Lucien MALLARD, Jeremy MORAN, Morgan van HOFFEN, Robert PIETSCH, Ingo JAHN, David BUTTSWORTH
DOI Number: N/A
Conference number: HiSST-2025-070
In aircraft design, wind tunnel testing is an important part of the aerodynamic identification process. It serves to extend knowledge gained from simulations (e.g. CFD) and reduces uncertainties before real flight tests. Being able to perform dynamic manoeuvres in a wind tunnel creates a better understanding of the system dynamics and enables a first validation of control algorithms. However, for hypersonic vehicles, such experiments are challenging due to the short test durations and limited space for testing. Recent experiments at the University of Southern Queensland demonstrated the ability to perform actuated experiments that control motion in pitch and roll for a sting-mounted model.
Building on this work, this current paper describes the development of system upgrades and new tools to achieve pitch and heave manoeuvres, and free flight testing subsequently. As part of this work, a new embedded hardware architecture was developed. This has resulted in a more compact system using new actuators, improved control bandwidth, on-board power for control and actuators, and improved flight computers. Embedded software was also updated to include more complex state estimation to allow improved determination of aerodynamic angles for post-treatment. A digital twin framework was developed to tune and validate controllers before the experimental runs, and to enhance the ability to post-process experimental data.
The new system is evaluated in bench tests. These highlight critical capabilities – the new embedded system is completely autonomous from ground support, estimators accurately track aerodynamic angles, and altitude estimation is acceptable. Similarly, the digital twin framework displays good performance when analysing previous campaigns, validating linear controllers and when comparing transient simulations to experimental data.