DRDO-VRDE - Engine Developments For UAVs

ENGINE DEVELOPMENMT FOR
UAV APPLICATIONS. EXPERIENCES AND CHALLENGES.

Dr C.P.RAMANARAYANAN
Vehicles Research and Development Establishment, Ahmednagar
UNMANNED AERIAL VEHICLE
UAV is an aerial vehicle capable of sustained flight without need

Although UAVs are mostly used in military applications nowadays,
for a human operator onboard. the UAVs can also perform such scientific, public safety and commercial
tasks as image acquisition of disaster areas, map building, communication

relays, search and rescue, traffic surveillance and so on.. EUROUVS has drawn up a classification of UAV systems:
1. Micro and Mini UAVs

2. Tactical UAVs Close/Short/Medium/Long Range/MALE 3. Strategic UAVs HALE 4. Special Task UAVs Lethal/Decoys/Stratospheric/ExoStratospheric
UAV ENGINE TECHNOLOGY
Engines for unmanned aerial vehicle applications that require 120 hp or less are typically based on spark ignition, reciprocating internal combustion engines using gasoline or similar fuels. The engine construction includes 2-stroke, 4-stroke (naturally aspirated and boosted) as well as rotary style engines. New requirements are also dictating the need for the use of new light weight materials and multi fuel capabilities.
UAV ENGINES - SPECIAL REQUIREMENTS
High Power to weight ratio.
- Ratio of the order of 2 or more. Long Endurance Mission duration of 20-50 hours or more. Duty Cycle Demanding duty cycle with high Altitude take off. Compactness Low Volume Simple Maintainability Robustness, lower skills ground crews. Signature Low heat signature/EMC
POWER PACK FOR VARIOUS CLASS OF UAVs

ENGINES FOR UAVs UAV TYPE Micro Mini TAC, CR/LE ENGINE TYPE Electrical Piston (2 X 2) Rotary (WANKEL) POWER RANGE (HP) 1 1 20 20 90
MALE
MALE HALE / TCUAV
Piston (4 X 4)
Turbo Prop Turbo Jet / Fan
90 250
250 500 Above 500
VRDE ASSOCIATION IN UAV ENGINES
VRDE has been tasked for development of mini UAVs of less than 150kg class. It is also involved in the development of small, low weight, high-specific power output engines. VRDE has successfully developed a few two stroke engines and have been tested.
Development of Wankel Rotary Engine was taken up in collaboration with NAL and ADE and has been realised successfully with completely indigenous technologies. Currently development of engines of higher class is in progress.
VRDE IN UAV ENGINE DEVELOPMENT

The salient features of the engines developed include: High power to weight ratio Hard chrome plated aluminum cylinders
Diaphragm type carburetors for all position operation

Multi-piece crankshaft.
SPECTRUM OF 2-STROKE UAV ENGINES
Four-cylinder 37 hp engine
Two-cylinder 21 hp engine
Single-cylinder 11 hp engine
TBI system for 2-cylinder engine
VRDE ASSOCIATION IN UAV & AERIAL ENGINES

5.00
Fuel Consumption (g/sec)
4.50 4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 0.00 3000
Fuel Consumption Vs Speed

Four Cylinder Two Cylinder Single Cylinder
4000
5000
6000
7000
RPM
70.0
Thrust Vs RPM: Single, Twin and Four-cyl engine

60.0
Four-cylinder Two-cylinder Single cylinder
50.0
Thrust (kg)
40.0
30.0
20.0
10.0
0.0 3000
4000
5000
6000
7000
RPM
FLIGHT ROTARY ENGINE FOR NISHANT UAV
The engine is jointly designed and developed by NAL, VRDE and ADE.
The engine weighs less than 30 Kgs, and has high power to weight ratio in single rotor category.
The engine has a power of 55 hp and can also be used for powering smaller air vehicles.
55 HP ROTARY ENGINE
Power output Swept Volume Compression Ratio Min SFC Idle Speed Ignition System 55HP@ 8000rpm 324 CC 9.2 250 gm/bhp-hr 2700-2900 rpm Electronic 28v CD Ignition
Cooling
Water cooled Housing & air cooled rotor

Diaphragm Type Total loss type lubrication 26 kg
Carburetor Lubrication Weight (Dry)
TESTING OF ROTARY ENGINE

100
Thrustin kgf
Various testings carried out: - Thrust cradle testing - Dynamometer testing - Running-in testing - Endurance testing
80 60 40 20 0 3000 5000 7000 9000 RPM

60 50
Power HP
(Based On JAR Cycle/ Cemilac Reco. Cycle)
40 30 20 10 0 3000 5000 7000 RPM 9000
- Mission cycle testing
Thrust Cradle & Dynamometer testing
INTEGRATION & FLIGHT TRIAL
Integration of Engine on UAV Nishant Flight testing on Nishant
4-STROKE ENGINE FOR MALE UAV
VRDE is currently working on horizontally opposed 4-cylinder 4-stroke turbocharged SI engine.

The engine will develop thrust for the take off weight of about 2000kg.
BROAD SPECIFICATION PORPOSED ENGINE.

TARGET 4-STROKE ENGINE Type of the engine Take off power
4cylinder, 4 stroke horizontally opposed, spark ignited reciprocating piston engine with turbocharger
120 3 BHP with turbocharger at sea level
Maximum continuous power

Maximum operating altitude Specific fuel consumption
105 3 BHP with turbocharger at sea level

36000 ft 275 5 g/kWh at max. continuous throttle
Dry engine weight

Max engine speed Endurance Operating temperature Maximum propeller speeds
75 2 Kg
6000 RPM 36+ hours -40C to +55 C 2300 to 2500 rpm
WORLD/INDIAN SCENARIO IN MALE UAV ENGINES
Most of the MALE UAVs are fitted with four-stroke four-cylinder engines For 125 HP engine for MALE UAV, a 1500 2000cc engine will be adequate for meeting the requirements Four-cylinder Horizontally opposed four-stroke engine configuration with Turbocharger will serve the purpose of propulsion system for INDIAs version of MALE UAV RUSTOM
ROTAX ENGINES (AUSTRIA)
LYCOMING ENGINES (USA)
LIMBACH (GERMANY)
4-STROKE ENGINE FOR MALE UAV - RUSTUM
Critical factors/technologies involved:
Turbo-charging technology for SI Engine

Multi Point Fuel Injection (MPFI) for multi-cylinder four-stroke engine.
Composite coating technology on aluminium alloy.

Application of High specific strength material like Maraging steels and Al alloys.
FUTURE UAV ENGINES
DIESEL UAV ENGINES Highly Fuel-efficient than present gasoline engines Strategically suitable for single fuel concept
HYDROGEN OPERATED ENGINES Suitable for very high altitude operation Highly complex challenging technology Very long endurance is possible
DIESEL ENGINES FOR UAVs
REQUIREMENT OF DIESEL ENGINE FOR UAVs

The vast majority of UAVs are using currently utilizing gasoline fuels (e.g. Hunter, Shadow, Predator etc.)However, these engines can be
improved to Diesel version due to following:
1. Causes a specific gasoline logistics train since most military vehicle use
diesel fuel.
2. Gasoline vapor is explosive, hence is a hazard to the aircraft and ships that transport it. 3. Gasoline engines are less efficient than heavy fuel engines thus providing shorter flight/loiter times.
ADVANTAGES OF DIESEL ENGINES
Reliability
Maintenance Turbocharge
and supercharge
Fuel economy Durability Efficiency
CHALLENGES IN HEAVY FUEL ENGINES
High peak pressure Produce black soot Expensive
DIESEL UAV ENGINES GAP DIESEL ENGINE DYNA CAM ENGINE ECOMOTORS DIESEL ENGINE AUSTRO ENGINE AE 300 DELTA HAWK DIESEL ENGINE CENTURIONS DIESEL AIR LIMITED
DEVELOPERS NASA DEVELOPMENT USA GERMANY AUSTRAIN USA GERMANY UK
THANK YOU

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ENGINE DEVELOPMENMT FOR

UAV APPLICATIONS. EXPERIENCES AND CHALLENGES.

UNMANNED AERIAL VEHICLE

UAV is an aerial vehicle capable of sustained flight without need

tasks as image acquisition of disaster areas, map building, communication

1. Micro and Mini UAVs

Vehicles Research and Development Establishment, Ahmednagar

UAV ENGINE TECHNOLOGY

Vehicles Research and Development Establishment, Ahmednagar

UAV ENGINES - SPECIAL REQUIREMENTS

High Power to weight ratio.

Vehicles Research and Development Establishment, Ahmednagar

POWER PACK FOR VARIOUS CLASS OF UAVs

Vehicles Research and Development Establishment, Ahmednagar

VRDE ASSOCIATION IN UAV ENGINES

VRDE IN UAV ENGINE DEVELOPMENT

Diaphragm type carburetors for all position operation

Vehicles Research and Development Establishment, Ahmednagar

SPECTRUM OF 2-STROKE UAV ENGINES

TBI system for 2-cylinder engine

Vehicles Research and Development Establishment, Ahmednagar

VRDE ASSOCIATION IN UAV & AERIAL ENGINES

Fuel Consumption (g/sec)

Fuel Consumption Vs Speed

Thrust Vs RPM: Single, Twin and Four-cyl engine

Four-cylinder Two-cylinder Single cylinder

Vehicles Research and Development Establishment, Ahmednagar

FLIGHT ROTARY ENGINE FOR NISHANT UAV

Vehicles Research and Development Establishment, Ahmednagar

VRDE ASSOCIATION IN UAV & AERIAL ENGINES

Water cooled Housing & air cooled rotor

Carburetor Lubrication Weight (Dry)

Vehicles Research and Development Establishment, Ahmednagar

VRDE ASSOCIATION IN UAV & AERIAL ENGINES

TESTING OF ROTARY ENGINE

80 60 40 20 0 3000 5000 7000 9000 RPM

(Based On JAR Cycle/ Cemilac Reco. Cycle)

40 30 20 10 0 3000 5000 7000 RPM 9000

- Mission cycle testing

Thrust Cradle & Dynamometer testing

Vehicles Research and Development Establishment, Ahmednagar

VRDE ASSOCIATION IN UAV & AERIAL ENGINES

INTEGRATION & FLIGHT TRIAL

Integration of Engine on UAV Nishant Flight testing on Nishant

Vehicles Research and Development Establishment, Ahmednagar

4-STROKE ENGINE FOR MALE UAV

VRDE is currently working on horizontally opposed 4-cylinder 4-stroke turbocharged SI engine.

Vehicles Research and Development Establishment, Ahmednagar

BROAD SPECIFICATION PORPOSED ENGINE.

Maximum continuous power

105 3 BHP with turbocharger at sea level

Dry engine weight

Vehicles Research and Development Establishment, Ahmednagar

WORLD/INDIAN SCENARIO IN MALE UAV ENGINES

ROTAX ENGINES (AUSTRIA)

LYCOMING ENGINES (USA)

Vehicles Research and Development Establishment, Ahmednagar

4-STROKE ENGINE FOR MALE UAV - RUSTUM

Critical factors/technologies involved: