Design optimization and virtual testing of a morphing aileron with high actuation bandwidth

One of the key strategies to make future aviation more sustainable is to improve the aerodynamic efficiency-to-weight ratio of aircraft while simultaneously reducing the energy required to actuate onboard control surfaces. This paper presents a novel morphing aileron, designed for a hybrid-electric regional aircraft, developed to replace a conventional aileron while providing multiple benefits. Unlike traditional ailerons, which are restricted to rigid-body rotation, a morphing aileron changes its external shape, enabling greater design flexibility. This shape-changing capability has been exploited to first optimize the external morphed shapes of the aileron that match the aerodynamic performance of the conventional surface, while requiring half the deflection. This results in reduced aerodynamic drag and lower actuation effort. The optimized shapes were then used as targets to design a compliant structure capable of deforming as needed while remaining insensitive to external loads, with the overall actuation force minimized under additional dynamic performance requirements. Virtual testing of the complete device successfully validated its static and dynamic performance. The static validation, carried out in the presence of aerodynamic loads, confirmed the device’s ability to reduce actuation forces under realistic operational conditions. The dynamic validation, conducted in dry conditions, demonstrated the potential of the system to reduce dynamic actuation loads. This implies the potential use of smaller and lighter motor actuators, thus improving the overall system efficiency.