Challenge

Powertrain for aircraft in runways

1) Aircraft

An aircraft is a vehicle that is able to fly by gaining support from the air. It counters the force of gravity by using either static lift or by using the dynamic lift of an airfoil, or in a few cases the downward thrust from jet engines. Common examples of aircraft include airplanes, helicopters, airships (including blimps), gliders, paramotors and hot air balloons.

Aircraft weight

Manufacturer's empty weight (MEW) also called Manufacturer's Weight Empty (MWE) or Licensed Empty Weight

  • It is the weight of the aircraft "as built" and includes the weight of the structure, power plant, furnishings, installations, systems and other equipment that are considered an integral part of an aircraft. This excludes any baggage, passengers, or usable fuel.

Zero-fuel weight (ZFW)

  • This is the total weight of the airplane and all its contents (including unusable fuel), but excluding the total weight of the usable fuel on board. As a flight progresses and fuel is consumed, the total weight of the airplane reduces, but the ZFW remains constant.

Operating empty weight (OEW) (Roughly equivalent to basic empty weight on light aircraft)

  • It is the basic weight of an aircraft including the crew, all fluids necessary for operation and all operator items and equipment required for flight but excluding usable fuel and the payload.

Payload

  • It is the carrying capacity of an aircraft. It includes cargo, people, extra fuel. In the case of a commercial airliner, it may refer only to revenue-generating cargo or paying passengers.

Maximum takeoff weight (MTOW)

  • This is the maximum weight at which the pilot of the aircraft is allowed to attempt to take off.

Regulated takeoff weight (RTOW)

  • Depending on different factors (e.g. flap setting, altitude, air temperature, length of runway), RTOW or maximum permissible takeoff weight varies for each takeoff. It can never be higher than MTOW.

Maximum Landing weight (MLW)

  • This maximum weight at which an aircraft is permitted to land.

Maximum ramp weight (MRW) also called maximum taxi weight (MTW)

  • It is the maximum weight authorized for maneuvering (taxiing or towing) an aircraft on the ground.

Aircraft gross weight

  • It is the total aircraft weight at any moment during the flight or ground operation. This decreases during flight due to fuel and oil consumption.

Classification of Aircrafts based on thier weights

This is a list of aircraft sorted by maximum takeoff weight.

MTOW = Maximum take-off weight,

MLW = Maximum landing weight,

TOR = Take-off run (SL, ISA+15°, MTOW),

LR = Landing run (SL, ISA+15°, MLW)

Type MTOW [kg] MLW [tons] TOR [m] LR [m] ICAO category FAA category
Antonov An-225 640,000 591.7 3500 Heavy Super
Scaled Composites Model 351 Stratolaunch 589,670 3660 Heavy Super
Airbus A380-800 575,000 394 3100 1930 Heavy Super
Boeing 747-8F 447,700 346.091 3100 1800 Heavy Heavy
Boeing 747-8 443,613 306.175 3100 Heavy Heavy
Boeing 747-400ER 412,770 295.742 3090 Heavy Heavy
Antonov An-124-100M 405,060 330 2520 900 Heavy Heavy
Boeing 747-400 396,900 295.742 3018 2179 Heavy Heavy
Lockheed C-5 Galaxy 381,000 288.417 2530 1494 Heavy Heavy
Boeing 747-200 377,840 285.700 3338 2109 Heavy Heavy
Boeing 747-300 377,840 260.320 3222 1905 Heavy Heavy
Airbus A340-500 371,950 240 3050 2010 Heavy Heavy
Airbus A340-600 367,400 256 3100 2100 Heavy Heavy
Boeing 777F 347,800 260.816 2830 Heavy Heavy
Boeing 777-300ER 351,800 251.29 3100 Heavy Heavy
Boeing 777-200LR 347,450 223.168 3000 Heavy Heavy
Boeing 747-100 340,200 265.300 Heavy Heavy
Airbus A350-1000 308,000 233.5 Heavy Heavy
Boeing 777-300 299,370 237.683 3380 Heavy Heavy
Boeing 777-200ER 297,550 213.00 3380 1550 Heavy Heavy
Airbus A340-300 276,700 190 3000 1926 Heavy Heavy
McDonnell Douglas MD-11 273,300 185 2990 1890 Heavy Heavy
Airbus A350-900 270,000 175 2670 1860 Heavy Heavy
Ilyushin Il-96M 270,000 195.04 3115 2118 Heavy Heavy
McDonnell Douglas DC-10 256,280 183 2990 1890 Heavy Heavy
Boeing 787-9 254,000 192.777 2900 Heavy Heavy
Boeing 787-10 254,000 201.849 Heavy Heavy
Airbus A340-200 253,500 181 2990 Heavy Heavy
Ilyushin IL-96-300 250,000 175 2600 1980 Heavy Heavy
Airbus A330-300 242,000 185 2500 1750 Heavy Heavy
Airbus A330-200 242,000 180 2220 1750 Heavy Heavy
Lockheed L-1011-500 231,300 166.92 2636 Heavy Heavy
Boeing 787-8 228,000 172.365 3300 1695 Heavy Heavy
Lockheed L-1011-200 211,400 Heavy Heavy
Ilyushin IL-86 208,000 175 Heavy Heavy
Boeing 767-400ER 204,000 158.758 3414 Heavy Heavy
Airbus A300-600R 192,000 140 2385 1555 Heavy Heavy
Boeing 767-300ER 187,000 136.08 2713 1676 Heavy Heavy
Concorde 185,000 111.1 3440 2220 Heavy Heavy
Airbus A300-600 163,000 138 2324 1536 Heavy Heavy
Boeing 767-300 159,000 136.078 2713 1676 Heavy Heavy
Airbus A310-300 157,000 124 2290 1490 Heavy Heavy
Vickers VC10 152,000 151.9 Heavy Heavy
Boeing 707-320B 151,000 97.5 Heavy Heavy
Boeing 707-320C 151,000 112.1 Heavy Heavy
Douglas DC-8-61 147,000 Heavy Heavy
Airbus A310-200 142,000 123 1860 1480 Heavy Heavy
Airbus A400M 141,000 122 980 770 Heavy Heavy
Douglas DC-8-32 140,000 Heavy Heavy
Douglas DC-8-51 125,000 Medium Large
Boeing 757-300 124,000 101.6 2550 1750 Medium Large
Boeing 707-120B 117,000 86.3 Medium Large
Boeing 757-200 116,000 89.9 2347 1555 Medium Large
Boeing 720B 106,000 79.5 Medium Large
Boeing 720 104,000 79.5 Medium Large
Tupolev Tu-154M 104,000 80 Medium Large
Tupolev Tu-204SM 104,000 87.5 2250 Medium Large
Convair 880 87,500 Medium Large
Boeing 737-900 85,000 66.36 2500 1704 Medium Large
Boeing 737-900ER 85,000 71.35 2804 1829 Medium Large
Boeing 727-200 Advanced 84,000 70.1 Medium Large
Airbus A321-100 83,000 77.8 2200 1540 Medium Large
Boeing 737-800 79,000 65.32 2308 1634 Medium Large
Boeing 727-200 78,000 68.1 Medium Large
McDonnell-Douglas MD-83 73,000 63.28 Medium Large
Boeing 727-100 72,500 62.4 Medium Large
Boeing 727-100C 72,500 62.4 Medium Large
McDonnell-Douglas MD-90-30 71,000 64.41 2165 1520 Medium Large
de Havilland Comet 4 70,700 Medium Large
Boeing 737-700 70,000 58.06 1921 1415 Medium Large
Airbus A320-100 68,000 66 1955 1490 Medium Large
Boeing 737-400 68,000 54.9 2540 1540 Medium Large
de Havilland Comet 3 68,000 Medium Large
Boeing 377 67,000 Medium Large
Boeing 737-600 66,000 54.66 1796 1340 Medium Large
Airbus A220-300 65,000 57.61 1890 1494 Medium Large
Hawker Siddeley Trident 2E 65,000 Medium Large
Airbus A319 64,000 62.5 1850 1470 Medium Large
Boeing 737-300 63,000 51.7 1939 1396 Medium Large
Boeing 737-500 60,000 49.9 1832 1360 Medium Large
Airbus A220-100 59,000 50.80 1463 1356 Medium Large
Airbus A318 59,000 57.5 1375 1340 Medium Large
Boeing 717-200HGW 55,000 47.174 1950 Medium Large
Douglas DC-7 55,000 Medium Large
de Havilland Comet 2 54,000 Medium Large
Boeing 717-200BGW 50,000 46.265 1950 Medium Large
de Havilland Comet 1 50,000 Medium Large
Douglas DC-6A 48,600 Medium Large
Douglas DC-6B 48,500 Medium Large
Embraer 190 48,000 43 2056 1323 Medium Large
Caravelle III 46,000 Medium Large
Fokker 100 46,000 39.95 1621 1350 Medium Large
Douglas DC-6 44,000 Medium Large
Avro RJ-85 42,000 36.74 Medium Large
Handley Page Hermes 39,000 Medium Large
Embraer 175 37,500 32.8 2244 1304 Medium Large
Bombardier CRJ900 36,500 33.345 1778 1596 Medium Large
Embraer 170 36,000 32.8 1644 1274 Medium Large
Bombardier CRJ700 33,000 30.39 1564 1478 Medium Large
Douglas DC-4 33,000 Medium Large
Vickers Viscount 800 30,400 Medium Large
Bombardier Q400 28,000 28.01 1219 1295 Medium Large
Bombardier CRJ200 23,000 21.319 1918 1479 Medium Large
ATR 72-600 22,800 22.35 1333 914 Medium Large
Saab 2000 22,800 21.5 1300 Medium Large
Embraer ERJ 145 22,000 19.3 2270 1380 Medium Large
ATR 42-500 18,600 18.3 1165 1126 Medium Small
Saab 340 13,150 12.930 1300 1030 Medium Small
Embraer 120 Brasilia 11,500 11.25 1560 1380 Medium Small
BAe Jetstream 41 10,890 10.570 1493 826 Medium Small
Learjet 75 9,752 8.709 1353 811 Medium Small
Pilatus PC-24 8,300 7.665 893 724 Medium Small
Embraer Phenom 300 8,150 7.65 956 677 Medium Small
Beechcraft 1900D 7,765 7.605 1036 853 Medium Small
Cessna Citation CJ4 7,761 7.103 1039 896 Medium Small
de Havilland Hercules 7,000 Medium Small
Embraer Phenom 100 4,800 4.43 975 741 Light Small

2) Difference between ground speed and air speed

Wind Speed

For a reference point picked on the ground, the air moves relative to the reference point at the wind speed.

Notice that the wind speed is a vector quantity and has both a magnitude and a direction. Direction is important.

A 20 mph wind from the west is different from a 20 mph wind from the east.

The wind has components in all three primary directions (north-south, east-west, and up-down).

A positive velocity is defined to be in the direction of the aircraft's motion.

We are neglecting cross winds, which occur perpendicular to the flight path but parallel to the ground, and updrafts and downdrafts, which occur perpendicular to the ground.

Ground Speed

For a reference point picked on the ground, the aircraft moves relative to the reference point at the ground speed.

Ground speed is also a vector quantity so a comparison of the ground speed to the wind speed must be done according to rules for vector comparisons

Airspeed

The important quantity in the generation of lift is the relative velocity between the object and the air, which is called the airspeed.

Airspeed cannot be directly measured from a ground position, but must be computed from the ground speed and the wind speed.

Airspeed is the vector difference between the ground speed and the wind speed.

Airspeed = Ground Speed - Wind Speed

On a perfectly still day, the airspeed is equal to the ground speed. But if the wind is blowing in the same direction that the aircraft is moving, the airspeed will be less than the ground speed.

3) Reason for not using airplanes engines for airplane movement on the ground at Airport

Pushback using the jet-engine's thrust-reverser is a highly fuel-consuming and noisy process and also potentially hazardous for personnel working near the plane.

Although many aircraft are capable of moving themselves backwards on the ground using reverse thrust (a procedure referred to as a powerback), the resulting jet blast or prop wash ight cause damage to the terminal building or equipment.

Engines close to the ground may also blow sand and debris forward and then suck them into the engine, causing damage to the engine. A pushback is therefore the preferred method to move the aircraft away from the gate.

Once the plane is tugged away to a safe distance from the terminal, the plane begins using its own engine power for the rest of the taxing process.

4) How an aircraft is pushed to runway when its ready to take off?

Aircraft pushback using a towbarless TUG.

Pushbacks using Tugs

Pushbacks at busy aerodromes are usually subject to ground control clearance to facilitate ground movement on taxiways.

Once clearance is obtained, the pilot will communicate with the tractor driver (or a ground handler walking alongside the aircraft in some cases) to start the pushback.

To communicate, a headsetmay be connected near the nose gear.

Since the pilots cannot see what is behind the aircraft, steering is done by the pushback tractor driver and not by the pilots.

Depending on the aircraft type and airline procedure, a bypass pin may be temporarily installed into the nose gear to disconnect it from the aircraft's normal steering mechanism.

Once the pushback is completed, the towbar is disconnected, and any bypass pin removed.

The ground handler will show the bypass pin to the pilots to make it clear that it has been removed.

The pushback is then complete, and the aircraft can taxi forward under its own power.

Taxing

Taxing is the movement of an aircraft on the ground, under its own power, in contrast to towing or push-back where the aircraft is moved by a tug.

The aircraft usually moves on wheels, but the term also includes aircraft with skis or floats (for water-based travel).

An airplane uses taxiways to taxi from one place on an airport to another; for example, when moving from a hangar to the runway.

The term "taxing" is not used for the accelerating run along a runway prior to takeoff, or the decelerating run immediately after landing, which are called the takeoff roll and landing rollout, respectively

Thus by using combination of both Tugs and taxing airplanes are moved on ground in airport.

5) Airplane Take OFF

Takeoff is the phase of flight in which an aeroplane leaves the ground and becomes airborne. This usually involves starting with a transition from moving along the ground on a runway.

For light aircraft, usually full power is used during takeoff.

Large transport category (airliner) aircraft may use a reduced power for takeoff, where less than full power is applied in order to prolong engine life, reduce maintenance costs and reduce noise emissions.

In some emergency cases, the power used can then be increased to increase the aircraft's performance.

The aircraft is permitted to accelerate to rotation speed (often referred to as Vr).

The nose is raised to a nominal 5°–15° nose up pitch attitude to increase lift from the wings and effect liftoff.

The speeds needed for takeoff are relative to the motion of the air (indicated airspeed). A headwind will reduce the ground speed needed for takeoff, as there is a greater flow of air over the wings.

Typical takeoff air speeds for jetliners are in the range of 240–285 km/h . Light aircraft, take off at around 100 km/h . Ultralights have even lower takeoff speeds.

The takeoff speed required varies with air density, aircraft gross weight, and aircraft configuration (flap or slat position, as applicable).

V1, VR and V2 speeds

Operations with transport category aircraft employ the concept of the takeoff V-speeds, V1, VR and V2.

These speeds are determined not only by the above factors affecting takeoff performance, but also by the length and slope of the runway and any peculiar conditions, such as obstacles off the end of the runway.

Below V1, in case of critical failures, the takeoff should be aborted; above V1 the pilot continues the takeoff and returns for landing.

After the co-pilot calls V1, he/she will call VR or "rotate," marking speed at which to rotate the aircraft.

The VR for transport category aircraft is calculated such as to allow the aircraft to reach the regulatory screen height at V2 with one engine failed.

Then, V2 (the safe takeoff speed) is called. This speed must be maintained after an engine failure to meet performance targets for rate of climb and angle of climb.

Tyre design

An aircraft tire or tyre is designed to withstand extremely heavy loads for short durations.

The number of tires required for aircraft increases with the weight of the aircraft, as the weight of the airplane needs to be distributed more evenly.

Aircraft tire tread patterns are designed to facilitate stability in high crosswind conditions, to channel water away to prevent hydroplaning, and for braking effect.

Inflation

Aircraft tires are usually inflated with nitrogen to minimize expansion and contraction from extreme changes in ambient temperature and pressure experienced during flight.

Dry nitrogen expands at the same rate as other dry atmospheric gases (normal air is about 80% nitrogen), but common compressed air sources may contain moisture, which increases the expansion rate with temperature.

The use of an inert gas for tire inflation will eliminate the possibility of a tire explosion

Rolling resistance

Rolling resistance, sometimes called rolling friction or rolling drag, is the force resisting the motion when a body (wheel) rolls on a surface.

It is mainly caused by non-elastic effects; that is, not all the energy needed for deformation (or movement) of the wheel, is recovered when the pressure is removed.

The "rolling resistance coefficient" is defined by the following equation:

- the rolling resistance force
- the dimensionless rolling resistance coefficient or coefficient of rolling friction (CRF), and
- the normal force, the force perpendicular to the surface on which the wheel is rolling.

Usually airplanes have very low rolling resistance coefficient of such as 0.06.

Rolling resistance for an aircraft depends upon a lot of factors such as aircraft weight, runway condition, tyre conditions, tyre pressure and environmental factors (such as weather conditions)

Tyre pressure

Aircraft tyres are designed to withstand extremely heavy loads for short durations, with the number of tyres required increasing with the weight of the plane in order to better distribute the weight.

Tests of airliner aircraft tires have shown that they are able to sustain pressures of maximum 800 psi (55 bar; 5,500 kPa) before bursting.

There are 2 primary hazards associated with tyres:

  1. Deflation; the tyre deflates in a controlled manner with minimal direct consequence to other systems.
  2. Explosive break-up; the tyre (and sometimes the wheel holding the tyre) deflates or breaks-up in an uncontrolled manner with a significant probability of secondary damage to other unrelated systems.

These hazards are associated with 4 distinct periods of aircraft operation:

  1. Ground operations e.g. taxiing
  2. Take-off (up to gear retraction)
  3. Post take-off (gear stowed)
  4. Landing (to the end of the roll-out)

The various combinations of hazard and flight period can have markedly different influences, but all can affect operations to some degree.

Landing:

A number of issues can arise from landing with a deflated tyre:

Handling issues may arise during the landing roll-out phase, and in severe cases may cause the aircraft to depart the prepared surface.

Landing with a deflated tyre will put additional strain on the remaining tyres, with an increased potential for one or more to subsequently suffer an explosive deflation due to overstress. The implication for secondary damage to the aircraft is high and the potential for rapid aircraft arrest and evacuation is enhanced.

Brake forces

Bringing an aircraft to a safe stop is the most important part of a flight. In order to do this, pilots have a number of facilities available to them.

The brakes bear the brunt of the hard work with the spoilers and reverse thrust lending a helping hand to ensure maximum efficiency.

The autobrake system helps keep the deceleration nice and smooth whilst the anti-skid system reduces the distances needed to stop by modulating the brakes on individual wheels and stopping them from skidding.

Aircraft can also depart with part of the braking system not working.

By carrying out a performance calculation before every takeoff and landing, we ensure that the aircraft will stop safely in the given conditions, even at maximum takeoff weight.

A rough estimate for the maximum energy that the A380’s 16 brakes need to dissipate during landing can be obtained by calculating the kinetic energy of the aircraft (neglecting the effects of thrust reversers, air brakes, tailwinds, headwinds and runway slope).

kinetic energy (KE) is a function of mass (m) and velocity (v) according to the equation:

KE = ½mv2

Typical landing speed for an A380 is around 130kts to 140kts

The kinetic energy of the A380 during Landing is calculated as follows:

KE = 0.5 * 575,000 kg * (87.4556 m/s)2 = 1.49131922169 x 109 J = 1.49 GJ

To generate the necessary frictional forces and to handle this much energy within the length of a runway, large commercial transport aircraft typically require multiple discs per brake assembly and brakes on most, if not all, of their wheels.

6) Force and Power required to push / pull an aircraft by a towing vehicle.

The Embraer E-Jet family is a series of narrow-body short- to medium-range twin-engine jet airliners, carrying 66 to 124 passengers

For the calculation purposes the specifications E-195 model is used.

E-195 weight specifications.

 

The maximum take off weight is 52,290 Kg. Aircraft business is very stringent in safety measurements. Thus the aircraft is never operated at its maximum limitations.

Assuming the maximum aircraft weight during taxing is limited to only 95% of it's maximum take off weight, the design of aircraft is done at 54,900 kg

The main forces acting during taxing of an aircraft are

rolling resistance

and darg force (due to atmospheric air)

Rolling resistance of the aircraft

rr_a = (59400*0.006*9.81) rolling resistance coefficient of aircraft tires is taken as 0.006

Rolling resistance of aircraft = 3496.2840 N

Rolling resistance of the Tug ( Towing vehicle)

rr_t = (7620*0.01*9.81) rolling resistance coefficient of towing vehicle tires is taken as 0.01

Rolling resistance of tug = 747.522 N

Drag force while taxing the aircraft

The drag force D exerted on a body traveling though a fluid is given by


Where:

C is the drag coefficient, which can vary along with the speed of the body. Here it is assumed as 0.25

ρ is the density of the fluid through which the body is moving . Air density vale of 1.225 kg/m3 is taken

v is the speed of the body relative to the fluid. Taxing velocity is assumed to be 4.5 m/s

A is the projected cross-sectional area of the body perpendicular to the flow direction (that is, perpendicular to v). Frontal area is taken as 2 m2.

drag_force = (0.25*1.22*2*4.5*4.5)/2

Drag force = 6.17 N

Total force required by a tug to pushback the aircraft is = Rolling resistance of aircraft + Rolling resistance of tug + Drag force

= 3496.2840 N + 747.522 N + 6.17 N

= 4249.98 N

Assuming the wheels of the tug are 17.5 inches (0.4445 m) in diameter, the torque reuired by the Tug is

Toruqe required of the wheels of the Tug to pushback the aircraft = Force * Radius

= 4249.98 N * 0.4445 m

= 1889.11 Nm

Power required by the Tug to pushback the aircraft = Force * velocity

= 4249.98 N * 4.5 m/s

= 19.12 x 103 W

= 19.12 kW

7) Electric powertrain with type of motor, it’s power rating, and energy requirement to fulfill aircraft towing application and the duty cycle range to control the aircraft speed from zero to highest.

Electric powertrain has three main components

Battery ------- Power Converter -------Motor

First motor ratings is calculated, then power converter ratings are calculated and finally battery capacity is also calculated

Motor Design

Torque calculation

The Electric Tug is assumed to have a gear ratio of 1:10. Thus the torque produced by motor is multiplied by a factor 10 at wheels.

Toruqe required of the wheels of the Tug to pushback the aircraft = 1889.11 Nm

Required motor torque = 1889.11 /10 = 188.911 Nm (Assuming there are no transmission losses)

Assumtions made

motor loss = 10%

Transmission losses = 20%

Required motor torque = 188.9 + 188.9(0.1+0.2)

= 245 Nm

Power calculation

The power required = 19.12 Kw

Assumtions made

motor efficiency = 90%

motor is designed to run at 80% of the full capacity for the safety purposes

Required motor power = 19.12/(0.9*0.8)

= 26.5 kW (or) 35.563906 HP

Thus the required motor specifications are

Torque rating = 245 Nm

Power rating = 35.56 HP

With these motor requirements the below mentioned motor is chosen and its specifications are given below

The Danaher Motion - 80V A/C Brushless

MOTOR SPECIFICATIONS

Power Train 80V A/C ELECTRIC
Traction Motor Danaher Motion - 80V A/C Brushless
Output @ 1300 rpm 55 HP / 41 kW (Peak)
Torque (Electric) 210 ft lbs / 284 Nm

Power converter

Required power is 26.52 kW and the motor's full rated power is 41kW

Thus a DC-AC converter such as sine wave inverter with 41 kW handling capacity is chosen

Duty cycle calculation = 26.52/41 = 0.64

The duty cycle range is from 0 to 0.64%.

Battrery Capacity

Assuming an avergae taxing time for E-195 aircraft is about 10 minutes. The energy required to move the aircraft for 10 minutes is calculated

Time = 10 mins (600 seconds)


Energy = power*time*60

= 26.5*10*60

= 15900 KJ

= 15.900 MJ or 4.4167 kWh

= 4.4167 kWh

Thus for operating the Tug for 10 minutes to tow one aircraft the energy required is 4.4 kWh.

Apart from towing the aircraft, the Tug should move from its parking place to tow the aircraft and then comeback from runway to parking place. To accomodate this travel an additional 0.6 kWh is added to required energy.

Thus for single towing opertaion the energy required is 4.4 kWh + 0.6 kWh = 5.0 kWh.

This is the energy required for sinlge opertaion. Assuming a single full charge of battery the Tug can perform 25 Towing operations.

The required battery capacity is = 5.0 kWh * 25 = 125 kWh

Electric Powertrain

Motor specifications - Torque 284 Nm Power 41 kW (Peak)

Power inverter specifications - The duty cycle range is 0 to 0.64%. Handling capacity - 41 kW

Battery capacity - 125 kWh

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