HI Uplift: Making dreams of electric power come true with magniX

Eurodisco anthem “Together in electric dreams” was a mid-1980’s hit for synth-pop combo Philip Oakey and Giorgio Moroder. It could also sum up the partnership between electric transport developer magniX and rotary manufacturer Robinson Helicopter Company. But their plans to build an electric-powered helicopter engine are far from dreams.  

The maiden flight of the electric Robinson R66 helicopter powered by the magniX HeliStorm engine is scheduled to take place early next year. It’s not difficult to understand why the developer and the OEM want to replace the single 270shp (201kW)-rated Rolls-Royce RR300 turbine engine, currently powering the five-seat R66, with an electric powerplant.

Ben Loxton, vice president of New Product Development at magniX picks up the theme. “The main attraction of the HeliStorm engine compared with the turbine-powered power plant is it’s lower operating cost,” he tells us. It’s an argument that becomes ever more compelling as oil prices climb following conflict in Iran and the closure of the Strait of Hormuz. US jet fuel prices are currently averaging $3.56/gallon – up 88% on a year ago.

‘Much cheaper power plant’

But it’s not just the soaring cost of global crude oil prices that makes the argument for electric helicopter propulsion. “An electric powerplant has far less maintenance, it doesn’t have the life limitations and it doesn’t have the hot-end inspections,” he tells us. “Overall, it makes for a much cheaper powerplant solution that should make for a lower cost and more available aircraft for the end user. One that doesn’t have to come offline for maintenance [as often as turbine engines].”

Then there are the benefits linked to zero carbon emissions flight and a much lower noise footprint compared with turbine-powered helicopters. Noise reductions could reach between 10–20 decibels less than the conventional helicopters during cruise or approach. That’s based on an electric engine reducing or eliminating engine combustion noise, exhaust noise and some of the gearbox noise. While rotor noise remains, it may be less harsh and lower in pitch removing the high pitch turbine noise generated from conventional powerplants. magniX’s engine operates at less than 60 decibels.

The engine developer revealed its HeliStorm engine at the Verticon event in Dallas last year. Designed to operate at a constant 6000rpm like the engine it replaces, the HeliStorm powerplant has been specifically for rotary-wing aircraft.

‘Battery density’

A key factor bringing the prospect of electric helicopter flight within reach has been advances in battery technology. “It’s been steady progress over the past decade,” Loxton tells us. “And progress in battery density continues to increase year on year.”

The HeliStorm motor is designed to work with the developer’s own Samson aviation battery range to provide a complete electric rotorcraft propulsion system. magniX has considered battery modules with an energy density of about 300 Wh/kg with up to 10 modules installed in each aircraft. Last year magniX revealed plans for a next-generation Samson battery using 400 Wh/kg cells, although that does not necessarily mean every HeliStorm installation will use those cells.

“Our battery systems are modular, and because we have the development programmes with the cells, we’re able to develop cells that replace straight into those modules and then replace the modules themselves,” says Loxton. “So, the good thing about that is while the HeliStorm engine may last decades in service, the batteries can be swapped out.”

The length of battery life will depend upon how the operators use the engines, according to the developer. But Loxton expects them to be capable of thousands of flights. “There’s a lot of data from the car industry that shows these batteries perform a lot better than people thought they would – based on that cell-level lab data versus what you actually get in real-world conditions.”

‘Like having two engines’

Another benefit of the HeliStorm engine is that it is a dual-channel motor, explains Loxton. Driven by two inverters, which are independent from each other. So a fault in one will not cause the engine to shut down, the remaining inverter can power the aircraft to a safe landing. “It’s effectively like having two engines,” explains Loxton. “The R66, which is a single-engine aircraft, has become a two-engine aircraft.”

The electric R66 will retain its older sister’s single main two-bladed rotor. The electric version is expected to have an endurance of about one hour plus a safety reserve. Tourism flights and training missions are expected to be the main markets for the early electric R66 helicopters.

In March, Robinson also entered a partnership with battery developer KULR to design a battery system for the eR66 battery-electric light helicopter demonstrator.

The company’s electric power plants are not confined to rotary lift. In April the developer launched magniAIR – an air-cooled electric engine aimed at kit planes, light sport aircraft and electric flight trainers. Sport plane manufacturer Van’s Aircraft has chosen the electrjc motor to power its RV-10 four-seat, home-built kit plane. The first flight of the electric RV-10 is planned for later this year. The electric motor is expected to be offered for sale next year.

First flight

Meanwhile, magniX is trial running its HeliStorm engine at its Washington site with Robinson modifying an R66 at its Torrance, California facility ahead of the electric helicopter’s first flight at the end of this year.

“After we have finished this demonstrator, then we’ll be able to start producing the units that have the pedigree to go through the certification process,” says Loxton. The engine will be certified under Part 33 legislation making it a two-year or more process. Then, there is the partnership with Robinson to certify the helicopter itself under Part 27 legislation.

So, it’s a clear flightpath ahead to turn magniX’s electric dreams into flying reality.

Meanwhile, we can’t wait for our Helicopter Investor London conference taking place in the capital the week after next between June 16th and June 17th. Don’t miss our updated conference agenda and speaker line up here.

The HeliStorm electric engine is designed to operate at a constant 6000rpm like the engine it replaces.