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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
Innovation Takes Off
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
Inve
stig
ate
adva
nce
d e
ngi
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inte
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& n
ove
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plin
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flex
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use
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, &
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uct
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Smar
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co
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surf
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& lo
ad &
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tter
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Pass
enge
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in;
ergo
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lexi
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, new
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ectu
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om
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lless
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d
fuse
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fo
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Tran
sve
rse
En
ablin
g C
apab
ility
Focu
sed
Inte
grat
ed
D
em
on
stra
tio
ns
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
Integration Profile Development Integrated
Concept demonstrat°
prototype airframe componts
Inte
rfac
ing
& c
ross
in
tera
ctio
n m
anag
emen
t
Novel innovation
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
Innovative Aircraft Architecture
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
Progress path versus State-of-the-Art enabled through Clean Sky 2
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
Progress path versus State-of-the-Art enabled through Clean Sky 2
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
TS3 – High level WP Scope
Progress path versus State-of-the-Art enabled through Clean Sky 2
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
Level 2 WP Technology Key demonstration vehicle / path
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
TS4 – High level WP Scope
Progress path versus State-of-the-Art enabled through Clean Sky 2
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
Level 2 WP Technology Key demonstration vehicle / path
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
TS5 – High level WP Scope
High Versatility & Cost Efficiency
Innovative Aircraft Architecture
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)
Level 2 WP Technology Key demonstrator vehicle
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)
Level 2 WP Technology Key demonstrator vehicle
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
Level 2 WP Technology Key demonstrator vehicle
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)
Level 2 WP Technology Key demonstrator vehicle
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
Level 2 WP Technology Key demonstrator vehicle
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)
Level 2 WP Technology Key demonstrator vehicle
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)
Level 2 WP Technology Key demonstrator vehicle
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)
Level 2 WP Technology Key demonstrator vehicle
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
Level 2 WP Technology Key demonstrator vehicle
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)
Level 2 WP Technology Key demonstrator vehicle
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)
Level 2 WP Technology Key demonstrator vehicle
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
Innovation Takes Off
Thank you for your attention !