HEPAD

Brief Description

The “HEPAD – High Efficiency Payload Arial Dron” project aims to develop a highly innovative transport drone with significantly enhanced powertrain performance, specifically for inner-city and short-distance logistics tasks. The goal is to achieve a performance increase of over 50% compared to conventional transport drones. The core innovations include a high-performance battery architecture with an optimized cell design and an integrated battery management system (BMS). The increase in powertrain efficiency is achieved through cross-system optimization of the interaction between the machine, electronics, and storage to maximize power density. This hardware is complemented by cloud-based algorithms for fleet control and data analysis, enabling seamless integration into existing logistics networks.

The synergistic optimization of these components significantly increases range, flight time, payload, and efficiency, while simultaneously reducing total weight and ensuring robust operational reliability. Implementation follows a three-phase iterative process, ranging from the definition of target parameters through the detailed development of core innovations to the construction of a complete demonstrator and its validation in flight tests. Beyond technological progress, “HEPAD” serves as a strategic flagship project that strengthens regional value creation in North Rhine-Westphalia and minimizes technological dependencies on non-European manufacturers. The resulting transfer potential also fosters innovation in adjacent sectors such as the transportation and automotive industries, robotics, and industrial energy systems.

WP1: Requirements Analysis

The first work package is designed to lay the technical and organizational groundwork for the entire project. During a kick-off workshop, existing knowledge about current technologies and market conditions will be gathered and analyzed. In parallel, the partners will conduct a use-case analysis to define the requirements and application scenarios for a highly efficient drone. This includes aspects such as payload capacity, range, and energy requirements.

WP2: Concept Development

In this phase, the foundation for technical implementation is laid. Based on the results from WP1, the project partners develop a comprehensive system architecture for the drone and its optimized components. Particular focus is placed on the integration of the high-performance battery, the innovative electric motor, and the new battery management system. Each of these components is worked out in detail and validated theoretically. Finally, a prototype design is created that fully meets all system requirements.

WP3: Component Production

This work package encompasses the development and manufacturing of the core technologies:

• Battery and BMS:  A high-performance battery with optimized materials for maximum energy density and low weight is manufactured. Additionally, a custom battery management system is developed to increase battery efficiency and enable more accurate condition analysis.
• Electric motor: The production of an innovative electric motor through a holistic system approach. Instead of purely component-based optimization (e.g., copper fill factor), the interactions between the motor, power electronics, and energy storage are integrated to maximize system power density. The application of numerical field calculations and advanced control strategies ensures that both efficiency and performance are increased.
• Cloud system: The development of a server-based data management infrastructure enables real-time data transmission for drone fleet management as well as analyses of energy consumption and operational safety.

WP4: Design and Prototype Testing

In the fourth work package, the first demonstrator is assembled and tested. The company exabotix provides the drone’s basic airframe, which is equipped with the components developed in WP3. Following integration, ground tests will be conducted to verify the functionality of the components working together. Subsequently, the capabilities of the HEPAD prototype will be evaluated in realistic flight tests, during which its performance will be compared with a reference drone.

AP5: Techno-ecological Support

In parallel with the technical developments, a comprehensive market, technology, and life-cycle analysis is being conducted. This analysis assesses the ecological benefits resulting from reduced emissions and the economic potential, e.g., for industrial manufacturing. The goal is to promote the production of regional value chains and ensure the sustainability of the core technologies developed.

WP6: Exploitation of Results

At the end of the project, the results will be utilized. A key focus is on the development of business models and licensing opportunities. In addition, the potential applications of the individual innovations beyond the drone sector, such as in the fields of electromobility and high-performance applications, will be examined. Each system will be analyzed for market readiness, and a roadmap for industrialization will then be created.

WP7: Public Relations and Management

The final work package covers the administrative and organizational management of the project. This includes regular project meetings, updates, and PR activities. The project’s results will be presented at trade shows and industry events to attract potential investors and stakeholders from the logistics and technology sectors.