vehicle, it and fuel tanks to be installed respectively. (For interpretation of the references to
is estimated by calculating the required wing loading ratio (W / S) color in this figure legend, the reader is referred to the web version of this article.)
for several critical flight conditions, such as stalling, climb and loi-
ter, and the lowest W / S value is eventually selected, so that the
main wing has adequate surface area [13]. In the case of the hy-
brid configuration though, the required solar panel area has to be
taken into account as well, and consequently the W / S value was
set between the typical values for conventional and solar aircraft
[6,11,13,18,30,31].

2.4.4. Configuration layout


Having defined the basic performance and aerodynamic param-
eters, a first concept of the configuration layout can now be de-
termined. Namely, a boom mounted twin tail configuration was
selected (Fig. 13). The main wing geometry was based on the pa-
rameters that were defined during the previous section. The fuse-
lage and nacelles were designed in order to provide adequate inter-
nal storage space at a low aerodynamic drag penalty. Specifically,
an innovative shape was designed, by combining airfoil profiles, as
presented in Fig. 8. Such a design has also been used in the HCUAV
fuselage [18], as it yields a reduction in drag force, whereas the
contribution in the lift component, and consequently, the stability Fig. 10. Computational mesh on the surface of the hybrid solar UAV.
aspects of the aerial vehicle is insignificant.
A first winglet concept was also developed. Designing an opti- rate estimation is vital. For that purpose both analytical methods
mized winglet requires an extensive study and effort [32], however and computational fluid mechanics (CFD) were employed.
this is only an initial geometry, in order to introduce the winglet For the analytical calculations, the aerodynamic coefficient es-
concept to the configuration and define some key parameters. For timation methods that are presented in Roskam [16] were em-
example, sweeping the tips aft and downwards was chosen for no- ployed, which are based on theoretical aerodynamic relations, and
shading purposes, given that the upper wing surface is covered by semi-empirical equations and charts. Specifically, these methods
solar cells. Finally, the empennage consists of two vertical surfaces use the main geometric and aerodynamic parameters of each part
and a horizontal stabilizer, and its sizing satisfies the requirements as an input (e.g. the main wing mean chord, airfoil type, aspect
in solar panel area, low drag and stability. The stability analysis ratio and taper ratio, the fuselage length and mean diameter etc.)
was based on the methodology presented in [13]. and can be used to carry out a fast, low-fidelity aerodynamic anal-
In Fig. 9 a simplified view of the internal layout is presented, ysis. The drag component is estimated separately for each part and
where some possible locations for the installation of the engines, is then added to the total drag force, by taking the appropriate
motors, fuel tank and batteries are shown. To sum up, the con- interference factors into account, whereas the lift component is es-
figuration layout of the hybrid solar aerial vehicle concept ensures timated by summing the effect of all lifting surfaces, which in the
that key design parameters, such as aerodynamic efficiency, surface case of the current concept were the main wing and empennage.
shading and internal space for payload, engine and fuel storage, are Considering the CFD computations, a 3D CAD of the concept
taken into account. was designed, and by using the Ansys MESHING tool an unstruc-
tured grid was generated. Following a grid dependency study,
2.4.5. Aerodynamic study and CFD analysis a number of approximately 8,800,000 computational nodes was
After defining the external geometry of the aerial vehicle, an eventually selected. Furthermore, 17 inflation layers were imple-
estimation of the aerodynamic characteristics has to be made in mented on the walls, the first of which was placed at 2.5 · 10−5 m
order to proceed with the energy sizing of the aircraft. The aero- from the wall. Thus, it was made sure that the y + does not ex-
dynamic coefficients play a major role in the methodology that ceed the value of 5 at any point of the surface grid, so that the
will be discussed in the following sections, therefore their accu- boundary layer phenomena can be properly modeled (Figs. 10, 11).
214 P. Panagiotou et al. / Aerospace Science and Technology 53 (2016) 207–219

Fig. 11. Computational mesh around the hybrid solar UAV. Mesh detail around the
airfoil of the main wing is presented on the bottom right, where the denser parts Fig. 12. Power chart of the hybrid solar UAV concept. (For interpretation of the refer-
of the mesh near the surfaces are also visible. ences to color in this figure, the reader is referred to the web version of this article.)

The Reynolds-Averaged–Navier–Stokes (RANS) were solved, cou-


pled with the Spalart–Allmaras turbulence model [33], using the eq. (15) yields a value for T req , i.e. the required thrust. The required
Ansys CFX commercial software. The flow field was examined at a power, or P req,flight [W] can then be calculated:
wide range of angles of attack (from −8◦ to 20◦ ) in order to en- P req,flight = T req · V (16)
sure that the stalling phenomena will be modeled as well.
The boundary conditions correspond to the flight conditions of The power consumption of the electro-optical equipment, or
the loiter mission segment, which constitutes the largest part of P electronics , was estimated based on the designers’ experience on
the mission, i.e. flight speed of 70 km/h, and ambient tempera- similar applications [18]. The total required power of the UAV can
ture and pressure corresponding to the flight altitude of 7,000 m. now be estimated:
The resulting Reynolds number equals to 1.1 · 106 , based on the
mean aerodynamic chord. Furthermore, regarding the turbulence P req = P req,flight + P electronics (17)
inlet conditions, the turbulence intensity was set at 1% and the Moreover, an estimation was made regarding the total number
eddy viscosity ratio at 0.2, which represent some typical external of solar cells that can be installed on the vehicle, by assuming that
flow conditions, based on [34]. they cover 90% of the upper side of the wing and empennage sur-
faces [10]. Therefore, the next step of the refined weight estimation
2.4.6. Performance evaluation procedure is to employ the solar power estimation methodology
At this point, the key performance characteristics of the concept described in section 2.1 and to calculate the power collected by
are calculated by employing the methods presented in Anderson the solar panels, let this be P solar ,collected [W].
[12] and Raymer [13]. Specifically, the operational and minimum Following the aforementioned steps, estimates for i) the power
speeds, flight altitude and flight endurance are being estimated.
that is required in order to operate the aircraft, or P req , and ii) the
Based on the results, appropriate corrections were made to the
power that is collected from the solar panels, or P solar ,collected , have
aerodynamic and geometric parameters of the UAV, to ensure that
been calculated. The difference between those two values has to
the hybrid aerial vehicle fulfills the requirements and is up to the
be covered by fuel, hence:
task.
P req = P solar,collected + P fuel (18)
2.4.7. Refined weight estimation
The solar aspects of the design are taken into account during If multiplied with the flight time, eq. (18) yields:
this stage, including the contribution of the solar panels to the
E req = E solar,collected + E fuel (19)
total energy budget of the system. At first, the aerodynamic coeffi-
cient calculations, allow for the estimation of the required thrust, which essentially represents the energy budget of the aircraft.
which in turn yields the power that is required in order for the Power charts can now be drawn, like the one presented in
aerial vehicle to maintain a steady level flight. For this purpose, Fig. 12, which shows the power budget of the UAV during 48 hours
the following equations are used: of flight. The area surrounded by the black line represents the en-
1 ergy collected by the solar panels, or E solar,collected [J]. Two maxima
W 0 = Lift = ρ V 2 SC L (14) appear in the chart, one for each day of operations. Furthermore,
2 it is assumed that the aircraft takes-off during the night, to make
1
T req = Drag = ρ V 2 SC D (15) sure that it has reached the operational flight altitude above the
2 clouds by the time the sun has risen, in order to maximize the
where “Lift” and “Drag”, are the lift and drag forces [N] generated flight endurance. The area surrounded by the red line represents
by the main wing respectively, ρ [kg/m3 ] is the freestream den- the energy which is required in flight, or E req . As the time passes
sity, V [m/s] is the freestream velocity, S [m2 ] is the reference and the mission progresses, the aircraft burns fuel and its weight
area of the main wing, C L is the lift coefficient and C D is the drag is reduced (eq. (13)), therefore the required lift force (eq. (14)) and
coefficient. The latter coefficients depend on the airfoil and wing consequently the drag force (eq. (15)) are reduced as well. That is
characteristics (geometry), and the angle of attack of the aircraft, the reason why the red line has a negative slope i.e. the power-
or α [deg]. Hence, with the flight altitude, and consequently ρ , required-to-fly diminishes over time.
defined from the requirements, W 0 defined from the initial weight Thus, after drawing the power chart of the aerial vehicle
estimation, and the aircraft’s geometry defined from the config- (Fig. 12), the areas in green, orange and blue can now be calcu-
uration layout section, eq. (14) can be solved for α and V . Then, lated. Specifically:
P. Panagiotou et al. / Aerospace Science and Technology 53 (2016) 207–219 215

• The area in green represents the energy that is instantly used Hence:
in order to power up the aerial vehicle, or E solar,instant [J].
• The area in orange is the solar energy surplus which is stored W empty = W e,conventional + W sc + W batteries (29)
in the batteries in order to be used during the night, or
In conclusion, by summing up the refined estimations of fuel
E solar,stored [J].
weight, empty weight, and the fixed value of the payload weight,
• The area in blue represents the remaining energy needs of the
a refined estimation of the W 0 can be calculated, by employing
hybrid solar aerial platform, or E deficit [J], that must either be
eq. (12).
covered from the energy stored in the batteries, or by burning
At this point it should be noted that in eqs. (18) to (23) the effi-
fuel. That is:
ciency ratios were skipped on purpose. As analyzed in section 2.2,
more than one propulsion systems have been conceptualized, fea-
E deficit = E solar,stored + E fuel (20)
turing different components and configurations, and therefore, dif-
Eq. (19) can now be transformed to: ferent efficiency ratios apply at each case. An attempt to develop
different equations for all possible systems is beyond the scope of
E req = E solar,instant + E solar,stored + E fuel = E solar,instant + E deficit the study and would rather confuse the reader. Therefore, it was
(21) decided to express the equations in their general form, so that
the designer may configure them appropriately, based on the data
Therefore, E fuel can now be calculated. In order to estimate the given in section 2.2 and Table 1.
corresponding fuel weight, the following equation was used:
E fuel = W fuel · CV (22) 2.4.8. Iterative process and final weight estimation
As expected, the inclusion of the energy collected from the so-
where CV is the Calorific Value of the fuel. For simplification pur- lar panels into the total energy budget of the aircraft results in
poses, it was assumed that the internal combustion engine will a decrease in the weight of the fuel and, consequently, the total
utilize diesel fuel, and an average between the Higher and Lower weight of the UAV. Therefore, an iterative process has to be de-
calorific values was used [35], that is: fined in order to calculate a final estimate of the total weight of
HCV Diesel + LCV Diesel the hybrid solar aerial platform.
E fuel = W fuel · = W fuel · 44100 (23) The first step is to calculate a new value for T req and P req . For
2
simplicity purposes the geometry of the concept, both planform
The value that is estimated by eq. (23) corresponds to the fuel
and airfoil, remains unchanged and the flight altitude constant, so
burned during the loiter and cruise mission segments, since an
that the S and ρ can be treated as constants. Hence, eq. (14) and
assumption for steady level flight conditions was made. For the
eq. (15) can be written as
remaining missions segments, i.e. the take-off, climb, descent and
landing missions segments, statistical data were employed and ap-  
propriately adjusted. An extra 6% of fuel that is stored in the tanks
W 0 = Lift = f α, V 2 (30)
 2

for emergency purposes was also taken into account [13]. There- T req = Drag = g α, V (31)
fore, eqs. (24) to (28) are defined:
respectively. The most recent value of W 0 is substituted in eq. (30),
W1
Warmup & takeoff (0 → 1) : = 0.985 (24) yielding a combination for α and V . It is possible that more than
W0 one combination satisfies eq. (30), hence it is up to the designer
W2 to come up with the values that maximize aerodynamic efficiency.
Climb(1 → 2) : = 0.95 (25)
W1 These values are in turn substituted into eq. (31), yielding a new
Cruise & Loiter (2 → 3) : W 2 − W 3 = W fuel (26) estimate of T req , and by employing eq. (18) and eq. (19), a new
estimate of P req is calculated and a new energy chart is drawn.
W4
Descent & Landing(3 → 4) : = 0.995 (27) As the geometry characteristics do not change, the area of so-
W3 lar panels and, consequently, the amount of collected solar energy
 
Wf W4 remain fixed as well, that is
= 1.06 1 − (28)
W0 W0
E solar,collected = constant (32)
where W 1 , W 2 , W 3 , W 4 are the aerial vehicle’s weight at the end
of each mission phase (Fig. 6). W fuel has been calculated from the Hence only the values E solar,stored and E fuel are readjusted, yield-
energy method described above and W 0 is the first weight esti- ing different values for W batteries and W fuel . Equations (24) to (29)
mate that was calculated in a previous section. are in turn employed, a 6 × 6 system of equations is solved, and a
Furthermore, considering the empty weight estimation, the pre- new estimate for W 0 can be calculated at each step.
sizing methods described in Noth [9] and Hall [36] were initially The procedure is repeated, until a convergence for the total
employed, but the results were found to deviate greatly between weight of the aircraft is reached. The final weight estimates of the
the two methods. Therefore, they were dropped as unreliable for hybrid solar aerial concept were based on this methodology, and
the purposes of this study. This was attributed to the fact that are presented in Table 2. The calculations yielded a 50% decrease
they both refer to a different design case, as the former method- in fuel weight, between the first and the last iteration step, which
ology has been developed for low-weight sailplanes, which have a is attributed to the contribution of the solar power to the total en-
different design philosophy than the current concept, and the lat- ergy budget.
ter was developed in 1985, in a time where the technologies in Finally, it should be noted at this point that, during the concep-
aeronautics and solar equipment were not as advanced as in the tual design phase, cruise and loiter segments were dealt using a
present day. Hence, the empty weight estimation was based on common power chart, for simplicity purposes. During the prelim-
the well-established, advanced empty weight estimation methods inary design phase though, where more detailed calculations are
described in Raymer [13], modified in a way that the solar aspects required, cruise and loiter segments have to be dealt separately i.e.
3/ 2
of the aerial system, such as the increased battery size and solar C L /C D and C L /C D ratios should be maximized for each of the
cell structural weight, are also taken into account. two segments respectively [12].
216 P. Panagiotou et al. / Aerospace Science and Technology 53 (2016) 207–219

Table 2
Hybrid solar UAV technical characteristics and comparison between HALE solar- and fuel-powered UAVs. The values in bold correspond to the hybrid solar UAV concept that
was designed in this paper.

Hybrid Solar UAV concept HASSP HELIPLAT Altus II Viking 400


Gross takeoff weight 370 kg 370 kg 815.5 kg 968 kg 244 kg
Payload weight 50 kg 90.9 kg 100 kg 150 kg >34 kg
W p /W 0 0.135 0.246 0.123 0.155 0.139
Empty weight 215 kg 190 kg 555.5 kg 567 kg 145 kg
(incl. 45 kg batteries)
W e /W 0 0.58 0.51 0.68 0.58 0.59
Fuel weight 105 kg N/A N/A 251 kg 65 kg
Flight altitude 7 km 20 km 18 km >13 km 2 km
Flight endurance >48 h 1 year >6 months 24 h 10 h
Flight speed 70 km/h 100.6 km/h 71 km/h 130 km/h 111 km/h
Stall speed 27 km/h 77.8 km/h N/A N/A N/A
Wing reference area 50 m2 57.24 m2 176 m2 12.2 m2 4 m2
W /S 1.51 1.32 0.945 16.3 12.4
Wing span 31 m 29 m 73 m 16.9 m 6m
Wing mean chord 1.67 m N/A N/A N/A N/A
Aspect ratio 19 15 30 24 9
Taper ratio 0.5 0.6 0.32 N/A N/A
Wing airfoil FX 63-137 FX 74-CL6-140 E-216 (modified) N/A N/A

Fig. 13. 3D CAD model of the aircraft. The solar cell installation areas are illustrated
in blue color. (For interpretation of the references to color in this figure legend, the
Fig. 15. Lift coefficient vs. angle of attack.
reader is referred to the web version of this article.)

be mentioned at this point that the hybrid UAV is by no means


an optimized concept, since only the conceptual design phase has
been carried-out. There is still much room for improvement to be
made in the latter design phases, including for example parametric
studies and detailed structural analysis.
In order to provide information concerning the validity of the
concept, a comparison between this concept, and two solar- and
two fuel-powered UAVs is also made in Table 2. Specifically, the
HELIPLAT [7] and the HASSP [24] are two solar-powered unmanned
aerial platforms, whereas the Altus II [30] and the Viking 400 [31]
are two fuel-powered unmanned aerial vehicles that have been
developed for civil purposes and surveillance operations. A direct
Fig. 14. Hybrid UAV conceptual drawing. comparison in terms of e.g. weight values would be misleading, as
the five aircraft vary in terms of size and payload capacity. On the
3. Results contrary, a comparison between e.g. the W / S ratios can be made,
which shows that the hybrid concept has a slightly higher wing
The result of the design procedure is a UAV concept which loading than the solar-powered and a considerably lower wing
is capable of carrying-out the missions that it was designed for loading than the fuel-powered UAVs, for the reasons explained in
and fulfills the initial requirements, by utilizing both conventional Section 2.4.
and renewable energy resources. Fig. 13 shows a 3D CAD of the In Figs. 15 and 16 the aerodynamic coefficients of the hybrid
concept, whereas the external geometry of the hybrid UAV is pre- solar concept are presented and a comparison between the analyt-
sented in Fig. 14. ical and the CFD results is made. At low angles of attack the two
Table 2 sums up the main geometric, performance and aerody- methods are in very good agreement. In higher angles of attack
namic characteristics of the hybrid UAV concept, as they were cal- though, the analytical results deviate from the CFD ones, as they
culated following the presizing methodology of Section 2. It should cannot predict stalling and viscous effects.
P. Panagiotou et al. / Aerospace Science and Technology 53 (2016) 207–219 217

Table 3
Hybrid solar UAV energy data.

Energy collected during the flight


Mean case 73.5 kWh
Best case 113.5 kWh
Worst case 27 kWh

Energy surplus during the flight


Mean case 10 kWh
Best case 29.5 kWh
Worst case 0 kWh

Fuel consumption during the flight (Mean case)


Warmup & takeoff 5.47 kg
Climb 17.9 kg
Cruise & loiter 74.4 kg
Descent & landing 1.31 kg
Reserve (6%) 5.93 kg
Total 105 kg
Fig. 16. Drag polar of the hybrid solar UAV concept.

Fig. 17. Power chart of the hybrid solar UAV concept, on the 20th of March. (For
interpretation of the references to color in this figure, the reader is referred to the
web version of this article.) Fig. 18. Flow development around the aircraft at an angle of attack of 0◦ .

Fig. 17 presents the power chart of the hybrid solar UAV con- sun is directly used to power-up the aerial vehicle. Finally, the fuel
cept, for the 20th of March, which stands for the mean case in weight required for each flight segment is given.
terms of solar irradiation. At first, the red and black curves are A comment regarding the worst- and best-case scenarios has
drawn, and then the areas in blue, green, and orange are defined, to be made at this point. In a purely solar aircraft the lack of so-
which are used for the calculation of the required energy quanti- lar energy would cause the endurance of the vehicle to decrease
ties, as described in section 2.4. The starting point of the red curve, rapidly i.e. more than 60%, according to the “energy collected” fig-
i.e. the required power or P req , equals to 3.8 kW at the beginning ures given for the mean and worst cases in Table 3. In the case
of the cruise & loiter segments, for an operational velocity and alti-
of the hybrid concept though, fuel is used to power-up the aircraft
tude of 70 km/h and 7,000 m respectively (Table 2), and by taking
as well. Hence, during winter the batteries can be replaced with
the power consumption of the electro optical equipment into ac-
smaller ones, depending on the corresponding energy surplus, and
count as well. The black curve, i.e. the power collected from the
the difference in weight can consequently be covered with extra
sun or P solar,collected , presents two peaks, one for each day of op-
fuel in the tanks, so that the endurance of the hybrid-solar aerial
erations, corresponding to the maximum collected power of the
vehicle drops only by 5%, i.e. 45.6 h, without changing the W 0 .
system per day. Specifically, the maximum value of each peak is
On the contrary, during summer, where the energy collected by
at approximately 5.1 kW, collected from a panel area of 45 m2 , at
the sun increases more than 50%, according to the “energy col-
42◦ N latitude.
In addition, Table 3 presents the key energy values for the hy- lected” figures given for the mean and best cases in Table 3, the
brid solar UAV flight mission. The solar energy which is collected endurance that can be achieved with the same amount of fuel in
by the solar cells is presented for the mean (March 20th), best the tanks, i.e. same W 0 , can consequently increase by up to ap-
(June 20th) and worst (December 20th) cases. The mean case cor- proximately 72 h. These are important considerations that affect
responds to Fig. 17, whereas for the other two cases the black the flight performance of aerial vehicles which depend on the en-
curve is adjusted based on the methodology presented in Sec- ergy of the sun, and should be further examined in the preliminary
tion 2.3. Moreover, the energy surplus, i.e. the amount of energy design phase, where more information considering the aircraft e.g.
which is stored in the batteries, for both operational days, is pre- propulsion system type, is available.
sented in Table 3 as well, for the mean, maximum and minimum The flow around the aerial vehicle, as a result of the CFD cal-
cases. The maximum value of energy surplus corresponds to the culations, is presented indicatively in Fig. 18 for 0 degrees of angle
best-case, whereas at the worst-case scenario no amount of en- of attack. Studying the external flow field is very important in op-
ergy is left for storage at all, as all the energy collected from the timizing the external geometry of the configuration, as important
218 P. Panagiotou et al. / Aerospace Science and Technology 53 (2016) 207–219

Fig. 19. Pressure distribution over the surface of the UAV concept at an angle of attack of 0◦ (a) and 8◦ (b).

information can be extracted e.g. regarding the interference be- storage systems could aid a long way in decreasing the weight and
tween the different parts and wingtip vortical structures. size of solar aerial vehicles. Hence, it follows that future technolog-
Finally, Fig. 19 presents examples of pressure contours over the ical innovations in these areas could establish the solar energy as
surface of the UAV, at two different angles of attack. Namely, the the primary energy source in both unmanned and manned aircraft.
pressure distributions at 0 and 8 degrees are indicatively shown.
From these results, the loads that are applied to surface of the Conflict of interest statement
aircraft can be extracted. Consequently, in a more advanced design
phase, the required structural strength of the internal layout and None declared.
skin, as well as the required structural strength of the solar cells
can be calculated. Acknowledgements

4. Conclusions I. Tsavlidis would like to thank Alexander S. Onassis Public Ben-


efit Foundation for granting him a scholarship for his studies.
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