Control allocation is still a challenge for tiltrotor aircraft due to effectors' redundancy, dramatic nonlinearities and cross-coupling. Besides this, the external disturbance caused by the unique configuration of tiltrotor such as larger wing area and tiltable mechanism puts forward extra security requirement on control allocation method. Thus, this paper proposes an innovative control allocation framework from the perspective of flight safety to address this problem. Firstly, an effector distribution management scheme based on remaining control ability index (RCAI) is developed to reduce the effector saturation and ensure flight safety. Secondly, the energy consumption models for two classes of effectors: thrust vectoring and aerodynamic surfaces are introduced respectively for the subsequent optimization problem mathematically. Then, the null space transition is used to find the minimum-energy control input of effectors. Finally, key parameters of energy consumption model are identified by experiments. The realtime hardware-in-loop simulation platform is adopted to demonstrate the effectiveness of the proposed control allocation framework. Experimental results show that the energy consumption of proposed method can reduce by about 63.5% comparing to traditional control allocation method. INDEX TERMS Novel tiltrotor aircraft, effector distribution management scheme, flight safety, energy consumption model, minimum-energy control allocation.