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2024-04-04

Sikorsky’s Electric VTOL Charges Forward, Tests Hybrid Power

Sikorsky, a Lockheed Martin company, has revealed its ambitious plan to construct, test, and operate a hybrid-electric vertical takeoff and landing demonstrator (HEX/VTOL) with a tilt-wing configuration.

This design marks the inaugural step in a series of substantial next-generation VTOL aircraft, spanning from conventional helicopters to winged configurations. These aircraft will showcase a spectrum of electrification levels, coupled with an advanced autonomy system facilitating optionally piloted flight.

The HEX programme will put a premium on greater than 500 nautical mile range at high speed, fewer mechanical systems to reduce complexity, and lower maintenance costs.

“We never stop innovating at Sikorsky,” said Sikorsky President Paul Lemmo. “Autonomy and electrification will bring transformational change to flight safety and operational efficiency of large VTOL aircraft. Our HEX demonstrator programme will provide valuable insights as we look to a future family of aircraft built to the scale and preferred configurations relevant to commercial and military customers.”

Electric Testbed

Sikorsky Innovations, the prototyping arm of the company, in collaboration with GE Aerospace, is in the final stages of designing a testbed for hybrid-electric power systems.

This testbed will feature a 600kW electric motor and is aimed at assessing the hover performance of the upcoming HEX demonstrator.

The HEX demonstrator, with a maximum gross weight of 9,000 pounds, will incorporate a 1.2MW-class turbogenerator and related power electronics.

Igor Cherepinsky, Sikorsky Innovations director, noted: “Within Sikorsky’s electric pillar, we are designing electric motors, power electronics and our own vehicle management hardware and actuation. HEX will integrate these components, showcase the growing maturity of our MATRIX autonomy suite, and the potential for maintenance-free systems. Seeing the results will lead us to more efficient overall designs.”

HEX has passed its preliminary design review, and company engineering labs have proprietary electric motors and power distribution systems running. Sikorsky Innovations also plans a HEX propulsion system testbed to support development.

Concurrently, discussions regarding UAS certification are in progress with the U.S. Federal Aviation Administration (FAA) to incorporate the company’s Matrix autonomous flight controls into an undisclosed fixed-wing platform.

The introduction of this new UAS pillar targets both military and commercial clientele. Cherepinsky emphasised, “We don’t want to dictate whether a particular mission should be 100 per cent autonomous or should have a human on the loop. That’s for our customers to figure out. We want to provide the tools. That’s where Matrix coupled with things like electric flight and this new UAS pillar can revolutionise how we look at aircraft design holistically.”

Autonomy Progression

Matrix autonomy has evolved since its implementation on the Sikorsky Autonomy Research Aircraft (SARA) first flown in 2013. The fly-by-wire S-76 enabled untrained pilots to fly the helicopter through a tablet computer during the Aircrew Labor In-Cockpit Automation System (ALIAS) initiative funded by the Defense Advanced Research Projects Agency (DARPA).

Additionally, it was incorporated into a Cessna 208 Caravan fixed-wing turboprop aircraft utilising the same pilot interface. In June 2019, it was also integrated into a Sikorsky-owned UH-60A Black Hawk helicopter.

In 2022, Matrix empowered the unmanned ALIAS Black Hawk to execute tactical manoeuvres and transport cargo. Presently, Matrix has reached a technology readiness level (TRL) of 7, positioning it close to operational deployment. When SARA initially took flight with the original Matrix version, it possessed fundamental autonomy features, such as motion planning.

Enhanced Capabilities

Over time, Sikorsky enhanced its capabilities to enable operations in intricate airspace, including uncooperative see-and-avoid functionality, selection of landing zones, and execution of both routine and emergency landings, including full autorotations.

The current iteration integrates various light detection and ranging (lidar) scanners, cameras, and other sensors to facilitate complete landings in most degraded visual environment (DVE) scenarios, while establishing a protective perimeter around the aircraft to prevent controlled flight into terrain. Matrix functions as a software library applicable to platforms like Future Vertical Lift (FVL) and the Black Hawk.

The company is presently in discussions on how autonomy might be applied to the U.S. Army’s Enduring Fleet helicopters, and the company is exploring how to put Matrix on its commercial platforms with additional functionality.

On the UH-60, Sikorsky demonstrated the Black Hawk in its optionally piloted configuration, showcasing seamless transition between piloted and unmanned operations.

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