Patent Description:
Aircraft having electric propulsion have been proposed. Such aircraft comprise one or more propulsors (such as propellers or ducted fans) driven by electric motors, which are in turn supplied with power from a power source such as a battery, fuel cell, or internal combustion engine driven generator.

An issue with such aircraft is noise. The principle source of noise in such aircraft is usually the propulsors, which generate noise via various physical mechanisms. The perceived effect of this noise will vary depending on the overall loudness (in terms of perceived noise decibels - PdB), as well as other factors. Consequently, it is an objective of the present disclosure to provide an aircraft and a method of controlling an aircraft which has reduced perceived noise.

European patent application <CIT> discloses an aerial vehicle. The aerial vehicle is a vertical take-off and landing (VTOL) aerial vehicle which comprises an airframe and a plurality of rotors operatively coupled with one or more motors. The plurality of rotors comprise a first, second, third, and fourth rotor. Each of the first, second, third, and fourth rotors are arranged in a single plane and oriented to direct thrust downward relative to the airframe. In certain aspects, at least two of the plurality of rotors employ a different geometry to generate a targeted noise signature.

United States patent application <CIT> discloses aerial vehicles which include propulsion units having motors with drive shafts that are aligned at a variety of orientations, propellers with variable pitch blades, and common operators for aligning the drive shafts at one or more orientations and for varying the pitch angles of the blades. The common operators include plate elements to which a propeller hub is rotatably joined, and which are supported by one or more linear actuators that may extend or retract to vary both the orientations of the drive shafts and the pitch angles of the blades. Operating the motors and propellers at varying speeds, gimbal angles or pitch angles enables the motors to generate forces in any number of directions and at any magnitudes. Attributes of the propulsion units may be selected in order to shape or control the noise generated thereby.

According to a first aspect there is provided a propulsion system for an aircraft, the propulsion system comprising:.

Advantageously, in view of the freedom to operate within a range of speeds for a particular required thrust (in view of the blade pitch varying mechanism), each propulsor can be controlled to produce tone noise at different peak frequencies, since the blade passing frequency of the blades is dependent on speed. By generating a plurality of tones, this system can be used to produce a lower perceived noise. Consequently, an aircraft is provided which has a reduced overall noise signature during substantially all phases of operation.

The controller may be configured to control the speed and pitch of the blades such that a frequency spectrum of the propulsion system matches a predetermined spectrum.

The controller may be configured to control the speed and pitch of the blades such that the rotor speed of a respective propulsor is substantially constant over a range of thrust levels. Advantageously, the tone noise of a given propulsor is maintained at a substantially constant frequency during manoeuvres, thereby further reducing perceived noise.

At least one of the propulsors may comprise either a propeller or a ducted fan.

The rotor of the first propulsor may have a different number of blades relative to the second propulsor. Consequently, the principal noise frequency of the first and second propulsors may be different at the same rotational frequency. Blades of the first propulsor may have a different diameter to blades of the second propulsor. Advantageously, a similar thrust can be produced by the different rotors, but with a different tonal noise, by rotating a smaller diameter bladed propulsor at a higher speed.

One or more of the propulsors may be vectorable about a horizontal plane. The present disclosure is particularly suitable for aircraft featuring vectored propulsion, since the propulsors may need to produce more or less thrust by a large amount during operation in some modes.

The or each vectorable propulsor may be configured to provide vectorable thrust relative to one or more of the aircraft fuselage and the aircraft wing.

The propulsion system may comprise one of a chemical battery and a fuel cell configured to provide electrical power to the propulsors.

Alternatively or in addition, the propulsion system may comprise an internal combustion engine such as a gas turbine engine coupled to an electrical generator to provide electrical power to the propulsors.

According to a second aspect there is provided an aircraft comprising the propulsion system of the first aspect.

The aircraft may comprise a tilt-wing aircraft comprising one or more propulsors mounted fixedly to a wing, wherein the wing is pivotable relative to the aircraft fuselage. The tilt-wing aircraft may further comprise one or more cruise propulsors mounted fixed to the aircraft, and configured to provide forward thrust.

The aircraft may comprise a tilt-rotor aircraft comprising one or more propulsors pivotably mounted to a wing, wherein the wing is fixedly mounted relative to the aircraft fuselage. The tilt-rotor aircraft may further comprise one or more cruise propulsors mounted fixedly to the aircraft, and configured to provide forward thrust.

The aircraft may comprise a lift fan aircraft comprising one or more lift fans having a fixed orientation, and configured to provide vertical lift, and one or more cruise propulsors configured to provide horizontal thrust.

The aircraft may comprise a fixed wing aircraft comprising a plurality of fixed propulsors. According to a third aspect, there is provided a method of controlling an aircraft according to the first aspect; wherein the method comprises
by a controller, controlling the rotor speed and pitch of the blades (<NUM>) of the first and second propulsors (30a-d), according to a control method comprising:.

The method may comprise controlling the speed and pitch of the blades such that one or more of a frequency spectrum and the rotor speed is substantially constant over a range of thrust levels.

The method may comprise monitoring a frequency spectrum of the propulsion system, and controlling the propulsion system to ensure a separation of the peaks of the frequency spectrum in the frequency domain.

An embodiment will now be described by way of example only with reference to the accompanying drawings, which are purely schematic and not to scale, and in which:.

With reference to <FIG>, an aircraft <NUM> is shown. It will be understood that these drawings are illustrative only, and are not to scale. The aircraft comprises a fuselage <NUM> supported by landing gear <NUM>. The aircraft <NUM> further comprises a pair of forward main wings <NUM>, which are located such that a centre of lift in flight of the main wings <NUM> is approximately adjacent a centre of gravity. The aircraft <NUM> further comprises a tail <NUM> (also known as an empennage), which comprises horizontal (relative to when the aircraft is in horizontal flight) tail surfaces <NUM> and vertical (relative to when the aircraft is in horizontal flight) tail surfaces <NUM> which extend from ends of each horizontal tail surface <NUM>. The fuselage <NUM> comprises a nose <NUM>, which defines a forward end of the aircraft <NUM>, and the tail <NUM> which defines a rearward end of the aircraft <NUM>.

The aircraft <NUM> further comprises a propulsion system. Each wing <NUM> mounts one or more propulsors of the propulsion system. The wing mounted propulsors are in the form of propellers 30a-d in this embodiment, but it will be understood that different types of propulsors (fan for instance) could be employed. Similarly, one or more further propulsors in the form of propellers <NUM> are mounted to the tail <NUM>. Each propulsor 30a-d is driven by a respective electric motor <NUM> (shown in <FIG>), which is powered by an electrical power source. In the described embodiment, the power source comprises an electric storage device <NUM> such as one or more fuel cells or chemical batteries, and an electrical generator <NUM> driven by an internal combustion engine in the form of a gas turbine engine <NUM>.

As can be seen in the figures, the aircraft <NUM> defines several directions. A longitudinal direction A extends between the nose <NUM> and tail <NUM> in a generally horizontal direction when the aircraft <NUM> is in level flight or parked on the ground. A lateral direction (not shown) extends between tips of the main wings <NUM> in a direction normal to the longitudinal axis A in a generally horizontal direction. A vertical direction C extends in a direction generally normal to the ground when the aircraft is in level flight or parked on the ground.

Both the main wings <NUM> and the horizontal tail surfaces <NUM> are pivotable together between a horizontal flight configuration (as shown in <FIG>) and a vertical flight configuration (as shown in <FIG>). In other words, the main propellers 30a-d rotate about a fixed axis relative to the main wing <NUM>, with the main wing <NUM> being pivotable. In the horizontal flight configuration (shown in <FIG>), the wings <NUM> and horizontal tail surfaces <NUM> present respective leading edges <NUM>, <NUM> toward the forward, longitudinal direction A. The main wing <NUM> and horizontal tail surface <NUM> are configured to pivot about the lateral direction to transition to the hovering flight configuration, in which the leading edges <NUM>, <NUM> are directed upwards, in the vertical direction, as shown in <FIG>.

During VTOL operation, the aircraft normally starts on the ground with the wings <NUM> and tail <NUM> in the hovering configuration, as shown in <FIG>. The aircraft takes off in a vertical direction (though possibly with some horizontal component also), before transitioning to the horizontal flight mode as shown in <FIG>. During the transition, the wings <NUM> and tail <NUM> pivot slowly from the hovering to the horizontal positions as speed increases. Similarly, for landing, the aircraft transitions once more from the horizontal to the hovering modes.

During some phases of flight (particularly during hover and transition), conventional flight surfaces (such as rudders, elevators, ailerons etc.) may not encounter sufficient airflow to provide the necessary control authority to allow for stable flight and manoeuvring. Consequently, the propulsors 30a-d, <NUM> may be controlled differentially to augment or replace the flight control surfaces, by providing non-symmetric thrust to the aircraft. For instance, increased thrust may be provided by the propulsor <NUM> relative to the propulsors 30a-d, in order to pitch the aircraft forward, whereas increased thrust of the propulsors 30a, 30b relative to the propulsors 30b, 30d may be provided in order to provide roll. During however and transition, relatively large thrust changes may be required over short periods of time in order to provide the necessary control. This may result in repeated increases and reductions in thrust by individual propulsors <NUM>, 30a-d, which may result in substantial and rapid pitch changes of the noise generated by the propulsors <NUM>, 30a-d.

Referring to <FIG>, the propellers 30a-d are shown in further detail. Each propeller 30a-d comprises at least one rotor <NUM> comprising a plurality of blades <NUM>. The propellers 30a-d can be divided into two pairs - a first pair 30a, 30d and a second pair 30b, 30c. One of the propellers of each pair 30a, 30b, 30c, 30d is typically provided on one side of the wing <NUM>, with another propeller of each pair provided on the other side of the wing <NUM>, such that there is substantially no thrust imbalance in flight. Each propeller of the first pair 30a, 30d has four blades <NUM>, while each propeller of the second pair 30b, 30c has five blades <NUM> in this example. More generally, at least first and second propellers of the aircraft <NUM> comprise different numbers of blades. In principle, any number of blades can be provided, and typically, in order to minimise overall noise by reducing tip speed, a larger number of blades, for example between five and eleven, is desirable.

Typically, it is desirable that the blade numbers of the different propellers do not have common factors. For example, if the first pair of blades comprised two blades, and the second comprised four blades, then the second harmonic frequency of the first blade would match the first harmonic of the second blade.

Each blade <NUM> is mounted to a hub <NUM>. Each hub <NUM> comprises a variable pitch mechanism <NUM>, which is configured to pivot each blade about a generally radial axis, normal to the axis of rotation of the respective propeller 30a-d. The variable pitch mechanism <NUM> is of conventional construction, and could for example comprise an electric or hydraulic motor.

As can also be see in <FIG>, each blade <NUM> has substantially the same radius D. It will be appreciated therefore, that the tip speed of the propellers <NUM> will be the same, provided the propellers 30a-d rotate at the same speed.

A controller <NUM> is also provided. The controller <NUM> is typically electronic, and may for example comprise a multi-purpose computer. The controller <NUM> is configured to control both the rotational speed of the propellers 30a-d, as well as the blade pitch by controlling actuation of the variable pitch mechanism <NUM>.

It will be appreciated that, during flight, it is necessary to control thrust produced by the propulsors 30a-d, particularly during hover and transition. Conventionally, thrust on an electric aircraft would be controlled by controlling blade speed. A large proportion of noise, and particularly a large portion of tonal noise (which is more easily perceived) has a frequency related to the blade passing frequency f. The blade passing frequency f in Hertz (Hz) is given by the formula: <MAT>.

Where N is the number of blades on the propulsor, and x is the rotational speed of the propulsor in revolutions per minute (RPM). Consequently, the frequency of noise at the blade passing frequency is dependent on the rotational speed of the blade. Normally therefore, increasing thrust will result in increased noise pitch (i.e. the frequency of the tones and their harmonics), while reducing thrust will result in reduced noise pitch.

Consequently, controlling the thrust by controlling blade speed causes the noise from the propulsors to vary in pitch. In the present disclosure, thrust is instead controlled by the controller <NUM>, which is configured to control thrust for each individual propulsor 30a-d, <NUM>, by controlling electric motor torque.

It will be appreciated that, for a variable speed, variable pitch propeller rotor, there typically exist two combinations of blade pitch and rotor speed which will generate equivalent thrust. For example, a high blade pitch and low rotation speed may generate the same thrust as a relatively low blade pitch, and high blade speed. In conventional aircraft, the blade pitch is controlled to provide relatively constant blade speed, such that engine which drives the propeller is operated at its most efficient rotational speed. However, electric motors typically have a relatively wide efficiency band, which frees the blade speed and pitch angle for other forms of optimisation. In the present disclosure, this additional degree of freedom is utilised to minimise noise.

Referring to <FIG>, there is shown a control loop for controlling the propulsors <NUM>. In a first step, a change in thrust is input to the controller, either from a pilot, or from an autopilot or autothrottle. The controller <NUM> then considers the rotational speed of each of the propellers <NUM>, and finds a combination of rotor speeds and pitch angles for each propeller which provides the necessary thrust, while producing different tone frequencies from each propeller to generate a target propeller pitch and rotor speed for each rotor. Where each propeller comprises the same number of blades, this corresponds to different rotational speeds. Consequently, where the propellers are provided in pairs having the same blade number, a different rotational frequency is required for each blade in that pair. In some cases, a minimum noise frequency difference may be specified, to avoid "beating" noise, where the frequencies or their harmonics are closely matched. Similarly, the blade speed may be controlled such that, in aggregate, the propulsion system produces noise having a particular desired noise spectrum, e.g. having relatively "broadband" noise, in which distinct tonal noise is reduced as much as possible. In such a case, the speeds are controlled such that the overall range of tonal noise (i.e. the range from the lowest principal frequency to the highest principal frequency) is relatively large, with few frequency gaps.

In determining the necessary speeds and rotor pitch angles, the controller may comprise a model or lookup table, which correlates speeds and propeller pitch to thrust, to find a combination that produces the necessary thrust. Propeller speeds are determined for each propulsor, such that frequencies generated by each propulsor do not match by greater than the required minimum, and the required thrust is met. In some cases, the required thrust from the different propulsors may be different, particularly where differential propulsor thrust is utilised for pitch, yaw and roll control.

In one embodiment, the system may comprise a closed loop PID (proportional, integral, derivative) controller, in which target propeller rotor speed and pitch angle are determined for each propulsor, and sensors are utilised to determine the current motor and propeller pitch. The controller then seeks to minimise the error between the current and target values for the propeller speed and pitch. Alternatively, the system may utilise open loop or model based control, or some other control methodology as would be understood by the person skilled in the art.

Once a combination of rotor speeds and blade angles are selected which provides a broad range of distinct tones, the system may then attempt to maintain the blade speeds relatively constant, within a particular thrust range, to avoid rising or falling tone sounds.

For example, where an increase in thrust is requested, increased torque is provided by the electric motors <NUM>, while the hub <NUM> is controlled to increase the pitch angle of the respective blades <NUM> of that propeller 30a-d. Consequently, a constant tip speed is maintained, while thrust is increased, in view of the increased angle of attack of the blades. The opposite procedure is used for reducing thrust.

Such rapid thrust changes may be required during level flight, both for vectored thrust aircraft such as tilt-wings, and also for other aircraft types such as conventional, fixed wing aircraft. For example, it may be desirable to maintain constant speed over the ground during wind gusts, both for reasons of aircraft stability and passenger comfort. In such circumstances, rapid increases and reductions in thrust may be required.

<FIG> shows this control method in the form of a flow diagram. In a first step, a thrust demand change (either an increase or a decrease) is requested (either directly by a pilot controlling a throttle lever, or by a flight control or autopilot computer). This thrust change is then enacted by the controller <NUM> by increasing torque on the electric motors <NUM>. Typically, in normal level flight, thrust will be increased and reduced to the same extent for all motors <NUM>. However, during certain flight modes such as hover, thrust may be increased or reduced differently for individual blades to replace or augment aircraft control provided by flight surfaces. In some cases, the thrust change demand may originate from a control input, such as for instance a forward or sideways movement of the yoke, or stick. This is then translated into a thrust demand by the flight computer, which is provided in accordance with the above method. In a third step (which may occur simultaneously with the second step), the pitch of the propeller blades is altered to provide the increased thrust, without altering the propeller rotor speed.

<FIG> is a graph showing noise generated by a conventional aircraft (not shown) having two propellers driven by electric motors. The graph shows the noise in the frequency domain, i.e. noise intensity plotted against noise frequency. In this aircraft, the two propellers have a common number of rotor blades (e.g. four).

As can be seen, in view of their similarity, the two propellers generate tone noise A, B, having peaks at a particular frequency, which is the same for the two propellers. These peaks combine to create an overall noise signature C, which is a combination of the two noise sources. As can be seen, this creates a noise peak at a particular frequency, having a higher intensity than the two individual sources. Consequently, a large overall noise signature is produced. This is the case for any aircraft in which multiple propulsors are provided with each propulsor having the same number of blades. Furthermore, this noise is "narrowband", which can be perceived as a single tone or "hum". This can be perceived as being particularly annoying, and so it is desirable to avoid such a narrowband noise signature.

<FIG> are graphs similar to <FIG>, but of noise generated by the aircraft <NUM> when operated in accordance with the method of operating shown in <FIG>. As can be seen, each of the propulsors 130a-d generate tone noise having different frequencies, since the blades have different blade passing frequencies in view of the control method and the different numbers of blades in the different pairs of rotors. As can be seen, the maximum overall noise amplitude C is lower at any given frequency, and so a lower noise is perceived. Furthermore, in view of the increased range of frequencies, the noise spectrum is "broadband", which will be perceived as being closer to "white noise". This is in turn harder to distinguish from background noise, and thus has a decreased perceived noise.

<FIG> shows the propellers operated at a first, relatively low speed, during low speed operation. <FIG> shows one of the propellers operated 30b at a higher speed than in <FIG>, such as where a higher thrust is required to effect a roll or yaw. As can be seen, the frequency of the peak noise of that propeller is shifted toward the right of the graph, i.e. to a higher frequency. This shift in frequency is perceived as an increase in pitch. Experiments in which human subjects have been presented with such noise have shown that this shift in pitch is particularly distracting, and is regarded as being particularly annoying. Furthermore, the increased frequency spacing between the tone noises results in the tone noise being more perceptible as distinct tones, thereby reducing the "broadband" noise effect. Consequently, such shifts in pitch are undesirable.

<FIG> are graphs showing the aircraft <NUM> when operated in accordance with the method shown in <FIG>. As can be seen, at both low and high thrusts, the noise produced is the same in the frequency domain, albeit with a greater magnitude for the propeller 30b due to the increased blade loading. Consequently, the noise signature is maintained, and no change in pitch can be observed. Consequently, the perceived noise of the aircraft <NUM> when operated in accordance with the method of <FIG> is lower than when operated in accordance with conventional methods.

It will be understood that the general principle of the invention can be applied to a wide range of aircraft. For example, fewer propulsors (such as two) could be employed, or a larger number of propulsors. The propulsors could be of a ducted type, and the aircraft could be of a different vertical take-off configuration, (such as multi-rotor helicopter, tilt-rotor, compound helicopter, vectored thrust etc) or even a fixed wing aircraft.

For example, <FIG> and <FIG> show a second aircraft <NUM>, comprising a fuselage <NUM>, main wings <NUM> and a tail <NUM>. Main propulsors 130a-f are mounted to the main wings <NUM>. The aircraft <NUM> differs from the aircraft <NUM>, in that the aircraft <NUM> has fixed wings <NUM>, which do not pivot between hovering and cruise flight. Furthermore, the propulsors <NUM> are in the form of ducted fans, comprising bladed rotors <NUM> surrounded by an annular nacelle <NUM>. The fan ducts serve to reduce noise still further, and may increase propulsive efficiency, while increasing weight.

<FIG> shows a front view of the aircraft <NUM>. The aircraft comprises six ducted fans 130a-f. The fans are grouped into three pairs - a first pair 130a, 130f, a second pair 130b, 130e, and a third pair 130c, 130d. The first pair 130a, 130f. The propulsors 103a, 130f of the first pair of propulsors comprise four blades <NUM>, while the propulsors of the second and third propulsors 130b, 130e, 130c, 130d each comprise two blades. The first, second and third pairs of propulsors 130a-f also differ from each other in terms of their diameter - the first pair 130a, 130f has a larger diameter D<NUM> than a diameter D<NUM> of the third pair 130c, 130d, which in turn has a larger diameter than a diameter D<NUM> of the second pair.

Due to the different diameters, the fans 130a-f of each pair must rotate at different speeds, in order to generate the same amount of thrust. Consequently, a further "broadband" effect can be provided, in which tone noise can be provided at three separate frequencies.

<FIG> shows a further method which may be employed by the aircraft in order to minimise perceived noise by the aircraft.

In many cases (such as close to airports), large numbers of aircraft of the same type may be operating simultaneously. In such a case, where the noise spectrum of these aircraft is similar to one another, the total perceived noise may be relatively high. Consequently, the aircraft is configured to ensure that a noise spectrum of the controlled aircraft differs to that of other aircraft in the vicinity.

In a first step, the controller determines the presence of one or more further aircraft in the vicinity.

In a second step, the controller determines the principal frequencies of the noise generated by the other aircraft. This may be determined using either a sensor located on the aircraft, a sensor located on the ground, or by communication with the other aircraft.

In a third step, the controller determines a combination of propeller pitch and speed for each propulsor which differs from those of each other, and from the frequency generated by the other aircraft, and controls the aircraft propulsion system in accordance with this determined pitch and speed, in a similar manner as described above.

Claim 1:
A propulsion system for an aircraft (<NUM>), the propulsion system comprising: at least first and second propulsors (30a-d), each propulsor (30a-d) being independently driven by a respective electric motor (<NUM>), the first and second propulsors (30a-d) each comprise respective rotors (<NUM>) comprising a plurality of blades (<NUM>), the rotor (<NUM>) of the first and second propulsor each having a blade pitch varying mechanism; and a controller (<NUM>) configured to control the first and second propulsors independently of each other, such that each propulsor (30a-d) produces a tone noise at a different frequency to at the other propulsor <NUM>(a-d);
characterised in that:
the controller is configured to control the speed and pitch of the blades (<NUM>) of the first and second propulsors (30a-d), and is configured to:
receive a commanded thrust input; and
determine a combination of rotor speeds and pitch angles for each rotor which provides the commanded thrust while producing different tone frequencies from each rotor to generate a target blade pitch and rotor speed for each rotor.