Innovation Takes Off - Clean Sky · 2018-03-23 · Clean Sky 2 Information Day Lisbon, 28 November 2013 AIRFRAME ITD Alain Bouillon, Dassault Aviation Chargé d’affaires Clean Sky

Innovation Takes Off

Not legally binding

Clean Sky 2 Information Day Lisbon, 28 November 2013

AIRFRAME ITD

Alain Bouillon, Dassault Aviation Chargé d’affaires Clean Sky 2 Direction de la Prospective

Miguel Llorca Sanz, EADS CASA Head of Clean Sky 2


From Clean Sky towards Clean Sky 2

Step changes in the “efficiency” of all airframe elements by the means of a systematic “re-thinking”

Re-think the a/c architecture

Re-think the fuselage

Re-think the wing

Re-think the control

Re-think the cabin

Smart Fixed Wing Aircraft

• Greener Airframe Technologies •More Electrical a/c architectures

• More efficient wing •Novel Propulsion Integration Strategy •Optimized control surfaces

• Integrated Structures • Smart high lift devices

High-level Objectives

Not legally binding

From the Impact Perspective

From the Expected Impacts

Environmental Perspective • More resource efficient aircraft : challenging targets for up to • 30% cumulative CO2 • 10 EPNdB

• Eco responsible industrial capabilities

Smart & Efficient Mobility Perspective

• Increased operational flexibility (flight domain) • Access to dense populated areas : low noise and low speed

performances • Access to remote areas performances : short take off and

landing, reduced a/c ground infrastructure , remote repairing • Travelling Time not as a wasted Time : passenger well-being • Sustainable traffic growth

Industrial Leadership Perspective

• Cost efficient Products • Strong Product Differentiators • Cost efficient engineering, manufacturing & life cycle support

processes (up to recycling) • Reduced time to market • Sustainable industrial capability

Key Objectives • Validate through demonstration of integrated technologies :

• To introduce innovative airframe architecture

• To introduce techonogies for more efficient airframe : drag, weight, cost, environmental impact, passager well-being, maintenance, servicing, …

• To enhance the efficiency of the engineering & manufacturing process : time-to-market and competitiveness against low-cost labour countries,

• To fully address a technology issue from modeling to certification ability

• Serve maturity up to TRL 6 of airframe technologies

• De-risk novel generation product in the prospect of a next game changing step by 2030+

• Support next generation bizjets and general aviation directly

• Support Large a/c, regional a/c and rotorcraft directly and through IADPS

• Create Product differentiators

Supporting a 5 Product’s Segments Strategy Base

Setup and Implementation

Not legally binding

The Leadership : who are we ?

• Key world player in the aerospace industry. • More than 8,000 aircraft delivered,

representing some 28 million of hours of flight. • 1900 Falcon in operation. • Only group in the world to design, manufacture and support both combat aircraft and business jets.

RAFALE Omnirole

FALCON BizJets

nEUROn UCAV Demonstrator

• Saab serves the global market of governments, authorities and corporations with products, services and solutions ranging from military defence to commercial aeronautics.

• The product portfolio includes the Gripen combat aircraft, Unmanned Aerial Systems (UAS) and large aero-structures for OEM’s such as Airbus and Boeing.

• More than 70 years in business and more than 4000 aircraft manufactured, among them 500 airliners.

• World leader in turboprop aircraft with full

capabilities from design, manufacturing, aircraft

integration, certification and services.

• Product portfolio includes: full proven family of transport aircraft: A400M, C295, CN235 & C212; Eurofighter, Unmanned Aerial Systems (UAS), world leader in Air Refuelling Systems & Aircraft; large aero-structures for OEM’s such as Airbus and Boeing.

• More than 90 years in business and more than 6,000 aircraft delivered to more than 140 operators in 70 countries.

The Overall Partnerships

• Airbus, ALENIA, EUROCOPTER , AGUSTA WESTLAND, SAT Core Team and Fraunhöfer Institute have a central role to AIRFRAME ITD

• The role of industrial core partners, REs and Academia will be major in three main direction:

• Development of main technologies and elements of OEM defined demonstrators => direct contributions at models, design, development, manufacture & testing level to demonstrator components

• Development of other industrial core partner defined major demonstrators, in line with the defined demonstrations objectives and technology routes

• Development of lower TRL / longer term technologies

• The AIRFRAME ITD work scope is still under a consolidation process : it is expected to be adjusted and tuned against – The final outcomes from the regulation adoption process

– The recommendations from the expert panel of the Technical Evaluation

– The suggestions arising from the current Information Process

High Performance & Energy Efficiency High Versatility & Cost Efficiency

Innovative Aircraft

Architecture

Advanced Laminarity

High Speed Airframe

Novel Control

Novel travel

experience

Next generation optimized

wing

Optimized high lift configs.

Advanced integrated structures

Advanced Fuselage

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Novel Certificat°

Eco Design

Extended Laminarity

More Efficient Wing

Advanced Manufact.

Flow & shape Control

Overall Technical Overview

Concept

Analysis

Technology Streams

Innovative Aircraft Architecture

Advanced Laminarity

High Speed Airframe

Next Gen. optimized wing box

IADP LPA

IADP RA

IADP Rcraft

ITD Engine ITD Systems

Novel Control

Advanced Fuselage

Novel Travel Experience

Optimized high lift configurations

Advanced Integrated Structures

IADP LPA

IADP RA

IADP Rcraft

SAT Transverse

act°

ITD Systems

TEECO

Specifications & Requirements

Technology Development & Demonstration

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waveTRL <= 5

TS A-1:Innovative

Aircraft Architecture

WP A-1.1:Optimal engine integration on rear fuselage

WP A-1.2: CROR

configuration

WP A-1.3:Novel high speed

configuration

WP A-1.4: Novel certification

processes

WP A-1.5:Eco Design

TS A-2:Advanced Laminarity

WP A-2.1:Laminar nacelle

WP A-2.2:NLF smart

integrated wing

WP A-2.4:Extended laminarity

WP A-2.3:Laminarity for high lift wing

TS A-3:High Speed

Airframe

WP A-3.1: Multidisciplinary wing for high &

low speed

WP A-3.2:Tailored front

fuselage

WP A-3.3: Innovative shapes

& structure

WP A-3.4: Optimized cockpit

structure

TS A-4:Novel Control

WP A-4.1: Smart mobile

control surfaces

WP A-4.2:Active load

control

TS A-5:Novel travel experience

WP A-5.1: Ergonomic

flexible cabin

WP A-5.2:Office Centered

Cabin

High Performance & Energy Efficiency


Advanced Laminarity

Novel ControlNovel Travel Experience

Management & Interfacing

Leader : Dassault AviationCo leader : SAAB

High Performance & Energy Efficiency- WBS

40/45 M€ 65/70 M€ 35/40M€ 10/15M€ 10/15M€

Progress path versus State-of-the-Art enabled through Clean Sky 2

Conventional aircraft architectures have been primarily driven by component characteristics, requirements and performances (e.g. pod engine integration for undisturbed air ingestion, etc.); Progress on components and on the understanding of their integration requirements makes new more efficient configurations possible. Identically, radical change in major component such as with the CROR engine leads to a complete re-thinking of the aircraft configuration and the propulsion integration. With progress on certification process and Eco Design capabilities, evolutions in the design & production environment, will create favorable conditions to the coming out of ruptures in aircraft architecture.

Partnerships

framework

Engine Supplier, Research Institute, PLM & engineering software provider, Aero-Structure Industry with track record in Eco Design, Material & Coating provider

TS 1 : Innovative Aircraft Architecture

Level 2 WP Technology Key demonstration vehicle / path WP A-1.1

Opt. Engine

Integrat°

Conceptual design, overall aircraft design, engine design,

architectures, aero-shape optimization, vortex management (possibly

done by active means like flow control) on afterbody for drag

reduction, efficient air inlet, aero-structural validation, mechanical

integration, structural optimization, active noise reduction,

performance assessment, accurate noise footprint prediction

Ground test of engine with simulated

distortions

Large Wind Tunnel Test

WP A-1.2

Open Rotor Config°

Advanced pylon architecture

Active noise control with pylon trailing edge flow control

Validation of improved propeller design –acoustic & performance

Final down selection of best candidate engine integration – aircraft

configuration

Large scaled wind tunnel test with CROR

engine mounted to NSR (Next generation

Short Range) aircraft.

WP A-1.3

Novel High

Speed Config°

Conceptual design, overall aircraft design, engine burst

considerations, engine design, architectures, aero-shape optimization,

flow management techniques to reduce flow inhomogenities at the

intake, flight handling qualities, flexible structures, structural

validation, performance assessment

WTT of innovative configurations

Engine rig tests

Possibly (according to preliminary studies

results) flight test of aircraft with modified

inlet to simulate the buried engine

TS1 – High level WP Scope focused demonstrations

Level 2 WP Technology Key demonstration vehicle / path WP A-1.4

Novel Certi°

Process

Certification by models, lean and/or virtual means of conformity,

innovative methods and data bases for certification, certification by

increment;

Advanced modelling, Accurate flutter prediction at high speed.

Wide range of local demonstrations to

validate model accuracy & process

validity, from ground (Wind Tunnel tests,

structural tests, …) up to flight activities

(constitution of meteorological database,

…)

WP A-1.5

Eco-Design

Eco efficient technologies & logistics, including :

for Carbon Fibre Reinforced Polymers structures: wing stiffened

panel by infusion process, integral stiffened structures, low energy

curing

for thermoplastics : thermoplastic composites for aircraft structures

& interior applications

for special polymers applications : composites for high temperature

applications, conductive composite

for metallic structures: light alloys stiffened panel, long life

structures, light alloys and surface treatments, corrosion protection

and/or self healing, Magnesium Technologies

for biomaterials: green polyurethane foams for aircraft seating,

secondary structures and interior furnishing

for electronics materials: electronic connectors, lead-free solder, and

aircraft wiring

for tribology : novel coating & corrosion protection

for low energetic, waste saving novel processes : welding, forming,

bounding, surfacing

Processes will be demonstrated

individually by representative local

demonstrator

Use of the metallic fuselage section and

the composite fuselage demonstrator of

the Airframe ITD as reference case a

global impact assessment at life cycle level

TS1 – High level WP Scope (2/2) transverse enabling technologies


Laminar Flow is the aerodynamics technology with the highest drag reduction potential Within Clean Sky, Natural laminarity of wing for M=0.75 aircrafts is under way to be demonstrated at large scale in major ground rigs and in flight. A subsequent critical additional issue will be to demonstrate the integration of all key elements of a low drag wing into a main wing structural concept that allows for a high rate industrial production at competitive effort. In term of performances, the next step is the increase of Mach number applicability (up to M=0.85 for long range applications) and more extensive applicability on the wing. Laminarity Flow is also to be applied on nacelle as a mean to overcome the drag effect from substantial increase in Fan (respectively nacelle) diameters of innovative turbofan engine solutions.

Partnerships

framework

Research Institute, University, Aero-Structure Industry, Nacelle Supplier

TS 2 : Advanced Laminarity

Level 2 WP Technology Key demonstration vehicle / path WP A-2.1 Laminar

Nacelle

Aeroshape optimization Nacelle design with smart management of access doors and

bleed apertures Manufacturing and assembly technology “low geometrical

tolerance, high surface quality” based on CFRP composites with joints to hybrid components

Surface treatment and coatings with high erosion and self cleaning capability

Repair technologies for in-field “quick fix” for small damages and in-hangar for sever damages

Flow control for engine pylons

Dedicated structural component tests

Full size nacelle structural demonstrator,

manufacturing and assembly

Demonstration of repair and cleaning

technology

Demonstration of integration compliance with

major system components

Flight test of a modified nacelle

Potentially large scale flight test validation of

some key demonstration article in LPA-IADP

WP A-2.2 NLF Smart Integrated Wing

Light weight technologies, Multifunctional materials

Manufacturing and assembly technologies, e.g. “close

geometrical tolerance, high surface quality” based on CFRP

composites

Physical features of the design, integration of innovative wing

system such as WIPS and control surfaces etc...

Representative full scale test sections of a next generation natural laminar flow wing for a short and medium range LPA To be validated with respect to the efforts in materials, tooling, manufacturing, integration and assembly of components and systems.

WP A-2.3 high

lift, turbo-P

Laminar wing

Advanced CFDs, natural laminar flow, flow control

Manufacturing & assembly technologies

Wind Tunnels tests The optimal solution => integrated concept of high lift wing for the Regional Aircraft IADP.

WP A-2.4

Extended

Laminarity

Advanced CFDs, accurate transition modeling with shock-

boundary layer interaction, flow control, aero-shaping,

Innovative techniques for optimum shape design (krugger

device conf, hybrid laminar flow , active shock control)

Manufacturing, assembling & joining qualities, MEMs

Simulation & modeling Local demonstrations of flow control device in Wind Tunnel or possibly in Flight

TS2 – High level WP Scope


Further to Clean Sky progress on wings, integration of aerodynamic and structure innovations for wing efficiency, demonstration of novel fuselage shapes and structures, rethinking of the forward fuselage/cockpit structure can lead to further progress on drag and weight. Global aero structural optimizations will enable travelling time reduction while improving the global environmental balance of high speed. High speed design shall not come at the cost of the low speed capabilities

Partnerships

framework

Research Institute, University, Aero-Structure Industry, Material Provider, Equipment Supplier

TS 3 : High Speed Airframe

Level 2 WP Technology Key demonstration vehicle / path

WP A-3.1

Multidiscip.

wing for H&

L Speed

New architectural design => steering (i.e. shape/structure coupled optimization) Improved sizing criteria, , distributed control, sizing & structural optimization for high energy chocs, new coatings (erosion-proof, anti-accretion of ice & bugs ...)

Representative wing box demonstrator

WP A-3.2

Tailored

Front

Fuselage

Overall innovative front fuselage concept design in consistency with the Overall Aircraft Design, aerodynamic shaping, natural & hybrid laminarity (aero, manufacturing & assembly, surface integrity) discontinuities management: innovative antenna integration, novel anemometry, Synthetic Vision Systems based cockpit, thermal cooling

Simulation & Large Wind Tunnel Partial Structure ground demonstration Aero demonstration of realistic structure (large Wind Tunnel Testing and/or Flight Testing, TBC)

WP A-3.3

Cockpit &

Fuselage

Shapes &

Structures

New architectural design, new shapes to optimized drag, wing-body fairing optimization at high speed, structure & volume, aerodynamic noise reduction, noise transfer reduction, active noise control, systems & networks physical integration, improved sizing criteria and optimized fatigue sizing, failure tolerance, new low density material, multifunctional materials, composite structure optimization

Local demonstrators of multifunction materials, new structure architecture Fuselage panel demonstrator of assembly for innovative shapes (e.g. link to innovative engine integration at the rear).

WP A-3.4

Optimizes

Cockpit

Structure

•Manufacturing and assembly technology based on CFRP composites with joints to hybrid components • Surface treatment and coatings with high erosion resistance • Repair technologies for in-field “quick fix” for small damages and in-

hangar for sever damages, demonstration of NDT inspection techniques

Dedicated structural component tests Demonstration of repair technology



Linked to innovative wings and afterbodies is the possibility of innovative control strategies both at global level (aircraft control, load, vibration & flutter control) and locally (control of instabilities). Direct gains on efficiency (weight, drag, agility) are expected.

Partnerships

framework

Research Institute, University Aero-Structure Industry, Equipment Suppliers

TS 4 : Novel Control


WP A-4.1

Smart

Mobile

Control

Surfaces

Smart mechanism, aero-elasticity, mechanical structure, smart cinematic, assembly, actuation & control. Control surfaces with flow control on demand capability.

Full scale ground demonstrator : mechanism functional demonstration : motion & response time (control loop)

WP A-4.2

Active Load

Control

Control algorithm, aero-elasticity, structural dynamics, testing methods & tools, sensing, actuation

Flight control system demonstrator : functional test of the control loop (response time from the gust detection to mobile surface motion) on ground and in flight



Passenger cabins have not been addressed within Clean Sky. => Improved passenger comfort and ergonomy, safety and services, but also significant fuel efficiency through weight reduction & ecological benefit with environmental friendly materials.

Partnerships

framework

Cabin system provider, Research Institute, University, Material Providers, Equipment Suppliers, Design centers, Social behavior analysts

TS 5 : Novel Travel Experience


WP A-5.1

Ergonomic

Flexible

Cabin

•New seat arrangement and furniture concepts – not only for 1st and business class • Purpose focused functionalities of cabin areas • Local environment tailoring

•Dedicated digital and mock up studies • Contribution to component and

assemblies manufacturing and assembly including demonstration

WP A-5.2

Office

Centered

Cabin

Optimal volume usage, innovation by design, light weight multifunctional/convertible seat & couch, multifunctional furniture, smart galley, novel catering equipments, flexible interior lightning, waste & wastewater management, new –eco compatible material

Full size functional mock-up of a functional zone (catering for business jet) Local/partial cabin items demonstrators


High Versatility & Cost Efficiency


Advanced Laminarity

Novel ControlNovel Travel Experience

Management & Interfacing

Leader : EADS CASA

TS B-1 :Next Generation

optimized wing box

WP B-1.1:Wing for incremental

lift & transmissionshaft integration

WP B-1.2:More affordable

composite structures

WP B-1.3:More efficient wings

technologies

WP B-1.4:Flow & shape control

TS B-2:Optimized high lift

configurations

WP B-2.1:High wing / large

Tprop nacelle configuration

WP B-2.2:Optimized

integration of Tprop nacelles

WP B-2.3:High lift wing

TS B-3:Advanced Integrated Structures

WP B-3.1:Advanced

integration of system in nacelle

WP B-3.2:

All electrical wing

WP B-3.3:Highly integrated

cockpit

WP B-3.4:Advanced integration

of systems in small a/c

WP B-3.5:More affordable small

a/c manufacturing

WP B-3.5:New materials & manufacturing

TS B-4:Advanced Fuselage

WP B-4.1:Rotor-less tail for

Fast Rotorcraft

WP B-4.2:Pressurized fuselage for Fast Rotorcraft

WP B-4.3:More affordable

composite fuselage

WP B-4.4:Affordable low weight, human centered Cabin

High Versatility & Cost Efficiency- WBS

25/30M€ 30/35M€ 50/55M€ 65/70M€

Progress Path & Expected Impact

Progress path enabled through Clean Sky 2

Lead Actors / Key Contributors

Next Generation Optimized Wing Box

Structural improvements for wing, better use of composite materials and optimization of the wing efficiency will lead to further progress on drag, weight, for new, affordable and performing wing.

Dassault, EADS-CASA, EC, SAT Research Institute, University, Aero-Structure Industry, Material Provider

Optimized High Lift Configurations

Advanced aircraft configurations, more global aero structural optimizations and enhanced nacelle/engine integration will lead to further progress on drag and integration for high wing with large turbo propulsors.

EADS-CASA Research Institute, University, Aero-Structure Industry, Nacelle suppliers, Engine suppliers.

Progress Path & Expected Impact (Cont’d)

Progress path enabled through Clean Sky 2

Lead Actors / Key Contributors

Advanced Integrated Structures

Improvements in the design and production processes will lead to more affordable, weight optimized structural components. A native, optimized integration of equipment & systems in the structural design will improve the final quality of airframe equipped with numerous novel equipments & systems, more and more power addicts.

Airbus, Alenia, EADS-CASA, SAT, SAAB Research Institute, University, Aero-Structure Industry, Material Provider, Equipment Supplier

Low Speed A/C Advanced Fuselage

Innovations within Clean Sky have been limited to some major components or section with significant progress in particular on structural weight saving for the cockpit & forward fuselage barrel in GRA. More global aero structural optimizations, and more efficient system integration, including propulsion integration, can lead to further progress on drag, weight and manufacturing processes.

Alenia, EADS-CASA, EC, AW, SAT, GhG Research Institute, University, Aero-Structure Industry, Material Provider, Equipment Supplier

TS 1 : Next Generation optimized wing box

WP 1.1: Wing for incremental lift & transmission shaft

integration

WP 1.2: Optimized composite

structures

WP 1.3: More efficient wing

technologies

WP 1.4: Flow & shape control

HVCE Airframe ITD

June 2013

TS B1 : Next Generation optimized wing box

Level 2 WP Technology Key demonstrator vehicle

WP B1.1 Wing For Incremental Lift And Transmission Shaft Integration

•CFD optimization of aerodynamic design (airfoils, flaps, 3D) for full aircraft L/D. Wing-fuselage and wing-propeller integrated design. TE flaps ensuring incremental lift control with minimal drag impact and allowing to reduce wing blockage of rotor downwash in hover; •Design-to-stiffness, aero-elastic tailoring •Advanced structural design i.e. topologic optimization and smart combination of composite and metallic materials; •Study to consider interest of WIPS; if confirmed, provision for integration (no development); •Transmission shaft and harness integration for high integrity; full tank integration (optional); •Green materials, low energy & low scrap production processes (fiber placement, out-of-autoclave curing), reparability & recyclability •Design to Cost (NC, DMC)

•Full scale wing and flap, one article to be delivered for the Iron Bird (mechanical test bench), another article to be delivered for flight demonstrator assembly (shake test and flight campaign); •Full range of calculation and simulation tools (CFD, FEM, dynamics); sample, sub-components and full component ground tests; substantiation documents for Permit-to-Fly. •TRL 5 with Airframe ITD; TRL6 after flight demonstration in IADP R/C LifeRCraft project.

TS B1 : Next Generation optimized wing box (cont’d)


WP B1.2 More Affordable Composite Structures

•Investigation of the possibilities of application of modern out of autoclave technologies like low pressure and low temperature pre-preg and liquid infusion methods in the area of production, also enabling easy in-field repair possibilities. •Investigation of the possibilities of application of higher temperature resistant resin. •Improvement of automation during production process of composite structures. •Investigation of the possibilities of application of hybrid materials. •Application of modern thermoplastics for secondary aircraft structures using the better impact and damage tolerant capabilities compared to composite material.

•Design and manufacturing of a substantial part of a composite wing •Secondary aircraft structures nacelle designed and manufactured with the aim of low cost and weight, static test, fire resistance test, leading to TRL level 5-6 validation •Static testing of Floats aircraft structure manufactured in hybrid materials leading to TRL level 5-6 validation

TS B1 : Next Generation optimized wing box (cont’d 2)


WP B1.3 More Efficient Wing

•CFD and multidisciplinary approach •Aero-shape optimization •Morphing technologies •Flow control •Flow control for winglet •Winglets and wing plant optimization •Enhanced EMI EMC protection, lightning protection •Anti-icing coatings •Multifunction coatings •Repair technologies •Health monitoring, health assessment

Partial demonstrator for wing testing, in particular Wind Tunnel Possibly, according to preliminary studies, in flight demonstration of local/basic technology

WP B1.4 Flow & Load control

•Advanced CFD & flow control technologies applied to delay or mitigate the flow detachments •Morphing concepts for the loads control •Aerodynamics and aero-elastic concepts for the passive loads control •Active loads control using classical primary and innovative controls in combination with functionalities in the FCS

Demonstration in Wind tunnel test with scaled models The combined structural concepts and aerodynamics concepts with full scale models will be demonstrated in flight test in the R-IADP

TS 2: Optimized high lift configurations

WP 2.1: High wing / large Tprop

nacelle configuration

WP 2.2: High lift wing

WP 2.3: Optimized integration of

Tprop nacelles

HVCE Airframe ITD

June 2013

TS B2: Optimized high lift configurations


WP B2.1 High Wing / Large TProp Nacelle Configuration

Novel architecture design of propulsion integration on high wing New ventilation concepts and nacelle shapes

Analyses – CFD Wind tunnel tests

WP B2.2 Optimized Integration Of Nacelles For Turbo Propelled Aircraft

•Advanced architecture conceptual development •High Integration of hybrid components : metallic and composites •Use of multifunctional materials within new conceptual laminates with improved mechanical, acoustic, thermal, electrical, impact protection and anti-erosion behaviour •Multidisciplinary design harmonization •Methodology development for simulation, virtual & real testing •Systems-structure integration

–Assessment of systems functionalities. –Statement of updated requirements

•Simulation & virtual testing •Manufacturing trials of panels & structural details •Coupons & panels test •Components manufacturing (one hand mounting and cowlings) for non destructive testing research. •Integration & assembly of systems. Verification of accomplishment of structural and systems requirements & interfaces •Substantiation of systems performances & functionalities through ground testing

TS B2: Optimized high lift configurations (contd)


WP B2.3 High lift wing

•Advanced Structure concepts, manufacturing and testing •Technologies of active or passive means of lift increasing devices •Wing Leading edge Morphing – including actuation by EMAs providing the basis for the integration of anti-ice systems •Winglets morphing - structural devices that might be optimally adapted to different flight conditions through relatively minor shape alteration induced by relative displacement of trailing edge. •Adaptive High Performance high lift devices •Drag reduction including Improved laminar flow •Active Load protection •Improved high wing nacelle and power plant integration

– new cowling concept significantly lighter in terms of weigh/unit of area

•New fire resistant materials •Improved ventilation architecture •Enhanced sealing for .fire extinguishing

•Wind tunnel tests of future SAT •RA wing full scale ground demonstrator: •Flight physics assessment and analysis – CFD and wind tunnel •Structural & weight (includes bird strike) •Manufacturing (includes spring back) •Development of SHM application •Assessment of anti-ice system integration •Manufacturing trials of scaled component •Tooling design and manufacturing •Inspections & repairs •Development of the structural concept & manufacturing of structural elements •Assembly and rigging of 1st Article •Ground Test Program

TS 3: Advanced Integrated Structures

WP 3.1: advanced

integrated cockpit

WP 3.2: Advanced

integration of system in nacelle

WP 3.3: All electrical wing

WP 3.4: New materials & manufacturing

WP 3.5: MAME2 metallic

fuselage

HVCE Airframe ITD

June 2013

TS B3: Advanced Integrated Structures


WP B3.1 Advanced Integrated Cockpit

•Advanced structural architecture and systems integration taking into account the system installation and manufacturability aspects. Improvements in wiring leading to reduction of complexity (configuration control, safety) and weight •High Integration of hybrid components : metallic and composites – system installation optimization from modularity and use of advanced concepts (Optical fiber, wireless, etc) •Assessment of systems functionalities. Statement of additional requirements

•Full scale hybrid integrated cockpit demonstrator with cockpit system integration.

–Manufacturing trials of scaled component –Extended ground testing –Avionics systems functionality verification –Substantiation of structural and systems requirements & interfaces –Bird strike strength substantiated by analysis.

WP 3.2 All Electrical Wing

New architectures for Power supply and actuator control Actuator technologies – Duty Cycle – Life endurance – anti jamming capabilities Fiber optic optics and wireless technologies Installation characteristics – force fighting

Validation in bench facilities, integrated & tested into the high lift wing demonstrators part of the more efficient wing activities in the Airframe ITD Flight tested in the RA -IADP

TS B3: Advanced Integrated Structures (cont’d)


WP B3.3 Integration Of Systems In Nacelle

•High temperature / impact resistance composites •Highly coupled engine airframe integration •De-risking highly integrated airframe structures at competitive cost •Power management and electric anti-ices – synergies with engine & systems ITDs •Safety assurance in all normal/failure operating conditions •Advanced sensing system / power control •Operational validation of active (flow control) and passive (high DoF) liners for noise reduction •Structural integrated ducts and manufacturing challenges for impedance matching •Heating systems •Power reduction techniques and energy/heat management (SHS, wettability control, heat pipes, …)

•For Electric Anti-Icing System A 3D IWT Test Item For Large Scale Icing Wind Tunnel Campaign Is Foreseen •Acoustic Technologies And Models Will Be Demonstrated Via The Realization And Testing Of Full Scale Wide Frequency Absorbing Acoustic Panels For Anechoic Chamber Measures •Integration Of Heating Systems Into The Acoustic Treatments Will Be Demonstrated With 2D Icing Wind Tunnel Test Campaign.

TS B3: Advanced Integrated Structures (cont’d 2)


WP B3.4 New materials & manufacturing

•Automation, high speed machining, novel alloys machining, novel forming, bounding, welding techniques, novel part joining techniques, advanced jig technologies, composite parts production techniques. •Hybrid metal/composite joining techniques •Production control, testing in production, maintenance in production

Material testing & validation Local demonstrations on representative part to validate a production/assembly technique

WP B3.5 More Affordable Small Aircraft Manufacturing

•Automated metal structures assembling •Friction Stir Welding technologies for specific structural parts •Advanced technologies in jigs/fixtures production •Alternative joining methods •Effective combination of metallic and composite structures •Advanced production technologies

•Ground demonstrators consisting of central fuselage airframe subassemblies of metal fuselage and wing sections. •Technological demonstrators represented by airframe subassemblies. •Type of test:

–technology verification –strength test –fatigue tests

TS B3: Advanced Integrated Structures (cont’d 3)


WP B3.6 Advanced integration of systems in small a/c

•Advanced system technologies developed in ITD System and focused on reduction of the Operational Costs, improved cabin (noise, thermal, entertainment) & flight comfort and safety and security

Efficient operation of small aircraft with affordable health monitoring systems More electric/electronic technologies for small aircraft Fly-by-wire architecture for small aircraft Affordable SESAR operation, modern cockpit and avionic solutions for small a/c Comfortable and safe cabin for small aircraft

TS 4: Advanced Fuselage

WP 4.1: Rotor-less tail for Fast

Rotorcraft

WP 4.2: Pressurized fuselage for Fast Rotorcraft

WP 4.3: MAME2 composite

fuselage

WP 4.4: Low weight, Low cost

Cabin

HVCE Airframe ITD

June 2013

TS B4: Advanced Fuselage


WP B4.1 Rotor-less tail for fast rotorcraft

•CFD optimization of aerodynamic configuration & design (fuselage tail junction, tail boom, empennage and fins including control surfaces) taking into account constraints for rear access doors and rescue hoist operation, airframe angle of attack and attitude control, dynamic pitch and yaw stability (with and w/o active stability augmentation), interaction with propeller slipstream and tail shake prevention in the full flight envelope including mass and CG variations; •Flow control devices either passive or active to be studied if needed to prevent flow separation; •Aeroelastic tailoring •Advanced structural design i.e. topologic optimization using smart combination of composite and metallic materials for minimal weight; •Green materials, low energy & low scrap production processes, reparability & recyclability •Design to Cost (NC, DMC).

•Full scale, flightworthy tail assembly to be delivered for flight demonstrator (shake test and flight campaign); •Full range of calculation and simulation tools (CFD, FEM, dynamics); sample, sub-components and full component ground tests; substantiation documents for Permit-to-Fly. •The tail assembly includes: tail boom, empennage and fins with pitch and yaw control surfaces. •Flight demonstration in IADP R/C LifeRCraft project.

TS B4: Advanced Fuselage (cont’d)


WP B4.2 Pressurized fuselage for fast rotorcraft

Optimal design, through extensive use of design and simulation tools such as CFD, structural and vibrational analysis, aeroelastic modelling and systems integration. The detailed design will leverage a dedicated selection of materials and manufacturing technologies (including but not limited to hybrid composite-metallic structures, automated tape laying for single piece outer skin, lightweight hybrid transparencies for de-icing and bird strike resistance, use of thermoplastic matrix composites from initial conception).

•Manufacturing of physical components for testing and for assembly of the technology demonstrator with flight clearance related to each of the 3 components: front, central & rear fuselage parts. •The fuselage will be structurally tested on dedicated benches to support flight clearance. Individual sub-assembly tests will be performed as required

TS B4: Advanced Fuselage (cont’d 2) Level 2 WP Technology Key demonstrator vehicle

WP B4.3 More Affordable composite fuselage

•Methodologies for modelling & simulation for high efficient, high performance computing non linear structural analysis and damage models applied to composite & laminates. •Affordable technologies to reduce the environmental impact with use of a recycling process based on simple chemical-physical procedures involving no chemical reactions and low energy consumption. •hybrid & composite materials with a high impact resistance or multifunctional composite for acoustic improvements, thermal protection, EME or lightning features or integrated SHM/NDI systems. •technologies for low cost manufacturing with large one piece manufacturing, high automation, advanced infusion, curing & bonding techniques, and low cost assembling with high automation, lean, low infrastructure processes, efficient fastening. •Impact damage survey on full scale items. •NDI/SHM techniques for materials, assembling and design, including self-sensing. •Technologies for complex shapes and high-loaded parts. •Technologies for maintenance and repair

•In the framework of the AIRFRAME ITD, demonstrations are carried out up to component level by following the building block approach. Such will include a full scale barrel ground demonstrator. •The generated technology base will be integrated in the full scale fuselage demonstrator inserted in the R-IADP demonstration

TS B4: Advanced Fuselage (cont’d 3)


WP B4.4 Affordable low weight, human centred cabin

•Innovative multifunctional materials for interiors components including secondary structure integration concepts; •development of chemical-free processes (thermoplastic welding, thermoforming, etc.); •development of VOC (Volatile Organic Compounds) free materials in order to reduce passive toxicity related to the cabin furnitures. •human perception and psychoacoustics with respect to A/C interior noise and vibration; •new simulation technologies and methodologies for comfort (ergonomics, noise, thermal verification)

•A small-scale validation activity will be used, specifically targeted at a local change, to define the new concept(s) and validate in a local context according to type of application. Performance, operability and the acceptability of operational aspects will be the primary concerns. •Virtual Reality setups will also be used to support the design conditions, allowing an optimisation of the environment for these tasks and is already used for multiple design processes. •Small scale test will be performed for preliminary validation to assess the comfort index and noise/acoustic and FST performances.

44

European Small Aircraft OEM partnership*

Piaggio Aero - P180 Mielec – PZL M28 Aircraft Industries L-410

Grob -G120 TP Evektor EV-55 Diamond –DA42

The European Small aircraft industry has a market position on the global general

aviation and utility aircraft market both pistons and turboprops (excluding business

jets and new category of Light Sport Aircraft) of around 33% in value (around 5

Billions Euro last ten Years).

*OEM showed interest in SAT during consultation sessions

• Small Air Transport Overall A/C Design and Configuration Management • Interface & Cross-interaction Management • Reference aircraft • Coordination and execution (aircraft level) of demonstration activity

• Optimized Composite Structures (wing box, engine nacelle)

• Advanced out of autoclave (OOA) technologies • More automation for low-volume composite production

• More affordable metallic manufacturing (linear joints, local joints)

• Optimization of Friction Stir Welding technologies • Automated metal structures assembling in low volume production

• High Lift Wing (SAT)

• High/Low Speed Innovative Aerodynamic Concept

Major Research Areas to be addressed with JTI CS2– ITD Airframe

[email protected] Goran Bengtsson - SAAB Alain Bouillon – Dassault Aviation Miguel Llorca Sanz – EADS CASA

Further Information

mailto:[email protected]








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Documents

Innovation Takes Off - Clean Sky · 2018-03-23 · Clean Sky 2 Information Day Lisbon, 28 November 2013 AIRFRAME ITD Alain Bouillon, Dassault Aviation Chargé d’affaires Clean Sky