Sonex and AeroConversions E-Flight Initiative

December 12, 2008

The E-Flight design team has reached a major milestone in the development of the E-Flight Electric Powerplant System's Main Controller Unit (MCU) and Integrated Motor and Switching electronics (IMS). The E-Flight design team has been running the system at high voltage and amperage power inputs with a large bank of lead-acid batteries, simulating power levels to eventually be provided by the aircraft's Battery Containment Unit (BCU) containing Lithium Polymer batteries.

On December 4, 2008 the E-Flight system was successfully run under load with a test club propeller achieving 2800 RPM, a major benchmark RPM goal demonstrating the MCU and IMS systems' ability to provide the power necessary for flight (see video, above-right).

November 28, 2008

The E-Flight design team has been steadily making progress on the electric motor and controller systems. The E-Flight Electric Motor is being run at increasingly higher power settings using a ground test bank of lead acid batteries (see video at right).

As expected, development of the Main Controller Unit (MCU) and Integrated Motor and Switching electronics (IMS) for such a powerful electric motor has not been without challenges and setbacks, however, the E-Flight design team has made many significant advancements in the development and evolution of the E-Flight electric powerplant systems.

Since filming of this video, the design team has begun running the system using 100 percent back-EMF commutation sensing. Lithium Polymer Battery System cost, complexity and estimated charge times have been signifantly reduced through a change in battery selection and refinement of the Battery Containment Unit (BCU) and Charging System designs. Safety of the system has also been significantly increased through advancements in the design of system Instrumentation, Main Controller Unit (MCU), isolation of high- and low-voltage components, and advanced system integration, monitoring and control using a low-voltage comm buss. The E-Flight Electric Powerplant System is on-track to becoming not-only the most powerful electric aircraft power source ever built, but also the most advanced, safe and consumer-friendly system as well.

Prototype Integrated Motor and Switching electronics (IMS) installed on proof-of-concept Waiex E-Flight Electric Powered aircraft (click to enlarge).

Aircraft Flight Performance and Endurance estimates with current and future battery technology (click to enlarge).

E-Flight Battery Powered Aircraft System Schematic (click to enlarge).

April 2, 2008

A prototype AeroConversions E-Flight Electric Motor was first run in the fall of 2007 at low power using simple computerized commutation software. Since then, the prototype Hall effect sensing system for the motor has been built and tested, and the prototype E-Flight Electronic Motor Controller has been built and is currently being tested and refined. On March 17, 2008 the E-Flight Electric Motor was run for the first time under load, using a test club propeller, and for the first time using a rheostat throttle user interface with the prototype Controller (see video at right).

In the coming weeks, the E-Flight design team will pursue testing of the motor at significantly higher power settings using a bank of traditional lead-acid batteries to facilitate power for ground testing. Also, the test flight pack of Lithium Polymer batteries are due to arrive at Sonex Aircraft, LLC in the coming weeks for initial testing and integration into the proof-of-concept aircraft system.

July 24, 2007

The Sonex Aircraft, LLC E-Flight Initiative was officially unveiled at a Tuesday, July 24 press conference held on AeroShell Square at EAA AirVenture Oshkosh 2007. The unveiling included a proof-of-concept prototype electric powerplant installed in a Waiex airframe and the event was kicked-off with opening remarks by EAA President Tom Poberezny. During the press conference, Sonex Aircraft, LLC founder and President John Monnett announced the three major focuses of the E-Flight Initiative: Electric Power, Ethanol Fuels and Efficiency Enhancement technologies for existing and future Sonex and AeroConversions products. Sonex General Manager and CEO Jeremy Monnett uncowled the proof-of-concept electric-powered Waiex to the awe and excitement of the crowd and press representatives in attendance.

An informational E-Flight Initiative forum followed on Wednesday in the AirVenture Forums Plaza. The forum building was filled to standing-room-only capacity as John Monnett detailed the goals and challenges of the E-Flight Initiative. The proof-of-concept electric-powered Waiex and the E-Flight informational kiosk was moved from AeroShell Square to the Forums Plaza, where they were viewed by a steady stream of interested AirVenture attendees for the remainder of the show.

See the E-Flight Initiative Press Page for links to E-Flight press releases, more video clips and media coverage of the E-Flight Initiative.

John Monnett formally unveils the details of the E-Flight Initiative.

The AirVenture press corps swarms the E-Flight electric aircraft for a closer look.

The Sonex E-Flight R&D team presented an informational forum to a packed house on Wednesday.

The E-Flight electric powerplant FWF installation.

The Sonex E-Flight Initiative commanded top headlines in most relavent daily aviation publications and web sites. John Monnett spoke about the Initiative in several interviews throughout the week, including an appearance on EAA Radio (above, right) and two local television stations (above, left).

In 2006 Sonex Aircraft, LLC’s research and development team began work on what is now called the “E-Flight Initiative.” E-Flight is a push to explore viable alternative energies for powering sport aircraft and improve the efficiency and performance of current products and technologies to keep aviation affordable for the average pilot, and to keep recreational aviation available to future generations of pilots. Although E-Flight has been shrouded in strict secrecy to ensure intellectual property protection of its more cutting-edge components, public unveiling of E-Flight at EAA AirVenture Oshkosh 2007 has been a vital key to the Initiative since it’s inception. E-Flight is not only intended as a “push” for the Sonex R&D team, but also to help push the rest of the recreational aviation industry toward similar goals in the interest of preserving the future of our sport.		The E-Flight Initiative has three major areas of focus, taking a diverse approach to the problems of rising energy costs and an ailing environment to provide near, intermediate and long-term green powerplant solutions:

		Development of a proof-of-concept electric motor powerplant, controller, battery pack and charging system with the goal of determining the feasibility of a marketable line of Sonex and AeroConversions products. This project represents the most significant portion of E-Flight, in terms of investment, risks, challenges, and possible gains. Our endeavor is to not just addemble "off the shelf" components, as others have done before us, to prove that electric flight is possible. Our mission is to develop a truly integrated eco-friendly alternate power system that combines efficiency and safety for our line of existing aircraft, and the future of sport aviation.

		Investigation of converting the AeroConversions AeroVee engine for use of ethanol-based and future "Eco" fuels in order to evaluate their peformance, efficiency and reliability. Although ethanol-based fuels are the subject of much controversy, as long as there is a government mandate for integration of ethanol content into the nation's fuel supply, and increasing demand from foreign consumers, we are obligated to continue the research of ethanol fuel as an alternative aviation fuel supply. Our commitment to ongoing testing and development is to provide AeroConversions products that are prepared for the possible discontinuation of 100LL, similar aviation fuels, or non-blended auto fuels.

		Development of other enhancements to the existing AeroVee and other existing and future AeroConversions products to increase fuel efficiency and performance for the sport pilot. These enhancements will be built upon an already strong foundation, as an AeroCarb equipped AeroVee powered Sonex aircraft already boasts a fuel economy of over 42 miles per gallon when cruising at 150 mph TAS at typical cross-country cruising altitudes.