Thursday, 9 October 2025

Wing Sail Foil Testing - Trim Tab Size and Control Authority

Wing Sail Foil Testing - Trim Tab Size and Control Authority

One objective of testing was to clarify the relationship between trim-tab size and control authority. This was investigated by splitting the trim tab into two equal halves and comparing the aerodynamic response when operating one half versus both halves together.


Test foil with split trim tab allowing testing of a full size and half size trim tab



As expected, the relationship between trim-tab area and effectiveness proved to be approximately linear. Tests conducted with the wing pivot at 18% chord showed that halving the trim-tab area produced roughly half the change in angle of attack. The results confirm that, within this range of operation, trim-tab authority scales proportionally with its surface area.




Wednesday, 8 October 2025

Wing Sail Foil Testing - Optimum Axis Position

Wing Sail Foil Testing - Optimum Axis Position

What is the optimum position of the axis of a self-trimming wing sail expressed as a percentage of the chord ?

A self-trimming wing sail must naturally weathervane into the wind. 
It is well documented that the aerodynamic centre of a simple thin foil is at 25% of the chord.

This means that 25% is the absolute maximum position along the chord, because beyond that the wing sail won't weathervane into the wind.
As the position of the pivot is moved toward the 25% point, the wing sail becomes more balanced, requiring less effort to increase the angle of attack.
This also means that manufacturing tolerances will have an increasing effect as the pivot point moves toward 25%.
 
As the pivot point moves closer to the leading edge, the effort to increase the angle of attack of the foil increases.
Also manufacturing and assembly issues encourage the pivot point to be a reasonable distance back from the leading edge.

The image below shows the sail from Voyager 2.9. A practical issue is the need to have pivot far enough away from the leading edge to allow for mounting the magnetic encoder ring used for measuring the wing sail angle.



Voyager 2.9 wing sail with mast pivot at 16% of chord


The wing sail with 16% pivot point has been used successfully in lake trials and on the recent ocean passages.

Testing Pivot Position

A series of tests were performed with the test rig by setting the position of pivot at the following percentages of the chord:
15%, 16%, 18%, 20%, 25% and 27%.
Then the trim tab moved in 5° steps from -40° to +40°.
The resultant angle of attack was recorded at each step.




The results are plotted below with the trim tab angle on the horizontal access, and the resulting angle of attack (AOA) on the vertical access.

The Eppler 169 foil has an optimum AOA for lift vs drag, of around 5° to 6°.





The overall trends observed in testing were consistent with expectations.
The sensitivity of the wing’s angle of attack (AOA) to trim-tab deflection increases as the pivot axis moves aft toward the 25% chord point.
At 25% chord the system became too sensitive for practical use: we aim to operate the wing at an AOA below about 10°, yet a trim-tab change of only 1–2° was enough to drive the wing into stall.

It is important that the wing’s response to trim-tab input is not excessively sensitive.
The trim tab must move by a practical amount during normal operation—large enough to be repeatable and to overcome any mechanical backlash or stiction in the linkage—while still giving fine control over the AOA.

The tests revealed an apparent offset of approximately –3° in the trim-tab calibration.
This could be due to small manufacturing or alignment errors, but is more likely caused by flow-field asymmetries in the test setup.

A useful benchmark is the trim-tab deflection needed to achieve a 10° AOA:

  • about 7° of tab deflection when the pivot was at 15% chord,

  • about when the pivot was at 18% chord.

For completeness, we also explored operating with deliberately large trim-tab deflections that drove the wing well past the stall angle, even though such conditions are outside the intended flight envelope.

Overall, a pivot-axis position in the range of about 15–20% chord appears to be well-suited.
Within this range the wing shows stable weathervaning, and the tab response is strong enough to overcome backlash yet not so strong that small tab motions cause abrupt stalling.

I expect to continue using the 16% chord position for the pivot of self-trimming wing sails.


Tuesday, 7 October 2025

Wing Sail Foil Testing - The Setup

 Wing Sail Foil Testing - The Setup

The designs of the wing sails used with the Voyager sailing drones have been established by studying other designs, by using a lot of intuition and by judging whether it looks right. 

It is time to perform some more rigorous testing to determine the optimum values of some key parameters of a self-trimming wing sail.

Design Questions

These are some questions to be answered to assist in designing and operating the next wing sails.

  1. What is the optimum pivot point for a self-trimming wing sail ?
  2. What is the relationship between Trim Tab angle and Angle of Attack, and hence what size should a trim tab be ?
  3. What is the optimum trim tab angle when running ? Should the trim tab be reversed when running ?

Wing Sail Test Rig

 I developed a test rig to allow a series of relative measurements to be performed indoors.

The airflow is provided by a large domestic fan.

But tests quickly showed that the airflow from a fan is too turbulent to be useful for performing measurements. So a columnator or flow straightener was developed to improve the quality of the airflow.

This was constructed primarily from rolled up sheets of A4 paper, contained within a wooden frame. It wasn't great, but it was good enough to get useful results.


 

Fan, flow straightener and the test article.


Fan and flow straightener

The airflow in the vicinity of the test article was around 2.8m/s.
This was measured using an Air Velocity Sensor Module, the Renesas FS3000-1015.


Test Article

The test foil is an Eppler 169 (E169) with a 400mm chord. This chord size represents the approximate size to suit a wing sail for Voyager 3.

The 400mm chord yields a Reynold's number of around 76,000 for the 2.8m/s airflow.

The test foil has been designed to support testing with the following characteristics and adjustments:
  • The position of the axis may be varied from 15% of the chord to well over 35%.
  • The trim tab is adjustable with a scale to easily set a desired angle.
  • The trim tab is split in two, to allow for measuring authority versus size.
  • The test rig includes a scale to measure angle of attack.
  • The wing sail mast bearings are supported by load cells to provide a relative measure of the load in 2 dimensions. The load cells are rated at 1kg max, and include digital readouts in tenths of grams as a relative measure of force.

Test wing section, Eppler 169 with 400mm chord







Adjustable pivot point shown at 18%


View of Trim Tab and scale showing +10 degrees.


Angle of Attack scale showing 







View of mast mount and load cells providing independent support in the X and Y axes.




Digital readouts of relative force expressed in grams