Our innovative hybrid propulsion unit represents a revolution in the industry by combining cutting-edge combustion engine technology with a modern electric motor. Developed in partnership with Distar CZ a. s. and ČVUT – Department of Aerospace Engineering, we offer an innovative solution for ultralight aircraft.

The relentless evolution and innovation in the field of transportation electrification pose a daily challenge for our R&D department. Join us as we look at the development of the Hybrid Power Unit for the aviation industry.

Development and designing

At the beginning of the project, we needed to select a suitable aircraft and the most appropriate combustion engine for our application. We systematically evaluated the project’s needs and requirements and proposed the ideal type of aircraft for implementing the hybrid power unit. The second task was to select a suitable combustion engine for our application. Afterwards, we finally started with designing of hybrid propulsion unit.

3D Models and Design Work

Our teams contributed to the development of comprehensive 3D models and design work, encompassing the electric motor, battery system, combustion engine, interconnections between them, engine mounts, and cooling systems.

Analysis, Calculations, Simulations, and Testing

We conducted extensive analyses, calculations, and simulations to ensure the safety, reliability, and optimal performance of our hybrid power unit. We carried out strength tests, including tests of the engine mounts, maximum wing loads, combustion engine, and electric propulsion system, to verify their safety and reliability.

Construction of Flying Laboratory

All our research findings were ultimately transferred to successful testing in practice. Under our supervision, a completely new aircraft was created, which was converted into a flying laboratory, with which we successfully completed test flights.

Key Advantages of Hybrid Propulsion

Efficiency and Ecology: Reducing fuel consumption and emissions for more sustainable flights.

Low Operating Costs: Minimizing costs with long life and easy maintenance.

Increased Safety: Combining the reliability of a combustion engine with the clean energy of an electric motor.

Passenger Comfort: Smooth and quiet operation for an optimal travel experience.

Technical Specifications

Combustion Engine: Highly powerful, low-vibration, lightweight with minimal torsional vibrations.

Electric Motor: Modern propulsion based on BLDC / PMSM technology for optimal performance.

Battery System: Comprehensive design including integrated BMS for reliable energy supply.

We are excited about the achievements we have made so far, but our work is not done. Our goal is not only to develop new technologies but also to support further innovations and advancements in the aviation industry. Open the door to the future of aviation with our hybrid power unit.

COOPERATION WITH MGM COMPRO

MGM COMPRO and BEE appliance have been cooperating together. To be specific, MGM COMPRO provided REX30 and HBC280120 for our partner. We did an atypical firmware adjustments according to our partner specifications. It wasn’t easy at all, however we managed to deal with that, even though it was a big challenge. In the upshot, BEE appliance was contented with our work.

The system we prepared for our partner is fully functional and they are continuing with their tests. If you would like to see how it goes so far or want to read more about it, you can check it on their website.

To see our work and how astonishing it flies, checkout the video below. We are really happy about this cooperation with BEE appliance and we are ready to fulfil the partner’s future demands.

AIRCRAFT OF GREAT POTENTIAL, that’s dufour’s vision

Although the projects is still under development, it could already show its possibilities. Felix Rubin, lead engineer for aerodynamics, commented, “At larger scales, slipstream airflows over tilting wings become more turbulent and harder to predict, and care is needed to ensure that the aircraft remains stable during transition. With this large-scale unmanned aircraft, we’ve now been able to demonstrate that we can achieve that stability at high Reynolds numbers.”

“The goal for us ultimately is to develop a vehicle that is a helicopter replacement, particularly for medical transport,” said Jasmine Kent, chief technology officer of the project. “We believe there is a big opportunity in the market for an aircraft that can do medical transfer flights faster and much more cheaply than a helicopter.” She then declared Dufour aims to begin manufacturing a full-sized experimental VTOL prototype next year, with flight testing to begin with a human test pilot by 2022, if “there are no hiccups along the way.”

SPECS OF AERO 2

• 320km/h speed cruise
• Hover Performance at 2’000m/M at ISA +20 Deg C.
• 2 seats
• optional piloted
• hybrid or fully electric
• range 800km in hybrid mode and 120km in full electric mode
• low noise profile and low downwash profile makes it best in class for Urban Air
• Transport and operation in populated areas

MGM COMPRO INCLUDED IN DEVELOPMENT

We are proud that altogether with Dufour Aerospace team we are on the right way to tune the system towards the full scale prototype. Except complex motor management we talk about electric motor possibilities and battery pack design for the final stage of the project.

The main goal of this project is a development of one-seat helicopter with two independent emergency propulsion systems.

These two propulsion units are unique, their target is a maximum safety for the flight. Main propulsion unit is the combustion engine, electric ones are used in the event of any damage or malfunction of the main one as a backup drive.

Within a few seconds after damage or any problems of combustion engine, electric propulsion unit gives power for immediate emergency landing.

Helicopter features

• Combustion engine Subaru, performance 100 KW
• Diameter of blade 7 metres
• Prototype, manufacturing scheduled for 2018

Electric Propulsion System

• Electric Motor NT Power, 20 kW
• Industrial Electronic Speed Controller MGM COMPRO HBC 50063
• Li-Ion Battery Accupack for 63V (Battery Accupack Li-Ion 63V)

First testing of this unique electric propulsion system for helicopters was in the middle of July.

Check out the video from the testing!

This project is an evolution of the Cri-Cri electric plane, which was used by Airbus to test batteries and management technologies.

The E-Fan can proudly display its all-composite construction, which is 6.7 m long and has a wingspan of 9.5 m. If you look at this plane, you can’t overlook two jet engines, which are powered by 2 electric motors giving a total power of 60 kW.

The engines are powered by a series of 250 V Li-Pol batteries. They are ready to provide a range of one-hour flight and can be recharged in the same time. For a safety reasons there is also a backup battery to enable emergency landings.

MGM COMPRO industrial controllers are a part of E-FADEC energy management system, which is a crucial technology to operate the whole electrical system. This key technology automatically handles electrical systems of the aircraft.

We believe that our cooperation will help to come up with another great achievements!

Check out the video below from the first public flight of E-Fan project

Ruppert composite technology

MGM COMPRO and Ruppert Composite achieved a great success in the mutual collaboration in the development of complex electric propulsion system (industrial speed controllers HBC, electric motors Rotex Electric, Accupacks, special airborne BMS, industrial chargers) for the Ruppert Composite’s own lightweight aircraft called Archaeopteryx. MGM COMPRO became a sole proprietor of the whole system.

This legendary aircraft is one of the lightest on the market enabling the pilot to maneuver in unbelievable angles and change the direction of the plane with incredible precision.

The electric conversion of the plane is called Archaeopteryx Electeryx. This version enables the aircraft to launch even in the flat areas and makes it really versatile – you can take off almost everywhere.

Read more

MGM COMPRO technology in action: Archaeopteryx Electeryx

Archaeopteryx Electric “Electeryx” from Ruppert Composite on Vimeo.

Industrial controller HBC 280120 and electric motor Rotex Electric (REX series), which are set in the U-15 Phoenix as a matter of fact finalizes the whole project. Therefore were Martin and his team ready to realize their 6-day flight around the Czech Republic.

The batteries provide the aircraft with approx. 1 hour flight at the cruise speed of 120 kph. The same time is needed to recharge them so the plane has to regularly stop along its journey.

U-15 Phoenix basic technical data:

• Length 6,5m
• Wingspan 14,5m
• Weight 300 kg (batteries 34 kg)
• Cruise speed 120 kph

PHOENIX AIR ACHIEVEMENTS

Martin Stepanek is not a freshman in the field of construction of ultra light aircrafts. His company Phoenix Air won the third place in the competition called Green Flight Challenge organized by the National Aeronautics and Space Administration (NASA) three years ago! This was really an impressive success!

We wish Martin and his team all the best for the future! MGM COMPRO is always keen on being part of such a project, which moves forward with electric driven aviation.

Check out the video!

To learn more, you can checkout the official website.