Background

The world is witnessing a paradigm shift in aviation, with electrified aircraft presenting a promising solution to reduce environmental impact through lower emissions of noise and pollutants. Within this transformative landscape, electric Vertical Take-Off and Landing (eVTOL) aircraft have emerged as one of the most innovative designs, offering quieter, safer, and low-cost possibilities for urban air mobility and sustainable transportation. However, the successful integration of eVTOL technology hinges on addressing critical concerns surrounding battery safety, a challenge that Warwick Manufacturing Group (WMG) took on with unparalleled determination and expertise.

Vertical Aerospace Ltd (VA) is a British technology aerospace that is pioneering electric aviation and was set up by entrepreneur Stephen Fitzpatrick in 2016. Based in Bristol, Vertical is working with world-leading suppliers and partners to decarbonise air travel using the best technologies from across the aviation, energy, and automotive industries with the aim to provide faster, quieter, greener, and smarter ways for people to travel around cities and regions.

As the eVTOL sector continues to gain momentum, lithium-ion batteries have become the primary choice for meeting the power and energy density demands of these aircraft. However, organisations express apprehension about battery safety, especially in the aerospace domain where the consequences of failure could be catastrophic.

Challenge

Vertical Aerospace are a pioneering and best in class management company with a technical team hand-picked from the aerospace and advanced automotive sectors and 300+ in-house engineers. The challenge for Vertical Aerospace for certifying batteries is that there was no battery diagnostic system capable of detecting potential faults in eVTOL battery packs before take-off.

With this challenge in mind, Vertical Aerospace approached WMG and set out to help fill this crucial gap in the industry. The diagnostic system was to be an innovative blend of cutting-edge electro-chemical methods, ensuring the seamless integration of advanced technology into aircraft systems.

In response to this pressing need, WMG embarked on a pioneering project to develop a revolutionary smart-diagnostic charge device for eVTOL aircraft batteries. This device aimed to enhance in-flight performance, safety, and, most importantly, enable fit-to-fly certification of the battery pack before every flight.

Image courtesy Vertical Aerospace

Solution

As part of a £2.3m project funded by ATI (Aerospace Technology Institute) through Innovate UK, a collaborative project was launched with VA. WMG's diagnostic algorithm demonstrated its capability to detect potential battery faults with unmatched accuracy. The algorithm capitalises on the battery data collected by the battery management system (BMS) during charging. The system underwent rigorous testing and validation using battery modules provided by VA. This crucial feature enabled VA to implement the diagnostic procedure for fit-to-fly certification of their battery packs before every flight, bolstering aviation safety and instilling confidence among passengers and industry stakeholders.

The device's exceptional performance and reliability not only met the project's objectives but also exceeded expectations, marking a remarkable milestone in aerospace technology.

Image courtesy Vertical Aerospace

“Battery systems including charge and diagnostics testing are well-known in academia and industry; having undergone years of development and research for the automotive market.

“An aerospace application provides a fantastic opportunity to utilise methods, designs, models, and algorithms that were not financially, volumetrically, or technically feasible before. Using these novel approaches, we plan to significantly improve the safety, range, and capability of our battery system.”

Limhi Somerville, Head of Energy Storage at Vertical Aerospace

Impact

The impact of WMG's eVTOL diagnostic technology reverberated far beyond the confines of the project. The successful outcome of this groundbreaking initiative opened doors to a broader consortium collaboration with AMEC, demonstrating the industry's recognition of WMG's ability and capabilities. AMEC (Advanced Mobility Ecosystem Consortium is aiming to demonstrate the commercial and operational viability of Advanced Aerial Mobility (AAM) in the UK, has been awarded a £9.5m grant by the UK Government’s Future Flight Challenge to develop the essential building blocks of a viable AAM ecosystem that has the potential to be progressed into full commercial operations. The algorithm for this is being further developed to extend its capability to work with new battery technologies.

Additionally, WMG's trailblazing work in aerospace electrification played a crucial role in securing funding for future projects like ZEST (Zero Emissions for Sustainable Transport). This has reaffirmed their position as pioneers in sustainable aviation research on battery safety evaluation through experimental research and creation of new models to prediction LIB failure modes appropriate to aerospace. It includes the use of novel in-cell instrumentation to measure failure and system level strategies to mitigate propagation.

The collaborative partnership with VA resulted in a mutually beneficial knowledge exchange. WMG shared invaluable expertise, code, and battery parameterisation insights with VA engineers, empowering the industrial partner with essential capabilities they lacked in-house. Furthermore, WMG provided unwavering support to VA in data factory generation, further enhancing their ability to optimise battery pack performance.

The smart charger will be used for Vertical's recently unveiled passenger model, VA-1X. Capable of carrying a pilot and four passengers for up to 100 miles at speeds of 150mph. They aim to certify in early 2026.

“The successful integration and management of battery systems within future electric aircraft represents a significant research challenge and one that WMG is excited to be working on in partnership with Vertical Aerospace.

“This project has allowed us to expand our capabilities in battery characterisation, battery system modelling and novel methods of fault diagnosis and prognosis. All within a sector that is strategically important for the UK as it move towards its zero emissions transport targets.”

Professor James Marco, University of Warwick

Notably, the development of the eVTOL diagnostic device revolutionised aerospace battery technology. The technology's uniqueness and pioneering nature can potentially increase battery pack usage in various aircraft and promote second-life applications. By extending battery life and repurposing used packs, the project aligns with sustainability goals, reducing the environmental impact associated with battery manufacturing.

Conclusion

WMG's commitment to innovation and excellence in aerospace technology has borne fruit through the development of the eVTOL diagnostic device. This project produced a prototype smart-diagnostic algorithm for the eVTOL aircraft battery. It will use innovative and cutting-edge electro-chemical methods and allow improved in-flight performance, safety, and assist in future certification of battery systems.

The prototype smart-diagnostic charge device is poised to redefine the future of eVTOL aircraft, enabling greener and safer flights, and paving the way for a sustainable aviation industry.

As the world continues to embrace electrified aviation, WMG's expertise stands ready to shape the future of aerospace technology. Their portfolio of success stories and invaluable contributions to the industry is a testament to their dedication for progress and sustainability. Companies and organisations in the aerospace sector can find a reliable partner in WMG, poised to propel them into a new era of innovation and success.

Find out how WMG can help you start your own success story in aerospace electrification. Contact us at wmgbusiness@warwick.ac.uk and embark on your journey towards innovation and sustainable aviation solutions.