Propeller-integrated airfoil heater system for small multirotor drones in icing environments: Anti-icing feasibility study

Abstract

Atmospheric icing is one of the most common and hazardous environmental challenges for aircraft operations. So far, only large passenger aircraft, a few general aviation aircraft, and specialized rotorcraft are equipped with ice protection systems because of their additional energy consumption and weight. The emerging markets of small electric aircraft like Urban Air Mobility and Unmanned Aerial Vehicles for transportation, logistics, search and rescue, and other specialized operations will require efficient, lightweight and all-electric ice protection systems in order to allow operations in ice and snow conditions. In this work, an electrothermal ice protection system with an average heat power density of 1Wcm−2 was designed and developed for use on small multirotor drones. Commercially available propeller blades with diameters of 33cm were retrofitted with lightweight multilayer heating foils independently powered by super-capacitors. The heated propellers were tested in close-to-real icing conditions in a small-scale icing wind tunnel. Thrust, rotational speed, and power consumption of a non-heated reference propeller and a heated propeller were compared. In glaze ice conditions at air temperatures > −5°C the thrust of the non-heated propeller fluctuated between 60 and 90% with frequent cycles of ice accretion and shedding for the entire duration of the test. The heated propeller maintained a thrust of >95% in the same icing conditions. In rime ice conditions at air temperatures < −8°C the heating was not sufficient and the thrust of the non-heated and heated propellers similarly decreased over time. Heat flux calculations along the span of the propeller were made for different icing conditions and compared to the heat power density distribution of the tested ice protection system.