So I got around to doing some more reading on the X-57 Maxwell. It’s a very interesting experimental program, and I have no reason to doubt NASA’s preliminary estimates for efficiency, etc.
Unfortunately, they indicate just how far we have to go to make electric aviation possible for mass use.
Here’s the original aircraft specs from the plane they started with, a Tecnam P2006T:
Passengers: 4
Payload: 618 lbs
Empty Weight: 1765 lbs
Max Speed: 178 mph
Cruise: 155 mph
Stall speed: 54 mph
Range: 853 miles
Endurance: 4.25 hours
Wing Loading: 16 lbs/sq ft
Now, the X-57 Maxwell plans to take that plane and ultimately put a new wing on it with 2.6 times the wing loading. By my rough guesstimate, that puts the stall speed up around 75-80 mph, way outside certification limits for a small plane. So NASA uses the 12 little electric motors on the wings to blow air past them to bring the stall back down to FAR 23 limits.
Once at cruise, or maybe a cruise climb of 120 mph or so, the inboard engines are shut down and the plane flies on the two tip engines. This is the cruise configuration that could see up to 500% improvements in efficiency. Some of that comes from electric propulsion, some comes from mitigation of wingtip vortices, but most comes from essentially putting a jet wing on a prop plane. You could get the same efficiency without the 12 little motors if you were willing to have a 175 mph plane that approaches at 120, lands at 100, and stalls at 80, and takes forever to climb to altitude. So the 12 electric motors are there essentially to improve low speed performance to the point where it can match other general aviation planes.
So, the specs of the Maxwell, if all goes according to simulation:
Capacity: 2 people
Range: 100 miles
Endurance: 1 hour
Battery Weight: 860 lbs
battery Usable Capacity: 47 kWh
Stall Speed: 63 mph (small motors running)
So basically what they’ve done is said, “We know wings are a compromise between low speed and high speed performance. Let’s just design a wing optimized for cruise, and use electric motors to augment it for takeoff and landing.” That’s a smart idea, and if it works it might really improve performance of all aircraft. Heck, imagine a normal gas-powered plane with electric-augmented wings. You could either make a normal plane a STOL plane, or you could put cruise wings on, say a Piper Cherokee and without hurting takeoff and landing performance make cruise more efficient and more stable against turbulence. A hybrid plane like this might make a lot of sense.
However… I sense many roadblocks here, especially around certification. Consider that any time you are below 80 mph, you are at the mercy of those little motors. If the motors shut off, instant stall. On takeoff, until you are above 80 (and at a reasonable angle of attack), if the motors quit you are simply going to crash. Even if only one quits just after rotation, it might be enough to stall a wing and crash the plane. The FAA hates flight modes like that.
Also, there will need to be extensive testing of what happens if one, or two, or three of those little motors fail. You’re going to get weird flows over the wing. If an outboard lift engine fails at a slow enough speed, you could get a stall-spin situation. So that entire system will not only have to be super reliable and multiply redundant, but every failure condition will have to be tested extensively. I suspect the motor system will have to be computer controlled, so if one motor fails or develops low power the system would instantly compensate by increasing power to others. That sort of thing. But that’s also a certification nightmare.
After all of this, though, and even if the numbers work out, you wind up with an aircraft that is barely usable. You’re going from an airplane that can carry four people to one that can carry two, and a range that drops from 853 miles to 100 miles. An endurance of 1 hour is only 15 minutes with VFR reserves. So this becomes a very marginal airplane. Also not clear is just how much 14 aviation-certified electric motors and all the control hardware will cost. Or how those 12 spinning or folded propellers will cause additional drag at cruise. Finally, extensive trials will be required for what happens when a tip motor fails at cruise. That should be exciting.
Great technology, and I can see electrically-augmented flight in our future if it works out. But I still don’t think we can do away with fossil fuels. This research could turn into a 10-20% improvement in light aircraft efficiency overall. Maybe more.
Those little motors are 14.4 KW, or 172 KW for all of them. If you only had to run them until you got to a cruise climb of 120 mph, You might only need them for 5 mins at the start and end of each flight. That’s about 28 kWh. We might be able to package that size of battery for a weigh of 400 lbs or so in the future. You’d claw back some of that for having a lighter wing, and you might not need as large a primary gas engine. Knock 50 lbs off the engine, and 200 lbs off the wing, and for the cost of a single passenger you might be able to get an airplane that cruises at half the energy as a traditional one but maintains the same takeoff and landing performance. For planes that travel long distances, this could actually work. They’d still use avGas, just a lot less of it.