Electric Beaver: Harbor Air's Groundbreaking Aircraft Conversion

The Electric Beaver: A New Era in Aviation

In the world of aviation, innovation often comes in unexpected forms. Harbor Air, a Canadian airline, has taken a bold step into the future by converting a classic de Havilland Beaver seaplane into an all-electric aircraft. This groundbreaking project not only preserves the iconic design of a beloved aircraft but also pushes the boundaries of what's possible in sustainable aviation.

The Conversion Process

Erica, the program manager and engineering lead for Harbor Air's electrification program, provided insights into the conversion process. In 2019, the team removed the original R985 450 horsepower piston engine from a Beaver aircraft and replaced it with a fully electric propulsion system. This includes an electric engine, battery system, and associated components.

The converted Beaver now operates entirely on electricity, with no fuel onboard. This transformation represents a significant leap forward in aviation technology, especially considering the aircraft's age - over 70 years old.

Performance Improvements

One might assume that converting a vintage aircraft to electric power would result in compromised performance. However, the Electric Beaver has demonstrated impressive capabilities:

• Payload Capacity: The aircraft can carry six passengers with a payload of over a ton.
• Range: With new battery technology, the Electric Beaver can achieve a range of about 82 km (51 miles) for a 1-hour mission, including reserve power.
• Efficiency Gains: The conversion has led to significant improvements in efficiency. The power required for level flight has been reduced from 62% to 41% compared to the original aircraft.
• Takeoff Performance: The electric version can take off using about 400 horsepower, matching or exceeding the performance of the original 450 horsepower engine.
• Thrust Improvement: Despite having the same rated power (450 hp / 336 kW), the electric powertrain produces 300 lbs more thrust than the original engine.

Technical Challenges and Solutions

Converting a vintage aircraft to electric power presented numerous technical challenges:

Battery Placement

Initially, the team faced difficulties in optimizing battery placement due to the need for additional components in the nose section. This limited their ability to distribute weight effectively. However, future iterations will address this issue:

• The new Magni 650 engine will integrate accessories, freeing up space in the nose.
• This will allow for better battery distribution throughout the aircraft, improving weight and balance.

Battery Technology

The current batteries offer an energy density of 200-210 Wh/kg at the aircraft level. However, Harbor Air's partner, MagniX, is developing new battery modules with the following characteristics:

• Energy density of 300 Wh/kg at the aircraft level.
• Custom-designed to fit the aircraft's existing fuel bay dimensions.
• Lithium-ion chemistry, with the specific cell type (prismatic, pouch, etc.) kept confidential.

Propeller Optimization

The team has focused on balancing performance and noise reduction:

• A new, efficient 4-blade propeller has been installed.
• The propeller spins at 1900 RPM for takeoff, compared to 2300 RPM in the original aircraft.
• This change, combined with the shorter propeller, results in slower tip speeds and reduced noise.
• Preliminary testing shows a 20 dB reduction in noise across all flight phases.

Flight Characteristics

Shawn Braden, Vice President of Maintenance and Manufacturing at Harbor Air, shared his experience flying the Electric Beaver:

• The aircraft flies similarly to a standard Beaver but with improved performance.
• Takeoff time at gross weight (5,600 lbs) is reduced to about 22 seconds.
• Climb performance is notably better, with a 14% climb gradient compared to the original 6.7%.
• The aircraft maintains its speed better due to reduced drag from the redesigned nose.

Certification and Future Plans

Harbor Air is working towards certifying the Electric Beaver for commercial operations:

• The target for certification completion is around the end of 2026.
• Commercial service is estimated to begin in 2027, depending on engine type certification.
• The certification process may involve a two-stage approach, with initial certification using one set of batteries, followed by an upgrade to more advanced batteries.

The company recognizes that battery technology is rapidly evolving. Their strategy includes:

• Certifying the aircraft with current battery technology.
• Developing a streamlined process for certifying new battery packs as technology improves.
• Planning for regular battery upgrades to take advantage of increasing energy density and performance.

Operational Considerations

Harbor Air's unique operational profile makes electric aircraft particularly suitable for their needs:

• Many of their flights are short duration, often around 20 minutes.
• The company is working with BC Hydro to install 150 kW chargers at their locations.
• The goal is to achieve a 30-minute recharge time, which aligns with their current turnaround times.
• The charging system will operate on 600 volts, matching the available power infrastructure and reducing the need for additional transformers.

Economic Viability

The economic aspects of operating electric aircraft are still being evaluated:

• Current estimates suggest that direct operating costs may be similar to those of conventional aircraft.
• Battery replacement costs are a significant factor, with batteries expected to require replacement after 2,000 to 3,000 charge cycles.
• The company is considering the potential residual value of used batteries for applications such as microgrids, which could improve the overall economics.

Environmental Impact

The Electric Beaver project aims to significantly reduce the environmental impact of Harbor Air's operations:

• Elimination of greenhouse gas emissions during flight.
• Reduced noise pollution, benefiting both passengers and communities near flight paths.
• Potential for using renewable energy sources for charging, further reducing the carbon footprint.

Scalability and Future Applications

Harbor Air sees the Electric Beaver as just the beginning of their electrification efforts:

• Plans to convert their entire fleet of Beavers to electric power.
• Potential for electrifying other aircraft types, including single-engine planes, Caravans, and Twin Otters.
• Estimates suggest that with battery energy density improvements to 400 Wh/kg, a single Otter or Caravan could carry nine passengers.

Challenges and Limitations

While the Electric Beaver represents a significant advancement, there are still challenges to overcome:

• Range limitations compared to conventional aircraft.
• The need for charging infrastructure at all destinations.
• Regulatory hurdles in certifying new electric propulsion systems and batteries.
• The rapid pace of battery technology development, which may require frequent updates.

Industry Implications

Harbor Air's Electric Beaver project has broader implications for the aviation industry:

• Demonstrating the viability of electric propulsion for commercial operations.
• Providing a model for converting existing aircraft to electric power.
• Encouraging investment in electric aviation technology and infrastructure.
• Potentially influencing regulatory frameworks for electric aircraft certification.

Conclusion

The Electric Beaver project by Harbor Air represents a significant milestone in the development of sustainable aviation. By combining the classic design of the de Havilland Beaver with cutting-edge electric propulsion technology, Harbor Air is paving the way for a new era of environmentally friendly air travel.

While challenges remain, particularly in terms of range and battery technology, the project demonstrates that electric aircraft can offer competitive performance for short-haul flights. As battery technology continues to improve and regulatory frameworks adapt, we can expect to see more electric aircraft taking to the skies, reducing the aviation industry's environmental impact and opening up new possibilities for regional air travel.

The success of the Electric Beaver may inspire other airlines and manufacturers to pursue similar conversions or develop new electric aircraft designs. This could lead to a transformation of the aviation landscape, particularly for short-haul and regional flights, where electric aircraft can offer significant advantages in terms of operating costs and environmental impact.

As we look to the future, projects like the Electric Beaver serve as a reminder that innovation in aviation doesn't always mean developing entirely new aircraft. Sometimes, it involves reimagining and upgrading the classics, combining the best of the past with the technology of the future. This approach not only preserves the heritage of iconic aircraft but also ensures that they can continue to serve for generations to come, in a more sustainable and environmentally friendly manner.

The journey of the Electric Beaver is far from over. As Harbor Air continues to refine the technology, seek certification, and plan for commercial operations, the aviation industry will be watching closely. The lessons learned from this project will undoubtedly inform future developments in electric aviation, potentially accelerating the transition to more sustainable air travel.

For now, the Electric Beaver stands as a testament to human ingenuity and the potential for technology to address environmental challenges. It represents a bold step towards a future where the skies are quieter, the air is cleaner, and aviation continues to connect communities in a sustainable way. As we move forward, it's clear that electric aviation will play an increasingly important role in shaping the future of air travel, and projects like the Electric Beaver are leading the charge.

Article created from: https://youtu.be/vbuHUSeWWFw?feature=shared