Project H2 - The dream of Hydrogen Flight

Nach fast einem Jahr ausgiebiger Tests aller Subsysteme ist es endlich soweit: Unser System ist bereit für den Einbau der grossen 92 kW Brennstoffzelle, mit welcher wir auch fliegen werden. Das System konnten wir auf unserem Teststand installieren. In den kommenden Wochen werden wir das System auf Herz und Nieren prüfen und letzte Kinderkrankheiten beheben. Ein wahrlich freudiger Tag für unser Projekt! 

Im April war der österreichische Flugzeughersteller Diamond in Dübendorf zu Besuch. Gemeinsam mit Dufour Aerospace wurden dabei inspirierende Gespräche über die Zukunft der nachhaltigen Luftfahrt geführt, die nicht nur den Horizont erweiterten, sondern auch wegweisende Impulse für die Aviatik der Zukunft setzten.

Nach erfolgreichem Zusammenbau des Motors und der Montage auf unserem Teststand konnten wir unseren Elektromotor erfolgreich das erste Mal drehen lassen. Während die Motorelemente von unserem Partner e+a Elektromaschinen und Antriebe AG gemäss unseren Anforderungen massgeschneidert entwickelt und produziert wurden, sind die gesamten mechanischen Bauteile inklusive Kühlung von uns selbst designt worden. Dadurch erhalten wir einen Elektromotor mit einem sehr niedrigen Gewicht von 35 kg bei einer Leistung von 100 kW. Angetrieben wird der Motor sowohl bei diesen Tests als auch später im Flugzeug von unserem selbstentwickelten Inverter, welcher somit ebenso positiv getestet werden konnte.

Das diesjährige Fokusteam hat die Arbeit am Wasserstoffflugzeug aufgenommen.

Während des Besuchs bei der Light Wing AG hatten unsere Teammitglieder die Möglichkeit, das zukünftige Flugzeug zu besichtigen, in dem unser wasserstoffbetriebener Antriebsstrang zum Einsatz kommen wird. Es fanden auch einige technische Gespräche mit den Technikern von Light Wing statt. Die Arbeit hört nie auf 🙂

During the visit at Light Wing AG our team members had the chance to see the prospective hydrogen powered airplane which will host our powertrain. Also some technical talks with the engineers of Light Wing took place. Work never stops :)

Nach langer Planung ist endlich unser dritter Schiffscontainer in Dübendorf angekommen. Er wird verwendet um eine sichere Testumgebung für unser Wasserstoffsystem zu schaffen

Although many sensors and other components are still stuck somewhere between production and delivery, we were able to carry out some tests on 5 May, for example to control the cooling pump with different signals. Further tests will follow in the course of the next few weeks.

On a sunny spring morning, we set up our metal framework for the test stand outside the hangar. With the help of Item's aluminium profiles and grooved plates, we can later attach all the components directly and still be very flexible if there are any small changes.

In the longer time between the test phase in February and Review 3, we have made great progress. The current status is that all components are in the hangar or at least ordered and that we will soon be ready to carry out the first tests. The biggest point that will still occupy us now is the software and the control system.

The sensitive membrane of the fuel cell requires very precise values of temperature, mass flow and pressure of the air and hydrogen in the fuel cell. To obtain these values, we created a digital twin on Gamma Technologies. This model can later be used to design the various controllers using Simulink.

For the control and regulation of our system, we decided to develop our own main control unit. So we started to design a circuit board on a professional programm and after several weeks we were finally able to send it to production. The assembly and testing will follow in the near future.

One of the most important milestones in our case was the complete assembly of our system in as compact a form as possible. Although the system will not be installed in an aircraft yet, it is still important to us to make the whole thing as compact as possible. After several challenging and time-consuming iterations, we are happy with the final result.

In Review 2, we were again able to bring the audience up to date on the project. Both modules have again gained a lot of new knowledge since the last review and were able to make further theoretical or practical progress on the aircraft and the fuel cell system. More information can be found in our blog post.

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We are proud to announce that the Swiss company EH-Group, which is based in Nyon, has entered into a partnership with us. The young company produces fuel cells and also develops complete systems. So they can support us with their know-how in our project in the best possible way. 

On Friday morning, 5 November, Review 1 of the new e-Sling project took place. The two modules, hydrogen and aeroplane, had to present their progress of the last months in a 20-minute presentation each. Afterwards, all those present were allowed to ask questions. The presentations finally flow into the final grade of the focus project.

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For two days, a group of focus students from e-Sling visited the Hydrogen Expo in Bremen. They were able to make important contacts there and secure one or two supports from larger industrial partners.

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Over 200 people attended the RollOut of the e-Sling Team 2020/21, including sponsors, patrons, family members, team members and supporters. Besides the big unveiling of the plane, Dominic Gisin's speech and the flight raffle were definitely a highlight.

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On the very first day of the new semester, we sat together as a new focus team and had our first meeting. Tasks were assigned, goals formulated and initial strategies explained. The first contacts were already made and we began to feel really comfortable in the team!