Future management of helicopter fleets will be more heavily based on individual component damage tracking and less on legacy usage monitoring (flight parameter-based) methods. This enhances health assessment capabilities by taking into account the actual loads on a component-by-component basis. However, accurate loads prediction in rotating frame components remains a challenge. Even with advanced computational fluid dynamics (CFD) techniques, prediction of the unsteady aerodynamic loads acting on the rotor blades is computationally intensive and problematic in terms of accurate loads prediction across the entire flight regime of the helicopter. High-speed flight can potentially introduce both shock and near-stall effects within a given rotor rotation. Low-speed flight can include blade-vortex interaction effects, wherein flow from a given blade (vorticity loading from tip vortices) impinges upon the preceding blade, causing unsteady aerodynamic loading that is difficult to quantity and predict numerically. Vehicle maneuvering can produce significantly higher blade pitching moments than steady flight. All of these regimes combine to represent the loading history of the rotor system. Therefore, accurate loads prediction methods, in terms of matching peak-to-peak, magnitude, phase, as well as vibratory/harmonic content, are required that capture all flight regimes for all critical structural components. This research focuses on the development of a loads prediction method, known as the Load Confluence Algorithm (LCA), and its application to the analysis of a large set of flight test data from the NASA/US Army UH-60A Airloads Program. The LCA combines measured response at a prescribed set of locations with a numerical model of the rotor system. For a given flight condition (steady flight, maneuvers, etc.) the numerical simulation's predicted loads distribution is iteratively incremented (by harmonic) until convergence with measured loads is reached at the prescribed locations (control points). Predicted loads response at non-instrumented locations is shown to be improved as well, thus enhancing fatigue lifing methods for these components. The procedure specifically investigates the harmonic content of the applied loads and the improved prediction of the harmonic components. The impact of the enhanced accuracy on loads predictions on component structural fatigue is illustrated by way of an example. Results show that, for a limited sensor set (two 3-axis sensors per blade), blade loads are accurately predicted across a full range of flight regimes. Hub loads are best modeled using the pushrod as the control point. Results also show that load magnitude has a tremendous influence on damage, with a 25% over-estimation of vibratory load resulting in a damage factor of nearly 3. This research highlights the importance of accurate loads prediction for a rotorcraft life tracking program. Small inaccuracies in loads lead to dramatic errors in damage assessment.

Recent advances in sensor and microcomputer technology and in control and aeroydynamics theories has made small unmanned aerial vehicles a reality. The small size, low cost and manoueverbility of these systems has positioned them to be potential solutions in a large class of applications. However, the small size of these vehicles pose significant challenges. The small sensors used on these systems are much noisier than their larger counterparts.The compact structure of these vehicles also makes them more vulnerable to environmental effects. This work develops several different control strategies for two sUAV platforms and provides the rationale for judging each of the controllers based on a derivation of the dynamics, simulation studies and experimental results where possible. First, the coaxial helicopter platform is considered. This sUAV’s dual rotor system (along with its stabilizer bar technology) provides the ideal platform for safe, stable flight in a compact form factor. However, the inherent stability of the vehicle is achieved at the cost of weaker control authority and therefore an inability to achieve aggressive trajectories especially when faced with heavy wind disturbances. Three different linear control strategies are derived for this platform. PID, LQR and H∞ methods are tested in simulation studies. While the PID method is simple and intuitive, the LQR method is better at handling the decoupling required in the system. However the frequency domain design of the H∞ control method is better at suppressing disturbances and tracking more aggressive trajectories. The dynamics of the quadrotor are much faster than those of the coaxial helicopter. In the quadrotor, four independent fixed pitch rotors provide the required thrust. Differences between each of the rotors creates moments in the roll, pitch and yaw directions. This system greatly simplifies the mechanical complexity of the UAV, making quadrotors cheaper to maintain and more accessible. The quadrotor dynamics are derived in this work. Due to the lack of any mechanical stabilization system, these quadrotor dynamics are not inherently damped around hover. As such, the focus of the controller development is on using nonlinear techniques. Linear quadratic regulation methods are derived and shown to be inadequate when used in zones moderately outside hover. Within nonlinear methods, feedback linearization techniques are developed for the quadrotor using an inner/outer loop decoupling structure that avoids more complex variants of the feedback linearization methodology. Most nonlinear control methods (including feedback linearization) assume perfect knowledge of vehicle parameters. In this regard, simulation studies show that when this assumption is violated the results of the flight significantly deteriorate for quadrotors flying using the feedback linearization method. With this in mind, an adaptation law is devised around the nonlinear control method that actively modifies the plant parameters in an effort to drive tracking errors to zero. In simple cases with sufficiently rich trajectory requirements the parameters are able to adapt to the correct values (as verified by simulation studies). It can also adapt to changing parameters in flight to ensure that vehicle stability and controller performance is not compromised. However, the direct adaptive control method devised in this work has the added benefit of being able to modify plant parameters to suppress the effects of external disturbances as well. This is clearly shown when wind disturbances are applied to the quadrotor simulations. Finally, the nonlinear quadrotor controllers devised above are tested on a custom built quadrotor and autopilot platform. While the custom quadrotor is able to fly using the standard control methods, the specific controllers devised here are tested on a test bench that constrains the movement of the vehicle. The results of the tests show that the controller is able to sufficiently change the necessary parameter to ensure effective tracking in the presence of unmodelled disturbances and measurement error.

For optimal rotor performance in a tiltrotor aircraft the difference in the inflow and the rotor speeds between the hover and cruise flight modes suggests different blade twist and chord distributions. The blade twist rates in current tiltrotor applications are defined based upon a compromise between the figure of merit in hover and propeller efficiency in airplane mode. However, when each operation mode is considered separately the optimum blade distributions are found to be considerably different. Passive blade twist control, which uses the inherent variation in centrifugal forces on a rotor blade to achieve optimum blade twist distributions in each flight mode through the use of extension-twist coupled composite rotor blades, has been considered for performance improvement of tiltrotor aircraft over the last two decades. The challenge for this concept is to achieve the desired twisting deformations in the rotor blade without altering the aeroelastic characteristics of the vehicle. A concept referred to as the sliding mass concept is proposed in this work in order to increase the twist change with rotor speed for a closed-cell composite rotor blade cross-section to practical levels for performance improvement in a tiltrotor aircraft. The concept is based on load path changes for the centrifugal forces by utilizing non-structural masses readily available on a conventional blade, such as the leading edge balancing mass. A multilevel optimization technique based on the simulated annealing method is applied to improve the performance of the XV15 tiltrotor aircraft. A cross-sectional analysis tool, VABS together with a multibody dynamics code, DYMORE are integrated into the optimization process. The optimization results revealed significant improvements in the power requirement in hover while preserving cruise efficiency. It is also shown that about 21% of the improvement is provided through the sliding mass concept pointing to the additional flexibility the concept provides for tailoring of the structure without any additional weight penalty on the system.

Recent increases in computing power and memory have created renewed interest in alternative grid schemes such as unstructured grids, which facilitate rapid grid generation by relaxing restrictions on grid structure. Three rotor models have been incorporated into a popular fixed-wing unstructured computational fluid dynamics (CFD) solver to increase its capability and facilitate availability to the rotorcraft community. The benefit of unstructured grid methods is demonstrated through rapid generation of high fidelity configuration models. The simplest rotor model is the steady state actuator disk approximation. By transforming the unsteady rotor problem into a steady state one, the actuator disk can provide rapid predictions of performance parameters such as lift and drag. The actuator blade and overset blade models provide a depiction of the unsteady rotor wake, but incur a larger computational cost than the actuator disk. The actuator blade model is convenient when the unsteady aerodynamic behavior needs to be investigated, but the computational cost of the overset approach is too large. The overset or chimera method allows the blades loads to be computed from first-principles and therefore provides the most accurate prediction of the rotor wake for the models investigated. The physics of the flow fields of these models for rotor/fuselage interaction are explored, along with efficiencies and limitations of each methodology.

In the development of modern rotorcraft vehicles, many unique challenges emerge due to the highly coupled nature of individual rotorcraft design disciplines therefore, the use of an integrated product and process development (IPPD) methodology is necessary to drive the design solution. Through the use of parallel design and analysis, this approach achieves the design synthesis of numerous product and process requirements that is essential in ultimately satisfying the customers demands. Over the past twenty years, Georgia Techs Center for Excellence in Rotorcraft Technology (CERT) has continuously focused on refining this IPPD approach within its rotorcraft design course by using the annual American Helicopter Society (AHS) Student Design Competition as the design requirement catalyst. Despite this extensive experience, however, the documentation of this preliminary rotorcraft design approach has become out of date or insufficient in addressing a modern IPPD methodology. In no design discipline is this need for updated documentation more prevalent than in propulsion system design, specifically in the area of gas turbine technology. From an academic perspective, the vast majority of current propulsion system design resources are focused on fixed-wing applications with very limited reference to the use of turboshaft engines. Additionally, most rotorcraft design resources are centered on aerodynamic considerations and largely overlook propulsion system integration. This research effort is aimed at bridging this information gap by developing a preliminary turboshaft engine design methodology that is applicable to a wide range of potential rotorcraft propulsion system design problems. The preliminary engine design process begins by defining the design space through analysis of the initial performance and mission requirements dictated in a given request for proposal (RFP). Engine cycle selection is then completed using tools such as GasTurb and the NASA Engine Performance Program (NEPP) to conduct thorough parametric and engine performance analysis. Basic engine component design considerations are highlighted to facilitate configuration trade studies and to generate more detailed engine performance and geometric data. Throughout this approach, a comprehensive engine design case study is incorporated based on a two-place, turbine training helicopter known as the Georgia Tech Generic Helicopter (GTGH). This example serves as a consistent propulsion system design reference highlighting the level of integration and detail required for each step of the preliminary turboshaft engine design methodology.

Formulation of linear time invariant (LTI) models of a nonlinear system about a periodic equilibrium using the harmonic domain representation of LTI model states has been studied in the literature. This thesis presents an alternative method and a computationally efficient scheme for implementation of the developed method for extraction of linear time invariant (LTI) models from a helicopter nonlinear model in forward flight. The fidelity of the extracted LTI models is evaluated using response comparisons between the extracted LTI models and the nonlinear model in both time and frequency domains. Moreover, the fidelity of stability properties is studied through the eigenvalue and eigenvector comparisons between LTI and LTP models by making use of the Floquet Transition Matrix. For time domain evaluations, individual blade control (IBC) and On-Blade Control (OBC) inputs that have been tried in the literature for vibration and noise control studies are used. For frequency domain evaluations, frequency sweep inputs are used to obtain frequency responses of fixed system hub loads to a single blade IBC input. The evaluation results demonstrate the fidelity of the extracted LTI models, and thus, establish the validity of the LTI model extraction process for use in integrated flight and rotor control studies.

Recent advances in sensor and microcomputer technology and in control and aeroydynamics theories has made small unmanned aerial vehicles a reality. The small size, low cost and manoueverbility of these systems has positioned them to be potential solutions in a large class of applications. However, the small size of these vehicles pose significant challenges. The small sensors used on these systems are much noisier than their larger counterparts.The compact structure of these vehicles also makes them more vulnerable to environmental effects. This work develops several different control strategies for two sUAV platforms and provides the rationale for judging each of the controllers based on a derivation of the dynamics, simulation studies and experimental results where possible. First, the coaxial helicopter platform is considered. This sUAV’s dual rotor system (along with its stabilizer bar technology) provides the ideal platform for safe, stable flight in a compact form factor. However, the inherent stability of the vehicle is achieved at the cost of weaker control authority and therefore an inability to achieve aggressive trajectories especially when faced with heavy wind disturbances. Three different linear control strategies are derived for this platform. PID, LQR and H∞ methods are tested in simulation studies. While the PID method is simple and intuitive, the LQR method is better at handling the decoupling required in the system. However the frequency domain design of the H∞ control method is better at suppressing disturbances and tracking more aggressive trajectories. The dynamics of the quadrotor are much faster than those of the coaxial helicopter. In the quadrotor, four independent fixed pitch rotors provide the required thrust. Differences between each of the rotors creates moments in the roll, pitch and yaw directions. This system greatly simplifies the mechanical complexity of the UAV, making quadrotors cheaper to maintain and more accessible. The quadrotor dynamics are derived in this work. Due to the lack of any mechanical stabilization system, these quadrotor dynamics are not inherently damped around hover. As such, the focus of the controller development is on using nonlinear techniques. Linear quadratic regulation methods are derived and shown to be inadequate when used in zones moderately outside hover. Within nonlinear methods, feedback linearization techniques are developed for the quadrotor using an inner/outer loop decoupling structure that avoids more complex variants of the feedback linearization methodology. Most nonlinear control methods (including feedback linearization) assume perfect knowledge of vehicle parameters. In this regard, simulation studies show that when this assumption is violated the results of the flight significantly deteriorate for quadrotors flying using the feedback linearization method. With this in mind, an adaptation law is devised around the nonlinear control method that actively modifies the plant parameters in an effort to drive tracking errors to zero. In simple cases with sufficiently rich trajectory requirements the parameters are able to adapt to the correct values (as verified by simulation studies). It can also adapt to changing parameters in flight to ensure that vehicle stability and controller performance is not compromised. However, the direct adaptive control method devised in this work has the added benefit of being able to modify plant parameters to suppress the effects of external disturbances as well. This is clearly shown when wind disturbances are applied to the quadrotor simulations. Finally, the nonlinear quadrotor controllers devised above are tested on a custom built quadrotor and autopilot platform. While the custom quadrotor is able to fly using the standard control methods, the specific controllers devised here are tested on a test bench that constrains the movement of the vehicle. The results of the tests show that the controller is able to sufficiently change the necessary parameter to ensure effective tracking in the presence of unmodelled disturbances and measurement error.

New rotorcraft configurations are emerging, such as the optimal speed helicopter and slowed-rotor compound helicopter which, due to variable rotor speed and redundant lifting components, have non-unique trim solution spaces. The combination of controls and rotor speed that produce the best steady-flight condition is sought among all the possible solutions. This work develops the concept of optimal rotorcraft trim and explores its application to advanced rotorcraft configurations with non-unique, constrained trim solutions. The optimal trim work is based on the nonlinear programming method of the generalized reduced gradient (GRG) and is integrated into a multi-body, comprehensive aeroelastic rotorcraft code. In addition to the concept of optimal trim, two further developments are presented that allow the extension of optimal trim to rotorcraft with rotors that operate over a wide range of rotor speeds. The first is the concept of variable rotor speed trim with special application to rotors operating in steady autorotation. The technique developed herein treats rotor speed as a trim variable and uses a Newton-Raphson iterative method to drive the rotor speed to zero average torque simultaneously with other dependent trim variables. The second additional contribution of this thesis is a novel way to rapidly approximate elastic rotor blade stresses and strains in the aeroelastic trim analysis for structural constraints. For rotors that operate over large angular velocity ranges, rotor resonance and increased flapping conditions are encountered that can drive the maximum cross-sectional stress and strain to levels beyond endurance limits; such conditions must be avoided. The method developed herein captures the maximum cross-sectional stress/strain based on the trained response of an artificial neural network (ANN) surrogate as a function of 1-D beam forces and moments. The stresses/strains are computed simultaneously with the optimal trim and are used as constraints in the optimal trim solution. Finally, an optimal trim analysis is applied to a high-speed compound gyroplane configuration, which has two distinct rotor speed control methods, with the purpose of maximizing the vehicle cruise efficiency while maintaining rotor blade strain below endurance limit values.

In 1967 the US Air Force solicited proposals for ``low-disc-loading [Vertical Takeoff and Landing] configurations suitable for high speed flight.' Bell Helicopter elected to respond with a proposal after initial analysis on configurations including a stopped edgewise disc and a trail rotor. They concluded that a folding proprotor design would best meet the requirements laid forth. Initial analysis work began on this folding proprotor (stop-fold) design in the same year and concluded in 1972 with a full scale 25 foot diameter pylon and rotor assembly wind tunnel test at the NASA-Ames Large Scale Wind Tunnel. The project was concluded at this point and never resulted in a production or research aircraft. The original proposed stop-fold tiltrotor design by Bell Helicopter allowed for vertical takeoff and landing, a transition sequence rotating the pylon rotor assembly from helicopter to airplane mode, a conversion sequence during which the rotor stopped and blades folded along the pylon, and a transition from prop thrust to auxiliary jet engine power while the rotor was being stopped. This configuration effectively removes the high-speed restraints typical of a prop-driven aircraft and instead opens a flight envelope comparable to a fixed-wing jet. This project entails both the simulation and basic analysis of the stop-fold concept with special attention to frequency responses and potential coupling between modes.

Thesis (Ph. D.)--Helsinki University of Technology, Applied Electronics Laboratory, 20-05. / Includes bibliographical references (p. 167-190). Also available online.