Launching Insitu’s ScanEagle UAV. Source: Ballard Power Systems Inc.

A next-generation high-performance fuel cell propulsion system to power unmanned aerial vehicles (UAVs), or drones, has been engineered by Ballard Power Systems. The company has partnered with Insitu, a Boeing subsidiary, over the last two years to integrate Ballard’s prior generation fuel cell propulsion system into the ScanEagle UAV platform. The new 1.3 kW system will now undergo extended durability testing by the two companies.

Insitu’s ScanEagle is 1.55 meters (5.1 feet) in length, has a wingspan of 3.11 meters (10.2 feet) and maximum takeoff weight of 22 kilograms (48.5 lbs). The UAV can fly at a maximum speed of 41.2 meters per second (80 knots) and reach a ceiling of 5,944 meters (19,500 feet).

The new fuel cell system delivers increased power density, resulting from a new membrane electrode assembly (MEA) design. A combination of new MEA and one-step fuel cell stack sealing process reduces cost and extends service life. An increase in rated power is realized without any appreciable increase in size or weight.

Fuel cell propulsion systems offer a number of advantages over ICE-powered drones (refer to accompanying chart). In addition, fuel cells offer a three times greater increase in mission time compared to battery-powered drones.

Insitu’s ScanEagle is a versatile platform with multiple payload capabilities, including high-definition imaging, at a fraction of the cost of larger UAV systems. The ScanEagle is operated in conjunction with Insitu’s Mark4 Launcher^® — a low-maintenance, runway-independent platform — along with its SkyHook^® recovery system.

In addition to military use, the commercial market for drones is expected to growth significantly over the next few years, from 0.25 million working drones in 2017 to more than 2.5 million working drones by 2021. Applications are anticipated in such areas as agriculture, construction, environmental management, urban and rural surveying, mining, emergency response and law enforcement.