AIRFRAME ITD Call for Proposals #6 - Clean Sky (f) AIR... · AIR-01-40 Infusion manufacturing methodolodies for Aircraft complex composite ... Low Cost Optical Wave Guide ... AIR-01-50

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Clean Sky 2

AIRFRAME ITD Call for Proposals #6

Brussels, 22nd February 2017


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

2


AIRFRAME Key General Objectives Weight New Materials

Manufacturing Cost

Drag Maintenance More Efficient Airframes Cabin

Efficiency of the engineering & manufacturing process Time to Market

(lead Time)

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

REG

IADP/Integrated Demonstrators

FRC

LPA

AIR Bizjet

SAT

SUPPORT TO IADP: Maturate technologies up to TRL 6

TRANSVERSE Eco-Design for Airframe & Modeling to certification ability

FUTURE: De-risk novel generation product in

the prospect of changing step by 2030+

Noise

FRC

AIR Bizjet

SAT

LPA

REG


AIRFRAME ITD Dassault – SAAB - Airbus DS

IADPs

4

AIRFRAME ITD Interfaces Overview with other SPDs

IADPs & SAT provide General Requirements

Airframe technologies development up to TRL5/6

TRL6+ demonstrations in IADPs and SAT

Leonardo

Leonardo

Airbus

Helicopters


Overall WBS and participants

5

5 Technology Streams 4 Technology Streams

Co-Leaders: DAv, SAAB Leaders: Airbus, Fraunhofer CP: NACOR, GAINS, ecoTECH, CASTLE, MANTA

Co-Leaders: Airbus D&S S.A.U. (CASA) Leaders: Airbus, FNM-VEL, FNM-HD/AW, AH, Fraunhofer, SAAB, Evektor, Piaggio CP: NACOR, OUTCOME, ASTRAL, SHERLOC, OPTICOMS, PASSARO, SAT-AM, CASTLE, LIFTT(?)

TS A-0:

Management &

Interface

TS A-1:

Innovative

Aircraft

Architecture

TS A-2:

Advanced

Laminarity

TS A-3: High

Speed Airframe

TS A-4: Novel

Control

TS A-5: Novel

travel

experience

TS B-0:

Management &

Interface

TS B-1: Next

Generation

optimized wing

box

TS B-2:

Optimized high

lift

configurations

TS B-3:

Advanced

Integrated

Structures

TS B-4:

Advanced

Fuselage

WP A-0.1 WP A-1.1 WP A-2.1 WP A-3.1 WP A-4.1 WP A-5.1 WP B-0.1 WP B-1.1 WP B-2.1 WP B-3.1 WP B-4.1

Overall

Management

Optimal engine

integration on

rear fuselage

Laminar nacelle

Multidisciplinary

wing for high &

low speed

Smart mobile

control surfaces

Ergonomic flexible

cabin

Overall

Management

Wing for

incremental lift &

transmission shaft

integration

High wing / large

Tprop nacelle

configuration

Advanced

Integration of

syst. in nacelle

Rotor-less tail for

Fast Rotorcraft

WP A-0.2 WP A-1.2 WP A-2.2 WP A-3.2 WP A-4.2 WP A-5.2 WP B-0.2 WP B-1.2 WP B-2.2 WP B-3.2 WP B-4.2

Business Aviation

OAD & config.

Mgt

CROR & UHBR

configurations

NLF smart

integrated wing

Tailored front

fuselage

Active load

control

Office Centered

Cabin

SAT

OAD &

configuration Mgt

More affordable

composite

structures

High lift wing All electrical wing

Pressurized

fuselage for Fast

RotorcraftWP A-0.3 WP A-1.3 WP A-2.3 WP A-3.3 WP B-0.3 WP B-1.3 WP B-3.3 WP B-4.3

LPA

OAD & config.

Mgt

Novel high

performance

configuration

Extended

laminarity

Innovative shapes

& structure

RotorCraft OAD &

configuration Mgt

More efficient

wings

technologies

Highly integrated

cockpit

More affordable

composite

fuselage

WP A-0.4 WP A-1.4 WP A-3.4 WP B-0.4 WP B-1.4 WP B-3.4 WP B-4.4

Eco-Design TA

Link

Virtual modelling

for certification

Eco-Design for

airframe

Regional a/c

OAD & config.

Mgt

Flow & shape

control

More affordable

small a/c

manufacturing

Low weight, low

cost cabin

WP B-0.5 WP B-3.5

Eco-Design TA

Link

Advanced

integration of

syst. in small a/cWP B-3.6

New materials &

manufacturing

A - High Performance and Energy

EfficiencyB - High Versatility and Cost Efficiency


AIR ITD Family Share of funding foreseen

Participants to date

Countries involved to date

Leader 16.7% 4* 4

Part. Leaders

23.2% 13* 6

Core Partners

30.0% 76* 12

Partners 30.1% 124 16

*incl. Affiliates and Third Parties


AIRFRAME ITD - CfP Status – CfP06

7

Identificatio

n Code CfP Title WP/Task

Project HPE

AIR-01-25 Improvement of the aerodynamic loads prediction at high Reynolds number A-1.4

AIR-01-26 Development of innovative and optimized stiffeners run-out for overall panel weight saving A-3.1

AIR-01-27 Innovative solutions for metallic ribs or fittings introduced in a composite box to optimally deal with thermo-

mechanical effects

A-3.1

AIR-01-28 Bigger cockpit windshields and associated trade-off between “plugged” design and “load-bearing” design A-3.2

AIR-01-29 Optimisation of Friction Stir Welding (FSW) and Laser Beam Welding (LBW) for assembly of structural aircraft parts A-3.3

Project HVC

AIR-01-39 Ice tunnel Model & test for Induction system + Ice tunnel Model & test for Heat Transport system B-2.1/B-

3.2

AIR-01-40 Infusion manufacturing methodolodies for Aircraft complex composite components. B-2.2

AIR-01-41 All Electric Wing: Integrated electronics for actuator data and power management for Morphing Leading Edge

activities

B-1.4 / B-

3.2

AIR-01-42 Lay-up tools for Helicopter Shells B-3.3.10

AIR-01-43 Materials & Process : Low Cost Optical Wave Guide for Damage Detection & Data Transfer B-3.3.2

AIR-01-44 Adjustable high loaded rod B-3.3.2

AIR-01-45 Development and deployment of PLM Tools for A/C Ground Functional testing with Eco-design criteria. B-3.6

AIR-01-46 Auto testing technologies and more automated factories for Aircraft validation test process B-3.6

AIR-01-47 Part specific process optimization in SLM B-3.6

AIR-01-48 Development and validation of a portable, automated and jigless system for drilling and assembly of fuselage joints B-4.3

AIR-01-49 Development and validation of a self-adaptive system for automated assembly of major composite aerostructures B-4.3

AIR-01-50 Design and manufacturing of innovative toolings for large curved fuselage panel B-4.3



8

Optimal engine

integration on

rear fuselage

UHBR & CROR

configuration

Novel high

performance

configuration

Virtual modelling

for Certification

WP A-1.4

TS A-1: Innovative Aircraft

Architecture

AIB

WP A-1.1 WP A-1.2 WP A-1.3



9

Multidisciplinary

wing for high & low

speed

Tailored front

fuselage

Innovative shapes &

structureEco-Design for Airframe

WP A-3.4

TS A-3: High Speed Airframe

DAV

WP A-3.1 WP A-3.2 WP A-3.3

BJ COMPOSITE WING ROOT



10

Multidisciplinary

wing for high & low

speed

Tailored front

fuselage

Innovative shapes &


WP A-3.4


DAV

WP A-3.1 WP A-3.2 WP A-3.3

BJ COMPOSITE WING ROOT



11

11

Multidisciplinary

wing for high & low

speed

Tailored front

fuselage

Innovative shapes &


WP A-3.4


DAV

WP A-3.1 WP A-3.2 WP A-3.3



12

12 12

Multidisciplinary

wing for high & low

speed

Tailored front

fuselage

Innovative shapes &


WP A-3.4


DAV

WP A-3.1 WP A-3.2 WP A-3.3

DOOR DEMONSTRATOR



13

High lift wing

TS B-2: Optimized high lift configurations

WP B-2.2

CASA, PAI, EVE

CASA

WP B-2.1

High wing / large Tprop

nacelle configuration

CASA

WP B-3.4

More affordable small

A/C manufacturing

EVE

WP B-3.3

Advanced integrated

cockpit

CASA, Airbus, FHG

TS B-3: Advanced Integrated Structures

CASA

WP B-3.2

All electrical wing

CASA, FHG

Anti Ice Loop Heat Pipe Nacelle Demonstrator

Anti Ice Induction Leading Edge



14

High lift wing

TS B-2: Optimized high lift configurations

WP B-2.2

WP B-2.2.1

Advanced composite

external wing box

CASA

CASA, PAI, EVE

CASA

WP B-2.1

High wing / large Tprop

nacelle configuration

CASA

DOOR DEMONSTRATOR



15

WP B-3.4


A/C manufacturing

EVE

WP B-3.3

Advanced integrated

cockpit

CASA, Airbus, FHG


CASA

WP B-3.2

All electrical wing

CASA, FHG



16

WP B-3.4


A/C manufacturing

EVE

WP B-3.3

Advanced integrated

cockpit

CASA, Airbus, FHG


CASA

WP B-3.2

All electrical wing

CASA, FHG



17



18



19

New materials and

manufacturing

WP B-3.4


A/C manufacturing

WP B-3.5

Advanced int. of

systems in small A/C

WP B-3.6WP B-3.3

Advanced integrated

cockpit


CASA



20

New materials and

manufacturing

WP B-3.4


A/C manufacturing

WP B-3.5

Advanced int. of


WP B-3.6WP B-3.3

Advanced integrated

cockpit


CASA



21

New materials and

manufacturing

WP B-3.4


A/C manufacturing

WP B-3.5

Advanced int. of


WP B-3.6WP B-3.3

Advanced integrated

cockpit


CASA



22

WP B-4.4

TS B-4: Advanced Fuselage

FNM VEL

Affordable low weight,

human centered cabin

WP B-4.1 WP B-4.2 WP B-4.3

Roto-less tail for

Fast Rotorcraft

Pressurized fuselage

for Fast Rotorcraft

More affordable

composite fuselage

Full Scale Fuselage Structural Ground Demo



23

23

WP B-4.4


FNM VEL



WP B-4.1 WP B-4.2 WP B-4.3

Roto-less tail for

Fast Rotorcraft


for Fast Rotorcraft

More affordable

composite fuselage

Full Scale Fuselage Structural Ground Demo



24

WP B-4.4


FNM VEL



WP B-4.1 WP B-4.2 WP B-4.3

Roto-less tail for

Fast Rotorcraft


for Fast Rotorcraft

More affordable

composite fuselage


Title: Development and validation of a portable, automated

and jigless system for drilling and assembly of fuselage joints

WP Location: AIR ITD WP B-4.3

Objective:

Development and validation of a flexible system for automated drill integrated holes inspection to be used for a regional aircraft composite fuselage assembly. Use of the system will allow a significant reduction of the overall production costs and flow.

The system will consist in a compact equipment, movable on curved surfaces, and able, through a dedicated Part Program, to perform one-shot drilling and hole inspection for assembly of primary structures. This solution will address longitudinal/circumferential joint of fuselage sections.

JTI-CS2-2017-CfP06-AIR-02-48


Capability: The portable equipment shall be able to perform drilling and hole check

for Composite regional aircraft fuselage longitudinal and orbital joints. Reference

components are shown in pictures.

JTI-CS2-2017-CfP06-AIR-02-48


Tasks description:

• Task 1 - Trade-off Study and Tool Technical Specification

The advanced technologies development for an automated drilling system on the Regional

TurboProp fuselage shall be driven by the following key factors: increase of integration,

reduction of assembly flow, reduction of assembling costs and increase of automation..

• Task 2 Equipment design Equipment shall be designed as an integrated system of the three main components: drilling

and measuring head, head moving equipment (both X and Y axis, moving on the fuselage, at

specific locations for panels joint) and positioning and alignment system.

• Task 3 - Test Plan of the three main components and their integration After design, a Test Plan for each of the three main components shall be produced by the

Applicant, listing and describing all the tests that have to be conducted to develop the process.

JTI-CS2-2017-CfP06-AIR-02-48


Tasks description:

• Task 4 - Equipment development and construction Equipment shall satisfy all design requirements. Tests required by plans shall be conducted during the equipment construction, thus supporting and orienting the development of the automatic equipment.

• Task 5 Pre-acceptance tests A pre-acceptance phase shall be conducted before equipment shipping to the Topic Manager plant in order to verify technology readiness and conformance to the requested performance level.

• Task 6 - Equipment Acceptance An acceptance task, similar but more in depth than pre-acceptance, shall be performed after final installation in the Topic Manager facility. A full-size demonstrator shall be successfully drilled, checked and assembled in order to validate the Equipment capabilities (6 longitudinal joints, 1 orbital joint).

• Task 7 - Fuselage Demonstrators Drilling and Fastening Equipment shall be tested on the final planned demonstrator. The partner shall provide the required operational and engineering support for drilling and assembly operations of one demonstrator (6 longitudinal joints and 1 orbital joint). Maintenance, technical assistance and spare parts shall be guaranteed by the partner until the completion of all the activities planned (2 full complete demonstrators, 12 panels).

JTI-CS2-2017-CfP06-AIR-02-48


Special skills: • Skill 1: Proven competence in design and construction of equipment for aeronautical composite

components assembly, by a documented experience in participating in actual aeronautical program. This competence shall include a strong knowledge of processes, quality, tooling, part programs for CN machines.

• Skill 2: Proven experience in experimental testing from coupon levels up to aeronautical full scale substructures. Evidence of qualification shall be provided.

• Skill 3: Proven experience in cost estimation at industrial level for aeronautical full scale composite structures.

Indicative Funding Topic Value: 900 k€

Duration of the action: 24 Months

T0 (Start): Q1 2018

JTI-CS2-2017-CfP06-AIR-02-48


Title: Development and validation of a self-adaptive system for

automated assembly of major composite aerostructures

WP Location: AIR ITD WP B-4.3

Objective:

Development and validation of self-adaptive system for automated assembly of major composite aerostructures of a regional aircraft composite fuselage which will allow a significant reduction of the overall production costs and flow.

The system will consist in a anthropomorphic automatic robot equipped with end effector for drilling/countersinking, sealing and fastener insertion.

JTI-CS2-2017-CfP06-AIR-02-49


Capability:

This solution will be applied for the assembly of stiffened panel skins, frames, window frames and door surround components.

Recognition of actual position and shape of sub structure is performed by a dedicated camera system, so that a specific algorithm will elaborate the 3D model holes pattern on the basis of the actual structure position and profile. Camera system and algorithm shall be able to perform visual and dimensional checks by matching the actual data with requirements and providing report.

Reference components is shown in figure 1.

JTI-CS2-2017-CfP06-AIR-02-49

Figure 1 -generic stiffened after frame/

shear tie clips installation.


Tasks description:

• Task 1 - Trade-off Study and Tool Technical Specification

The advanced technologies development for an automated drilling system on the Regional

TurboProp fuselage shall be driven by the following key factors: increase of integration,

reduction of assembly flow, reduction of assembling costs and increase of automation..

• Task 2 Equipment design Equipment shall be an integrated system of the three main components: drilling and fastening

(sealing and insertion) head, moving equipment and vision, analysis, positioning and alignment

system,

• Task 3 - Test Plan of the three main components and their integration After design, a Test Plan for each of the three main components shall be produced by the

Applicant, listing and describing all the tests that have to be conducted to develop the process.

JTI-CS2-2017-CfP06-AIR-02-49


Tasks description:

• Task 4 - Equipment development and construction Equipment shall satisfy all design requirements. Tests required by plans shall be conducted during the equipment construction, thus supporting and orienting the development of the automatic equipment.

• Task 5 Pre-acceptance tests A pre-acceptance phase shall be conducted before equipment shipping to the Topic Manager plant in order to verify technology readiness and conformance to the requested performance level.

• Task 6 - Equipment Acceptance An acceptance task, similar but more in depth than pre-acceptance, shall be performed after final installation in the Topic Manager facility. A full-size demonstrator shall be successfully drilled, checked and assembled in order to validate the Equipment capabilities (6 panels assembly).

• Task 7 - Fuselage Demonstrators Drilling and Fastening Equipment shall be tested on the final planned demonstrator. The partner shall provide the required operational and engineering support for drilling and assembly operations of one demonstrator (6 panels). Maintenance, technical assistance and spare parts shall be guaranteed by the partner until the completion of all the activities planned (2 full complete demonstrators, 12 panels).

JTI-CS2-2017-CfP06-AIR-02-49


General system

architecture

Capability of part/ hole pattern adaptation through a vision, analysis, re-positioning and alignment system (See Fig.2 for general system architecture);

JTI-CS2-2017-CfP06-AIR-02-49

Fig. 2


General system

architecture

Re-positioning algorithm approach is shown in fig. 3.

JTI-CS2-2017-CfP06-AIR-02-49

Fig. 3


Special skills:

• Skill 1: Proven competence in design and construction of equipment for aeronautical composite components assembly, by a documented experience in participating in actual aeronautical program. This competence shall include a strong knowledge of processes, quality, tooling, part programs for NC machines.

• Skill 2: Proven experience in experimental testing from coupon levels up to aeronautical full scale substructures. Evidence of qualification shall be provided.

• Skill 3: Proven experience in cost estimation at industrial level for aeronautical full scale composite structures.

• Skill 4: Proven experience in vision and inspection technology at industrial level.

Indicative Funding Topic Value: 2000 k€

Duration of the action: 30 Months

T0 (Start): Q1 2018

JTI-CS2-2017-CfP06-AIR-02-49


Any questions?

[email protected]

Innovation Takes Off

Last deadline to submit your questions:

29th March 2017

mailto:[email protected]










Thank You

http://www.fraunhofer.de/de.html

http://www.safran-group.com/?lang=fr

http://www.thalesgroup.com/

Documents

AIRFRAME ITD Call for Proposals #6 - Clean Sky (f) AIR... · AIR-01-40 Infusion manufacturing methodolodies for Aircraft complex composite ... Low Cost Optical Wave Guide ... AIR-01-50