Research Projects

VTOL platforms with high payload capacity (100 kg+), whether manned or unmanned, are a high priority technology for our nation. The Indian army plans to deploy these UAVs in forward areas that are located at high altitudes and face most security threats. Utilization of high speed and high-power density gearbox unlocks the design space for propulsion systems with high torque to weight ratio required to meet aggressive performance targets. Many nations are already working in this direction and very recently China has developed a 6 ton tiltrotor drone with 2-ton payload capacity which is ready for flight testing. Directly driven multicopters will fail to meet the challenge posed by heavy payload transport at high altitudes. Therefore, major players in the UAV arena have already switched to engine/motor + gearbox combination for their propulsion systems. All high payload capacity VTOL UAV currently flying are not driven directly by a motor/engine. The power range for UAV operations is from 3 kW/rotor to 1500 kW/rotor. While we have come a long way in the 3 - 10 kW range, our country needs to quickly build capability in the higher power range where we still have the advantage of an early mover. The heavy payload capacity UAV technology has critical strategic implications. There is an imminent need to develop capabilities for design, testing, and maintenance technologies for UAV drive system gearbox! The aim of this work is to develop design methods for high-speed gearboxes of the high payload UAVs and build a test facility for validation testing of mechanically interconnected UAV gearboxes. The only civil multi-rotor powered lift aircraft that is nearing certification is the AW609 tiltrotor. It is powered by two PT6C-67A turboshaft engines and has a unique prop-rotor gearbox design which is different from the fixed-wing prop plane. The PI has direct experience with design, testing, and certification of AW609 drive system and the learnings will be directly incorporated in the proposed gearbox development work. The research objectives proposed herein require building analytical as well as experimental capabilities. The proposed effort is divided into three parts - (i) design and analysis, (ii) test facility development and execution of test campaign, and (iii) test data analysis and validation of design methods (details in technical document). Successful completion of this project will enable us to indigenously design and build high payload capacity UAVs with a highly reliable propulsion system. Civil applications (air taxis) can also be explored.