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Structural Analysis of Test Flight Vehicles for Application of Multifunctional Energy Storage SystemUnder the NASA Aeronautics Research Mission Directorate (ARMD) Convergent Aeronautical Solutions (CAS) project, NASA Glenn Research Center has been leading Multifunctional Structures for High Energy Lightweight Load-bearing Storage (M-SHELLS) research efforts. The technology of integrating load-carrying structures with electrical energy storage capacity has the potential to reduce the overall weight of future electric aircraft. The proposed project goals were to develop M-SHELLS in the form of honeycomb coupons and subcomponents, integrate them into the structure, and conduct low-risk flight-tests onboard a remotely piloted small aircraft. Experimental M-SHELLS energy-storing coupons were fabricated and tested in the laboratory for their electrical and mechanical properties. In this report, finite element model development and structural analyses of two small test aircraft candidates are presented. The finite element analysis of the initial two-spar wing is described for strain, deflection, and weight estimation. After a test aircraft Tempest was acquired, a load-deflection test of the wing was conducted. A finite element model of the Tempest was then developed based on the test aircraft dimensions and construction detail. The component weight analyses from the finite element model and test measurements were correlated. Structural analysis results with multifunctional energy storage panels in the fuselage of the test vehicle are presented. Although the flight test was cancelled because of programmatic reasons and time constraints, the structural analysis results indicate that the mid-fuselage floor composite panel could provide structural integrity with minimal weight penalty while supplying electrical energy. To explore potential future applications of the multifunctional structure, analyses of the NASA X-57 Maxwell electric aircraft and a NASA N+3 Technology Conventional Configuration (N3CC) fuselage are presented. Secondary aluminum structures in the fuselage sub-floor and cargo area were partially replaced with reinforced five-layer composite panels with M-SHELLS honeycomb core. The N3CC fuselage weight reduction associated with each design without risking structural integrity are described. The structural analysis and weight estimation with the application of composite M-SHELLS panels to the N3CC fuselage indicate a 3.2% reduction in the fuselage structural weight, prior to accounting for the additional weight of core material required to complete the energy storage functionality.
Document ID
20190027405
Acquisition Source
Langley Research Center
Document Type
Technical Memorandum (TM)
Authors
Mukhopadhyay, Vivek (NASA Langley Research Center Hampton, VA, United States)
Olson, Erik D. (NASA Langley Research Center Hampton, VA, United States)
Ozoroski, Thomas A. (Analytical Mechanics Associates, Inc. Hampton, VA, United States)
Date Acquired
July 17, 2019
Publication Date
June 1, 2019
Subject Category
Structural Mechanics
Aircraft Design, Testing And Performance
Report/Patent Number
NASA/TM-2019-220288
NF1676L-33467
L-21033
Funding Number(s)
WBS: 533127.02.16.07.03
Distribution Limits
Public
Copyright
Public Use Permitted.

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