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Transitional electric conversion systems for legacy aircraft

Converting old planes to electric, also known as electric aircraft retrofitting or electrifying existing aircraft, is a growing area of interest in aviation as a potential solution for reducing greenhouse gas emissions and improving sustainability in air transportation. Electric aviation is still in its early stages, but FlyOnE has been increasing development in retrofitting existing planes with electric propulsion systems.FlyOnE has been developing 3 key versatile battery electric propulsion systems with our technology partners to suit aircraft from 2-9 seats in single or multi-prop configurations with 60kW, 120kW and 240kW system designs. In a dual configuration of 2 x wing-mounted 240kW systems, that is the equivalent of 640hp from a pair of piston engines, but with no emissions, a renewable energy source, less noise, less maintenance cost and safer operations. For select aircraft with efficient airframes that have an L/D ratio of 12:1 or better, we can achieve 2 hours (all-electric) endurance at the standard cruise speed of those airframes. For less efficient airframes or range extension, hybrid biofuel-electric generation systems can add more renewable onboard energy without burning fossil fuels.

Battery management

Unique battery architecture configurations and highly detailed battery management systems refined by decades of electric (unmanned) aircraft development and flight experience by our technology partners Electro.Aero is the Superpower #1 that we use in our Electric aircraft propulsion systems.
Image credit: Electro Aero

Electric motor

Superpower #2 that we use in our electric aircraft propulsion system development is the Australian-designed, engineered and built Kite Magnetics electric aircraft motor. The world’s highest flux density electric motor is achieved with a nanocrystalline magnetic core material called Aeroperm™. These motors offer high torque and high efficiency with low heat losses, allowing for high-powered convection-cooled power trains, further reducing the weight of liquid cooling requirements that other motors have.
Image credit: Kite Magnetics

Battery stacks

Unique battery architecture configurations and the latest in uniform cooling strategies allow us to build large-capacity onboard energy storage systems that can charge and discharge more rapidly than other systems. This reduces downtime on the ground during charging, reduces weight in the aircraft with less cooling hardware, and increases the battery service life and cycle capacity of the batteries before they need to be downcycled.
The process of converting old planes to electric typically involves several key steps:
Feasibility Assessment: The first step is to assess the feasibility of converting a particular aircraft to electric propulsion. Factors such as the size and weight of the aircraft, the placement and CofG of the FlyOnE electric propulsion system, the required modifications to the airframe, and regulatory requirements all need to be carefully evaluated.
Design and Engineering: Once the feasibility is determined, the next step is to design and engineer the electric propulsion system for the specific aircraft. This involves selecting appropriate electric motors, batteries, power electronics, and other components, as well as designing the necessary modifications to the airframe to accommodate the new propulsion system.
Retrofitting: After the design is finalized, the retrofitting process begins. This involves removing the existing internal combustion engine and related components, and installing the new electric propulsion system. This can include modifications to the wings, fuselage, and other structural components to accommodate the new components and optimize weight distribution.
Testing and Certification: Once the retrofit is complete, extensive testing and certification processes are conducted to ensure the safety, reliability, and performance of the converted aircraft. This includes ground testing, flight testing, and compliance with regulatory requirements, such as those from aviation authorities like the Federal Aviation Administration (FAA) in the United States or the European Aviation Safety Agency (EASA) in Europe.
Operation and Maintenance: Once the converted aircraft is certified for operation, it can be used for commercial or private aviation. Operation and maintenance of electric aircraft may require specialised training for pilots and maintenance personnel, as well as careful monitoring of the electric propulsion system and battery performance to ensure safe and efficient operation.
Converting old planes to electric has several potential benefits, including reduced greenhouse gas emissions, lower operating costs due to reduced fuel and maintenance requirements, and the potential for quieter and more sustainable air travel. However, there are also challenges to overcome, such as the availability and performance characteristics of available airworthy airframes, the weight and capacity characteristics of developing battery technology, and the regulatory and certification processes for electric aircraft. Despite these challenges, electric aircraft retrofitting is an exciting and rapidly evolving field with the potential to transform aviation in Australia and contribute to a more sustainable future for air transportation.