Cranfield Aerospace Solutions has integrated the design of its hydrogen fuel cell technology into the nacelle of an aircraft marking a step towards the certification and commercialization of the company’s zero-emissions technology.
Cranfield Aerospace Solutions (CAeS) has been quietly making strides in engineering to achieve zero-emissions flight, and it has now achieved a significant milestone with the successful integration design of its hydrogen fuel cell technology into the nacelle of an aircraft. This achievement not only represents important engineering and technological progress but also marks a significant step towards the certification and commercialization of the company’s zero-emissions technology.
At the heart of CAeS’s mission is the development of a hydrogen fuel cell drivetrain that will be a safe, certifiable, and commercially viable solution for the aviation market. By packaging the entire full power system, including the hydrogen fuel cell system and motor, into the nacelle, CAeS has addressed key technical and packaging challenges, laying the groundwork for engaging with regulators to certify the technology for safe flight. This milestone is crucial for realizing the vision of commercially viable zero-emissions aviation.
Jenny Kavanagh, Chief Strategy Officer, CAeS said, “The decision was taken early on in the programme that before proceeding to ground and flight test, we had to ensure that we had solved the packaging and thermal management challenges that underpin the commercial viability of the technology. Now that this significant milestone has been achieved, CAeS is progressing to the next stage of the project and to launching into manufacture for the testing campaign.”
While hydrogen fuel cell technology is not new, adapting it for aviation presents unique challenges. The successful integration of a 240kW system, equivalent to 110% of the power of the engine it replaces, into the nacelle showcases CAeS’s ability to overcome these challenges. This achievement underscores the feasibility of hydrogen-electric propulsion systems for aircraft and positions CAeS as a leader in commercializing zero-emissions aircraft, contributing to the industry’s environmental sustainability efforts.
Behind this milestone lies a formidable engineering effort. The design team faced numerous challenges in packaging the hydrogen fuel cell along with its electrical components, cooling equipment, pipe routing, and cable routing within the limited space of the nacelle. Meticulous planning, iterative design, and close coordination with partners were essential to ensure optimal performance.
The forward section of the nacelle houses the Hydrogen Fuel Cell System (HFCS), the HFCS Balance of Plant (BoP), an electric motor, inverters and controllers, a pitch control unit, and all the electrical cabling/routing and cooling systems for the HFCS. The rear nacelle contains the ground power interface and the high-voltage power distribution system, each presenting its own cooling and packaging challenges.
The integration of the HFCS heat exchangers around the existing main landing gear structure required meticulous planning and coordination to ensure optimal performance. CAeS’s successful packaging of the HFCS into the nacelle opens opportunities for integration into other aircraft platforms and applications. This includes collaborations with partners like Dronamics to explore the potential for zero-emissions middle-mile cargo UAVs, showcasing the versatility and applicability of CAeS’s technology across various aviation sectors.
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The development of this hydrogen fuel cell system has fostered a culture of innovation within the CAeS team, driving capabilities, technologies, and opportunities for the next evolution in HFCS powertrain technology. By pushing boundaries and driving innovation, CAeS remains committed to shaping a greener future for the aviation industry.
Question- What is the next step for CAeS after achieving this milestone?
Answer- CAeS will progress to the next stage of the project and begin manufacturing for the testing campaign.
Question- Is hydrogen fuel cell technology new?
Answer- No, hydrogen fuel cell technology has been around for some time. However, adapting it for aviation presents unique challenges.
Question- What is the power capacity of the integrated hydrogen fuel cell system?
Answer- The system has a power capacity of 240kW, which is equivalent to 110% of the power of the engine it replaces.
Question- What does this achievement mean for the future of zero-emissions aviation?
Answer- It is a crucial step towards realizing the vision of commercially viable zero-emissions aviation.
