Magnetics Business & Technology - November/December 2021 - 12

FEATURE ARTICLE
VoltAero and Safran Pioneer Propulsion Breakthroughs in Electric Aviation
us on track toward our goal of having initial Cassio production aircraft
entering service during late 2022 or early 2023, " explained Jean
Botti, VoltAero's CEO and chief technology officer.
EcoPulse hybrid to carry 50kW aviation motors from Safran next year
French companies VoltAero and Safran are pioneering stunning
breakthroughs in electric aviation powered by permanent-magnet
motors and hybrid propulsion systems. Crossing the Nouvelle-Aquitaine
region of France, VoltAero's Cassio 1 demonstrator aircraft is shown
performing its first flight equipped with the company's hybrid-electric
power module, which is installed in the aft fuselage-mounted " pusher "
position, along with a pair of electric aviation motors recently developed
by Safran that are mounted in " puller " position on the wings.
The power module for VoltAero's Cassio production aircraft is now
undergoing flight testing on the Cassio 1 testbed, marking another
major step in the company's development of a series production
hybrid-electric airplane family for regional transportation that will accommodate
four to 10
seats, with flight ranges
of up to 1,200 km. and
cruise speeds of 200 kts.
Cassio 1 made its maiden
flight equipped with
the power module in
October from VoltAero's
Royan-Médis Airport
home base in southwest
France.
The proprietary power
module is installed in an
aft-fuselage " pusher " position. It combines three 60 kW high-performance
electric motors arranged in a triangular " barrel " configuration,
with a 370-hp internal combustion engine. This configuration of the
power module prefigures the full-up powertrain for VoltAero's largest
production Cassio aircraft
version, the 10-seat Cassio
600, which is designed to
deliver a total hybrid-electric
power of 600 kW or 800 hp,
enabling the craft to cruise at
360 km/hr which is fast for an
aircraft in its category.
" The startup of power module
flight testing represents
a true milestone for hybridelectric
aviation, and it keeps
In regular operation, the power module's electric motors will be used
for low-noise takeoffs and landings, with the internal combustion
engine serving as a range extender and for recharging the Cassio's
batteries while aloft. With VoltAero's unique patented series/parallel
hybrid design, the power module can operate in modes from full
electric to full hybrid, depending on the mission profile and range
requirement. Additionally, as both the electric motors and internal
combustion engine are linked to a common shaft that drives a fiveblade
" pusher " propeller, the ability for each to operate independently
provides a high level of propulsion safety - with one source acting
as a backup in case of a problem or failure of the other.
VoltAero is developing
its hybrid power module
for multiple applications
including helicopters
and boats. For helicopters,
the takeoff would
typically use both power
sources, while the landing
can be performed
in a fully-electric mode.
During flight, the electric
power is derived at
its maximum efficiency,
allowing significant fuel savings when compared to the currentgeneration
of turbine engines. In certain cases, fuel consumption can
be reduced by up to 50%. When landings are performed in the fully
electric mode, noise levels will be lower than a conventional turbinepowered
helicopter.
VoltAero hybrid power module
Redundancy is another advantage. If one of the three electric motors
fail, it is automatically disconnected - enabling a pilot to land the helicopter
safely. In the event of a partial failure of the thermal combustion
engine chain, specific torque transmission is performed through
the power module to enable a safe landing.
In addition to the power
module on Cassio
1, the testbed aircraft
is equipped with two
wing-mounted ENGINeUS
45 electric motors
supplied by Safran Electrical
& Power. They are
installed in the forwardfacing
" puller " position.
Prior
to the
maiden
flight with VoltAero's
addition of the aftmounted
" pusher " power
module, Cassio 1 had logged 14 hours and 25 flights aloft with the
motors in a full range of operating conditions.
Safran ENGINEeUS @Thierry Mamberti
Jean Botti, CEO and CTO, of VoltAero
shown at right with Didier Esteyne,
technical director, celebrating test
flight of an earlier e-plane
" Safran is proud to be powering the Cassio 1 aircraft as VoltAero brings
12 Magnetics Business & Technology * November/December 2021
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Magnetics Business & Technology - November/December 2021

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