Call info day - Welcome to the Clean Sky | Clean Sky 1 Clean Sky –Info day/ 29th February 2012 in Madrid (SP) Call info day Sébastien DUBOIS, Project Officer (rotorcraft) Green

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Clean Sky –Info day/ 29th February 2012 in Madrid (SP)

Call info daySébastien DUBOIS,

Project Officer (rotorcraft)

Green Rotorcraft: 2012 workplan with topics presentation

Madrid, 29th February 2012

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Outlines

The Green Rotorcraft Project Environmental objectivesMembershipGRC at a glance2012 workplan and associated topics

proposedTopics currently openedQ&A

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Clean Sky / Green Rotorcraft : heading toward ACARE goals

REACH complianceREACH REACH compliancecompliance

Halving noise

Emissions reduction

Green Life Cycle

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ITD-leaders (< 50%)DLR (D)ONERA (F)PZL Swidnik (Pol)CIRA-SELEX ATS: cluster (I)

IGOR: cluster of 11 members (NL, B, D)Airborne Composite, Akustik Universiteit Twente

160M€ Total Budget: 10% of Clean Sky

Agusta-Westland (co-leader)Eurocopter

(co-leader)

Liebherr (D)Hispano-Suiza (F)Thales Avionics

Electrical Systems (F)

DLR (D)ONERA (F)PZL Swidnik (Pol)CIRA-SELEX ATS: cluster (I)

IGOR: cluster of 10 members (NL, B, D)Airborne Composite, Eurocarbon, Fibre Optic Sensors and Sensing Systems, LMS; Microflown Technologies, Micromega Dynamics, NLR, Technische Universiteit Delft, Universiteit Twente

Partners (>25%)

Associates (<25%)

Main Stakeholders of the domain presents in the ITD GRC:Helicopter Manufacturers, Research Institutes, Systems suppliers10 members composed of 23 legal entities

GRC: Participants & Global Shares

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GRC Master Plan

Legend

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2012 detailed workplan (GRC1)1. Innovative Rotor Blades

Active Twist: tests completion at component level, and confirmation of the full active twist blade design

Active blade deformation e.g. active twist Active Gurney Flap: design of the wind tunnel model incorporating Active Gurney Flaps (CDR early 2013), in parallel with the development of full scale rotor equipped with AGF (incl. actuation device, power transfer, control system & modified blades

Active control surface e.g. Gurney flap3D blade shape: Optimisation will continue, the detailed design process, including definition of the manufacturing process and tooling such as moulds will be conducted following the PDR

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2012 detailed workplan (GRC1)1. Innovative Rotor Blades: list of topics to be launched in 2012

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2012 detailed workplan (GRC2)

2. Drag reduction, required power reductionRotor head drag reduction:

Wind tunnel tests of different h/c configurations (incl fuselage cabin, landing skids, or sponsons, and rotor head) will be completed. Aerodynamic and structural design of a new full scale hub cap for light helicopter will be completed.

Reduction of airframe drag:improved aerodynamic design of the common helicopter platform and of the ERICA tilt-rotor will be conducted, incorporating passive and/or active flow control systems remotely controlled horizontal stabiliser for the wind tunnel model of the helicopter common platform will be manufactured, together with the remote control system

Turbo shaft engine installation: Aerodynamic and noise propagation analysis about new side air intakes

integrations will continue for light and heavy helicopters.

The new nacelle configuration, will be designed for the ERICA tilt rotor model, while astudy for evaluation of emission, engine performance and noise will be accomplished.

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2012 detailed workplan (GRC2)2. Drag reduction, required power reduction: list of topics to be launched in 2012

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3. More electrical HelicopterArchitecure study & assessment:

The analysis, simulation and assessment of the integrated all-electrical helicopter architecture.The new system EPGDS technology architecture will be defined integrating energy management and the different applications under study.

Technology study:Preliminary design studies:

Multi-source regenerative systems power conversion (incl. storage device)Brushless 28VDC Starter-GeneratorElectrical driven tail rotor motor

Detailed design studies:EMA system for medium/heavy helicopter flight controlElectric taxiingHeat Energy recovery systemPiezo Power Supply module ( Active rotor blade demonstration)Rotor braking recoveryManagement of energy recovery

Demonstration performed at system level in a dynamic and representative way on the Copper Bird Test Bench


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2012 detailed workplan (GRC3)3. More electrical Helicopter: list of topics to be launched in 2012

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2012 detailed workplan (GRC4)4. Lean powerplant

To reduce drastically CO2 emission thanks to the very low fuel consumption of modern Diesel engine technology: -30% to -40% over full flight envelope

Using regular kerosene fuel (or biodiesel)

To integrate the engine minimising the potential adverse effects:

weight penalty

Vibration

Cooling system

In 2012:

PDR/ CDR of the diesel power pack and engine installation on H/C

Preliminary study of the next h/c generation powered with a diesel engine


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5. Environment-Friendly Flight Path

Low-noise on-board system

En-route optimised flight paths for the reduction of polluting emissions

IFR & VFR approach and departure procedures (noise footprint minimisation)

Low level VFR & IFR en route navigation (noise impact minimisation)

SNI shorter routes to minimise fuel emission and gas emission

Operational Requirements

Flight guidance systems

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2012 detailed workplan (GRC5)5. Environment-Friendly Flight Pat: list of topics to be launched in 2012

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• Doors & Structural– Recyclable composite parts – Surface preparation for composite-

metallic bonding– Bonding and painting– Repair– testing

Gear Box HousingCr6 free Magnesium protection & touch up AND paintingTesting

Transmission componentsCd free protectionRepair AND paintingtesting

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2012 detailed workplan (GRC6)6. EcoDesign: list of topics to be launched in 2012

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List of topics expected in 2012


ID or N° Title 12.1 12.2 12.3

GRC1 - 1 Design of scaled systems representing the GRC1 technologies to be tested at wind tunnel facilities 30 July 12 591GRC1 - 2 Develop and manufacture moulds for active model rotor blades 18 July 12 400GRC1 - 3 Passive model rotor manufacturing and testing – to be replaced by CfP in support of full scale activitie 36 Jan 13 710GRC1 - 4 Design and manufacture power supply for full scale active blade 36 Jan 13 250GRC1 - 5 Design and manufacture data transfer system for full scale active blade 36 Jan 13 215GRC2 - 1 Manufacturing, CFD analysis and WT tests for common platform 36 Sept 12 700GRC2 - 2 CFD analysis and WT tests for tilt rotor fuselage 24 Jan 13 600GRC3 - 1 HPAS Adaptation Kit 12 Aug 12 100GRC3 - 2 HEMAS Adaptation Kit 12 Aug 12 1000GRC3 - 3 Energy Recovery Adaptation Kit 12 Aug 12 200GRC3 - 4 Development and delivery of EMA for a light Helicopter 18 Sept 12 650GRC5 - 1 Sensoring and cockpit monitoring to reduce noise in meneuvering flight 24 Sept. 12 1200GRC5 - 2 Curved SBAS guided helicopter approaches for low noise landing - Safety & ATM compatibility 24 Sept. 12 400GRC6 - 1 Recycling of Metallic Materials from Rotorcraft Transmissions 18 Sept 12 200GRC6 - 2 Disassembly of eco-designed helicopter demonstrators 18 Sept 12 200

Sub Total 1850 4966 600

TOTAL Budget 7416

Topic Description Anticipated Duration(months)

Latest starting date to match

program target

LBUDGET (K€) and Target

650

Blades

Drag

ElectricalSystems

Trajectory

Eco Design

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Topics still open

4 topics split as follows:

GRC1: Innovative Rotor BladesMould design and manufacture for the production of a very high

tolerance model helicopter blade 400 k€

GRC3: Integration of innovative electrical systemsDevelopment and delivery of Electromechanical Actuator for a light

H/C 650 k€

GRC6: Eco Design for RotorcfraftRecycling of Metallic Materials from Rotorcraft Transmissions 200k€Disassembly of eco-designed helicopter demonstrators 200 k€

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For further information:www.cleansky.eu

Sébastien DUBOISProject Officer

[email protected]

Contact us

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Thank you for your attention

Questions?

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© 2010 by the CleanSky Leading Partners: Airbus, AgustaWestland, Alenia Aeronautica, Dassault Aviation, EADS-CASA, Eurocopter, Fraunhofer Institute, Liebherr Aerospace, Rolls-Royce, Saab AB, Safran Thales and the European Commission.

Permission to copy, store electronically, or disseminate this presentation is hereby granted freely provided the source is recognized. No rights to modify the presentation are granted.

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GRC1Mould design and manufacture for the

production of a very high tolerance model helicopter blade

GRC1Mould design and manufacture for the

production of a very high tolerance model helicopter blade


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Background

The design and production of high tolerance moulds for a scaled composite helicopter blade with active gurney flap (AGF) for whirl tower testing

AGF


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Background

Challenge is:

to meet strict dimensional tolerances (<±0.1mm) on aerodynamic profile, and

to meet strict requirements on mass distribution between each blade produced (<±3% mass variation).


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Details

Comparison of two manufacturing methods using standard aerospace-grade composite materials

Design and production of at least two moulds (and necessary tooling) for:• Prepreg version• Resin transfer moulding version

In addition, other ideas eg SQRTM, are welcome!

It is not expected that the blades will be made in a one shot process due to complexity of electrical connections required

Up to 10 sets of rotor blades for each version must be made, therefore moulds must be durable.

AGF will be fitted after moulding process and therefore require a (partially) hollow structure and an access route.


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Scope

Design of tooling and mould sets including:• method for opening and closing of moulds• method for heating and cooling of moulds• design of preform tooling• integration of temperature sensors for cure monitoring• feedback to rotor blade design to improve manufacturability

Manufacturing and delivery of tooling and mould sets

Process testing/shape monitoring to validate functionality of mould and requirements on model blade will be met

The manufacture of 1 prototype per manufacturing process as proof of mould functionality

Reporting of routes for industrialisation and manufacturing of full-scale rotor blade

Assist in technology transfer to the consortium member such that they may manufacture the blades themselves


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GRC3Development and delivery of

Electromechanical Actuator for a light H/C

GRC3Development and delivery of

Electromechanical Actuator for a light H/C


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Sub-Project: GRC3 Integration of innovative electrical systems

Topic objectives: Develop and design the electromechanical actuator (EMA) with mechanical feet-beck system

Main features: The EMA will use the existing interfaces and attachments and it will replace the hydraulic actuators located on the main gearbox.

Topic: JTI-CS-2012-1-GRC-03-012Development and delivery of Electromechanical Actuator for a light H/C



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Main featuresGoals: Prototyping and delivery of Electromechanical Actuator for a light H/C

Inputs: Requirements including helicopter data

Work Plan:

T0: May 2012

T0+6 months EMA development (PDR) and first mock-up delivery

T0+10 months Final design of EMA (CDR)

T0+14 months Laboratory test results

T0+18 months Delivery of three prototypes

Topic Value: 650 000 €




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Competencies sought

• Good skill of EMA design• Knowledge about the EMA application on the aircraft.• Catia v.5 or NX6 abilities• Good knowledge in EMA software application (programming) • Good know-how on the EMA integration on the aircraft flight control

system• EMA manufacturing abilities• Electromechanical test facilities• Knowledge of the Civil Certification Rules and Certification activity




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GRC6Recycling of Metallic Materials from

Rotorcraft Transmissions

GRC6Recycling of Metallic Materials from

Rotorcraft Transmissions


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Recycling of Metallic Materials from Rotorcraft Transmissions

BACKGROUND

Helicopter power transmissions are critical to the operation of the aircraft and consist of a number of gear boxes which transmit power from the engines to the rotors via a series of shafts.

Transmission systems are primarily manufactured from metal alloys, high specification steel gears and casings of aluminium or magnesium alloys.

Performance of parts is enhanced by the use of various surface treatments including carburising or nitriding of steel working surfaces, hard metal plating (generally chromium or nickel), sprayed ceramic coatings and also polymeric coatings of various types.

Transmission components have a finite life after which they must be withdrawn from service and disposed of.


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RECYCLING

Out of life components cannot be returned to service and must therefore be returned to the raw material market.

The method for this must be;

energy efficient

generate a minimum of environmentally sensitive waste product

be capable of removing surface treatments cleanly with the minimum of waste product.

produce recycled materials of a quality acceptable for reuse by the general market without build up of contaminant elements.

avoid the use or generation of substances listed in REACH candidate lists


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SCOPE OF WORK

The aim of this proposal is apply modern recycling methods to aerospace materials and processes commonly found in helicopter gearboxes in a cost effective and environmentally sensitive manner.

GRC 6 partners will provide details of demonstrator components and assemblies and also trial components as appropriate.

The partner/consortium shall;

Apply recycling methods to the demonstrators of each ITD manager and provide detailed analysis.

Provide expert knowledge of recycling, have access to facilities to apply this knowledge and have the ability to measure the cost and efficiency of the processes selected.


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TIMESCALES AND DELIVERABLES

Deliverable Description Due DateD1 Survey of gearbox components and suitability for recycling methods. To +3

Months

D2 Detailed description of the dismantling methodology with several steps :1 - Separate the different parts2 - Remove the surface treatment3 - Recycling the materials (with minimized energy consumption)

To +6 Months

D3 Application of the dismantling methodology To +9 Months

D4 Evaluate the cost-effectiveness (operation cost and re-use percentage)

To +12 Months

Topic Value to be € 200,000


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GRC6Disassembly of eco-designed helicopter

demonstrators

GRC6Disassembly of eco-designed helicopter

demonstrators


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GRC-06-003Background

The current design of structural airframe parts in thermoset based composites makes it difficult to disassemble components in an ecological manner. Many parts are simply scrapped or burnt. To prolong the life of a rotorcraft airframe, it is for example, desired that specific components can be reused after disassembly.

Proposed solutionThermoplastic composites offer many ecological advantages over thermoset

based composites, such as recyclability, longer storage life, fewer additives, etc. Therefore within GRC6, rotorcraft airframe parts made out of thermoplastic composites are being demonstrated.In addition, by using thermoplastic composites for structural components a new ecological way of disassembly can be made feasible by localised melting and(re-)joining.

GoalHence, the goal of this Call is to investigate and evaluate different technology

concepts for separation of thermoplastic composite demonstrator components, such that they can thereafter be recycled or reused


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ScopeScope of work:The applicant is responsible for the following tasks:•Collect and assess possible component separation technologies and scenarios for particular helicopter structures based on thermoplastic composite materials and junctions, leading to preferred scenarios. •Investigate the quality of the separated components, to assess the component and waste quality, such that input for a ‘waste’ or ‘second-hand component’ catalogue can be made available.•Investigate the design influence on the solutions for component separation, and provide design recommendations.•Demonstrate and define with the cooperating companies a component separation plan and carry out demonstration activities for the most meaningful separation processes (demonstrator parts will partly be provided by industrial partner)•Collect and provide input for the Life Cycle Assessment tool.


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Requested skillsSpecial skills, certification or equipment expected from the applicantTo fulfil the scope of this Call, the applicant (single organisation or a consortium) shall include research laboratories, institutes and/ or companies having the following facilities and knowledge:•Strong knowledge on aerospace materials (CFRP with thermoplastic as well as thermoset matrices)•Extensive experience and capabilities for joining and disassembly of thermoplastic composite components and their joints.•Experience and capabilities for collecting data that serve as input for a life cycle assessment tool

Total Budget:200.000 €Duration: 18 months


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SummaryGoal:•Disassembly: separation of structural thermoplastic composite airframe components

• Extraction of thermoplastic composite parts• Presentation of possible end-of-life scenarios, including the proposed

disassembly technology

Steps:•Investigations and demonstration of technologies for disassembly•Verifying environmental aspects, cost analysis•Supply of quantitative input for LCA

Applications:

Door and floor section

Tailboom and other structural parts


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For further information:

[email protected]

Contact us


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© 2010 by the CleanSky Leading Partners: Airbus, AgustaWestland, Alenia Aeronautica, Dassault Aviation, EADS-CASA, Eurocopter, Fraunhofer Institute, Liebherr Aerospace, Rolls-Royce, Saab AB, Safran Thales and the European Commission.

Permission to copy, store electronically, or disseminate this presentation is hereby granted freely provided the source is recognized. No rights to modify the presentation are granted.

Documents

Call info day - Welcome to the Clean Sky | Clean Sky 1 Clean Sky –Info day/ 29th February 2012 in Madrid (SP) Call info day Sébastien DUBOIS, Project Officer (rotorcraft) Green