GRC ITD TOPICS FOR CFP#12 - Clean · PDF fileOptimised helicopter fuselage design provided by GRC consortium Existing reference model components and ... inside a simulated aircraft

1

1

Clean Sky Info Day on 7th call for proposals, 11 October 2010, Brussels

GRC ITD TOPICS FOR CFP#12

Giornata ACARE Italia

Torino, 17th May 2012

2

2

GRC0: Management

GRC1:

Innovative

Rotor Blades

GRC3:

Integration of

Innovative

Electrical

Systems

GRC4:

Installation of a

Diesel Engine

on a Light

Helicopter

GRC5:

Environment-

Friendly Flight

Paths

EcoDesign for

Airframe

EcoDesign for

Systems

SGO / Energy

Management

Technology

Evaluator

GRC6:

EcoDesign

Demonstrators

(Rotorcraft )

GRC7: Preparation of T.E.

for Rotorcraft

GRC2:

Reduced Drag

of Airframe &

Dynamic

Systems

Engines /

SAGE 5

Technology Developments & Demonstrations

Contribution from/to

transversal ITDs

Green RotorCraft ITD - Giornata ACARE Italia – GRC Topics for CFP#12, 17th May 2012 Torino

Green RotorCraft ITD: Top Level WBS

3

3

GRC - List of topics for CFP#12

5 topics split in 4 sub-projects

GRC1: Innovative Rotor Blades

Low weight, high energy efficient tooling for rotor blade manufacturing 710 k€

GRC2: Drag Reduction of Airframes and DynamicSystems

Wind tunnel tests on a common helicopter platform and contribution to its optimised aerodynamic design 800 k€

GRC3: Innovative Electrical Systems

Design and Implementation of a Load Simulator Rig and Ground Test Bench Adaptation Kit for a HEMAS Test Rig 1000 k€

GRC5: Environment-friendly Flight Paths

Sensoring and cockpit monitoring to reduce noise in manoeuvring flight 1500 k€

Curved SBAS-guided IFR procedures for low noise rotorcraft operations 580 k€


4

4

GRC1

Low weight, high energy efficient tooling for rotor blade manufacturing


5

5

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers

Low weight, high energy efficient tooling for

rotor blade manufacturing

Status manufacturing of helicopter rotor blades with composite materials use

currently metallic moulds with self heated technology or external heating by heat presses or ovens

the mould weight for a light helicopter (~5,0 meters long) is likely above 5tons Curing temperature is, for rotor blades, above 135°C High energy consumption and poor handling capabilities

Path Change to new manufacturing processes (e. g. preforming and liquid

composite moulding, LCM) Use of innovative, energy efficient and light toolings for preforming and

injection with short turnaround times in industrial manufacturing


6

6

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers

Objective Find new and innovative tooling for helicopter rotor blades manufacturing with

composite materials based on low energy and green aspects

Steps that should be performed by the applicant

Develop, design and manufacture of preform- and curing tools

Light and easy to handle Easy to heat up and cool down > short cycle times Less energy consumption / heat exchange device Heat up range up to 135°C curing or activation temperature Homogenous heat transfer and distribution Stiff and closed mould for injection (up to 3bar) Applicable to use with special impregnation technologies (e.g. LCM) Light, one sided, fast heatable preform tools




7

7

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers

Skills and capabilities required from the applicant (single organisation or consortium)

Knowledge to develop, design and manufacture new tooling concepts with respect to green aspects

Heat and energy management for toolings Able to collect LCA-data

As we intend to take a new approach regarding tooling design and manufacturing we are open to any proposal. A specific certification for aerospace and airworthiness items is not required from the possible applicants. Rotor blade manufacturing process details (e.g. position of injection line, preform technology,…) will be defined by topic manager.




8

8

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers

Project duration:

18months (January 2013 – June 2014)

Maximum Total Cost:

€ 710.000




9

9

GRC2

Wind tunnel tests on a common helicopter platform and contribution to its optimised

aerodynamic design


10

10

Wind tunnel tests on a

common helicopter platform

Title: Wind tunnel tests on a common helicopter platform and contribution to its optimized aerodynamic design

Expected start date : January 2013

Duration : 30 months


11

11

Objectives:

o Support of GRC consortium in benefit assessment process for a heavy-weight class H/C by:

Wind-tunnel tests of a reference helicopter fuselage

Wind-tunnel tests of optimised design of several

elements of the common helicopter fuselage

o The work comprises:

Design and manufacturing of some model components

Wind tunnel test preparation, execution and results post-processing

Background :

Optimised helicopter fuselage design provided by GRC consortium

Existing reference model components and wind-tunnel test results

Tasks :

Task 1 - Preparation of the Original and Optimised Models

Task 2 - Wind-Tunnel Tests on the Original and Optimised Configurations

Task 3 - CFD Analysis (optional) to address mount effects on fuselage aerodynamics

Reference fuselage


Wind tunnel tests on a common helicopter platform

Scope

12

12


Expected activities (1/3)

Task 1: Preparation of the Original and Optimised Models

Manufacture additional components for the reference configuration

Sponsons, hub cap, blade stubs.

Manufacture optimised components

to be finalised during the numerical optimisation phase

Instrumentation of reference and optimised components


13

13

Task 2: Wind-Tunnel Tests on the Original and Optimised Configurations

Perform wind-tunnel tests of the reference fuselage

Perform wind-tunnel tests of the optimised fuselage

Two set-up configurations

Strut configuration: for rotor head investigations (with/without rotation)

Upside down configuration: for fuselage backdoor ramp investigations

Main wind-tunnel requirements

Model size: L=4.097m, Sfrontral=0.55m²

Wind-tunnel speed > 40 m/s

fuselage angle of attack from -20° to +20°

rotating rotor-hub using suitable driving system (around 1000rpm expected) and monitoring system

Expected measurements

Global forces

Surface static pressure (~ 300 taps)

Surface unsteady pressure (~ 20 transducers)




14

14

Task 3: CFD Analysis (optional)

Numerical assessment of the drag reduction of the optimised design

Investigation of wind-tunnels effect (strut, walls)

Numerical/experimental correlations




15

15

Qualified and demonstrated skills in WT testing (appreciated previous experience in WT testing on helicopter configurations)

Wind Tunnel: wind speeds at least 40 m/s fuselage angle of attack from -20° to +20° (both mount systems) fuselage angle of side-slip from -20° to +20° (both mount systems) rotating rotor-hub using suitable driving system

Measurement capabilities global loads through an internal or external balance, all six components surface static pressures (~300 pressure taps in a full configuration) surface unsteady pressures (~20 unsteady pressure transducers in a full

configuration)

If the applicant offers CFD work in task 3, the following skills are encouraged mandatory

CFD code solving the RANS equations Optional

CFD code solving the URANS equations Moving body capabilities for rotating rotor head



Skills and capabilities required

16

16

Expected planning, assuming (T0 at Jan. 2013)

Budget: 800 kEuros,

Expected start date : January 2013; Duration : 30 months

Evaluation: Detailed break-down for Tasks 1&2 recommended

Contractual aspects: Selected partner will be offered to enter the GRC consortium

N° Task Nr. Task Name

1 1 W T Test of the original geometry

2 1.1 Input01: CATIA file of the original model delivered to the Partner

3 1.2 Manufacturing of new elements

4 1.3 Input02 & Input03: Existing model delivered to the Partner

5 1.4 Model adjustment

6 1.5 Input05: Specifications for the original configuration wind-tunnel tests

7 1.6 Wind tunnel test of the original configuration

8 1.7 Data analysis

9 1.8 Input04: CATIA file of the optimised model delivered to the Partner

10 1.9 Manufacturing of the optimised components

11 1.10 Input06: Specifications for the optimised configuration wind-tunnel tests

12 1.11 Wind tunnel test of the optimised configuration

13 1.12 Data analysis and synthesis

14 2 CFD computations

15 2.1 Original configuration

16 2.2 Optimised configuration

17 2.3 Comparison with WT data and synthesis

03/01

03/01

03/12

Sep Nov Jan Mar Mai Jul Sep Nov Jan Mar Mai Jul Sep Nov Jan Mar Mai Jul Sep2012 2013 2014 2015



Planning and budget

17

17

GRC3

Design and Implementation of a Load Simulator Rig and Ground Test Bench Adaptation Kit for a HEMAS Test Rig


18

18

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers

Design and Implementation of a Load Simulator Rig and Ground

Test Bench Adaptation Kit for a HEMAS Test Rig (1/4)

Topic background and rationale:

Electromechanic actuation is slowly replacing the hydraulic actuation

systems throughout the aviation industry.

To build a testing system composed by HEMAS for the simulation of main

rotor loads.

Test the HEMAS system inside a simulated aircraft architecture.

Related GRC3 objective: To develop a complete Adaptation Kit in order to

integrate the HEMAS equipment batch inside a simulated aircraft architecture .


19

19

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers

Summary task description:

Design, manufacturing and acceptance on site of a complete Adaptation Kit in

order to integrate the HEMAS equipment batch inside a simulated ground

aircraft architecture (ETB).

Commissioning and initial operation of the Adaptation Kit on two different

locations (Central Europe and Electrical Test Bench).

Support the rig operations to correct potential faults during the Clean Sky

Program Development.




20

20

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers

Background material & Information exchange:

Electrical test bench and electromechanic actuation specifications.

Information exchange with conventional tools and planned technical meetings.

Skills and capabilities required from the applicant: Experience in actuation test benches design, manufacture and installation is

an asset.




21

21

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers

Project duration:

24 months (Jan. 2013 – Dec. 2014).

Maximum Total Cost:

€ 1.000.000




22

22

GRC5

Sensoring and cockpit monitoring to reduce noise in manoeuvring flight


23

23

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers

Development and Test of Novel Rotor Measurement Systems to

Estimate Manoeuvring Noise During Rotorcraft Approaches and

Departures (1/4)

Related GRC-5 objective: To develop innovative on-board systems allowing pilot to minimise noise annoyance during rotorcraft approaches and departures

Topic background and rationale: Helicopter noise depends on rotor speed, thrust and angle of attack (AOA) For in-flight noise monitoring, future systems will relay on crude estimates

of these quantities, as they are hard to measure accurately Inaccuracies are relevant in manoeuvring flight, when for instance rotor is

flapping (change of AOA) to decelerate the vehicle and actual thrust is hundreds of kilograms different from weight or other estimates

Manoeuvring flight is typical during rotorcraft approaches and departures

Need of innovative measurement systems to monitoring rotor state in-flight and accurately estimating rotorcraft radiated noise


24

24

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers

Summary task description: Review of current and future technologies for rotor force and blade angle

measurement (D1) Definition of requirements of a Pilot Acoustic Indicator display to monitor

radiated noise (D2) Preliminary Design Review of measurement system, reporting design and

development activity (D3) Validation against flight data of CFD tools to predict noise in manoeuvring

flight (D4) Design and Implementation of Pilot Acoustic Indicator (D5) Critical Design Review of measurement system, reporting experimental

activity (D6) Application of unsteady noise prediction tool to study the effect of

perturbations on low-noise procedures (D7) Final demonstration of measurement system and pilot indicator (D8)

Development and Test of Novel Rotor Measurement Systems to

Estimate Manoeuvring Noise During Rotorcraft Approaches and

Departures (2/4)


25

25

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers


Suitable flight data for validation of tools and design of experiments

Vehicle system detailed design data, as required by the activity

Relevant material on rotor measurement systems

Skills and capabilities required from the applicant: Unsteady rotor noise prediction

Design, development and test of measurement systems

Airborne display systems

Experimental lab for structural and fatigue tests on the measurement system

Capability to comply with CS 27/29, MIL -810/RTCA DO-160, RTCA DO-254

GRC-05-006: Development and Test of Novel Rotor Measurement Systems to Estimate Manoeuvring Noise During Rotorcraft Approaches

and Departures (3/4)


26

26

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers

Project duration:

24 months (Jan 2013 – Dec 2014)

Maximum Total Cost:

€ 1.500.000

GRC-05-006: Development and Test of Novel Rotor Measurement Systems to Estimate Manoeuvring Noise During Rotorcraft Approaches

and Departures (4/4)


27

27

GRC5

Curved SBAS-guided IFR procedures for low noise rotorcraft operations


28

28

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers

GRC-05-007: Curved SBAS-guided IFR procedures for low noise rotorcraft operations (1/5)

Related GRC-5 objective: To develop and test new rotorcraft-specific flight procedures to minimise noise impact in approaches and departures

Topic background and rationale:

Curved flight paths allow to avoid overfly of noise sensitive areas

For IFR procedures, curved flight paths shall be designed in compliance with RNP-AR ICAO specification

Current RNP-AR specification relies on barometric vertical guidance which is not suited for precise flight path optimisation in the vertical plane

SBAS (EGNOS in Europe) is the best guidance mean to optimise flight paths for noise reduction, both in the horizontal and vertical plane

Need to define and assess new types of curved IFR procedures relying on SBAS guidance to minimise noise impact


29

29

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers


Summary task description:

Review and analysis of ICAO design criteria for curved segments (D1)

Assessment of SBAS guidance benefits for curved segments (D2)

Definition of design criteria for curved segments under SBAS guidance with or without transition to LPV in last part of final approach (D4, D3)

Adaptation of proposed design criteria to Point-in-Space procedures ((D5)

Comparison of benefits / constraints of the different solutions for curved IFR rotorcraft procedures (D6)

Safety study for a generic curved Point-in-Space (PinS) procedure (D7)

Detailed design and implementation of a PinS SBAS-guided curved helicopter approach to an heliport (D8)

Dissemination and organisation of a User Forum (D9)


30

30

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers



ICAO PBN and related navigation specifications (RNPx, RNP-AR)

Information exchanges with GARDEN (currently running CleanSky project)

Skills and capabilities required from the applicant: Full knowledge of ICAO air navigation regulations (PanOps, PBN manual, RNPx

and RNP-AR specifications) and foreseen evolutions

Detailed analysis of ICAO procedure design criteria:

Understanding of existing criteria and ability to propose new ones

Satellite navigation, in particular SBAS

Detailed design, charting and safety analysis of IFR procedures, in particular RNP-AR procedures including curved segments


31

31

© 2

01

2 –

CS

JU

/GR

C-I

TD

Me

mb

ers


Project duration:

24 months (Dec. 2012 – Nov. 2014)

Maximum Total Cost:

580 000 €


32

32

For further information:

[email protected]

www.cleansky.eu

Contact us


http://www.cleansky.eu/

33

33


BACK-UP SLIDES

34

34

GRC0: Management

GRC1:

Innovative

Rotor Blades

GRC3:

Integration of

Innovative

Electrical

Systems

GRC4:

Installation of a

Diesel Engine

on a Light

Helicopter

GRC5:

Environment-

Friendly Flight

Paths

EcoDesign for

Airframe

EcoDesign for

Systems

SGO / Energy

Management

Technology

Evaluator

GRC6:

EcoDesign

Demonstrators

(Rotorcraft )

GRC7: Preparation of T.E.

for Rotorcraft

GRC2:

Reduced Drag

of Airframe &

Dynamic

Systems

Engines /

SAGE 5

Technology Developments & Demonstrations

Contribution from/to

transversal ITDs


GRC: Top Level WBS

35

35


1. Innovative Rotor Blades

Active and passive technologies to reduce rotor power consumption and acoustic signature

2. Drag Reduction of Airframes and DynamicSystems

Passive and active flow controls for helicopter and tiltorotor components

Efficiency improvement (pressure losses) and noise emission reduction of engine intake

3. Innovative Electrical Systems

Replacement of hydraulic systems on rotorcraft by electrically-powered systems

Reduction of carbon emissions and improved electrical power system efficiency.

4. Diesel Engine

Integration of a Diesel engine on a light helicopter to reduce CO2 emissions.

5. Environment-Friendly Flight Paths

Noise abatement with optimized flight procedures in VFR & IFR including ATM constraints

Fuel consumption and pollutant emissions reduction through a mission profile optimization

6. EcoDesign

Exploitation of eco-friendly technologies to specific rotorcraft components

7. Technical Evaluator for Rotorcraft

Interface to Technology Evaluator for assessing actual impact of rotorcraft technologies

GRC: Technological objectives

36

36

Giornata ACARE Italia – GRC Topics for CFP#12, 17th May 2012 Torino

Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

GRC1 - Innovative Rotor Bades

TRL Progress

GRC2 - Drag Reduction

TRL Progress

GRC3 - Inn. Electrical Systems

TRL Progress

HEMAS for FCS & utilities

Helicopter Electrical Systems

Electrical Tail Rotor

GRC4 - Diesel Engine on a light H/C

TRL Progress

GRC5 - Environment Friendly Flight Paths

TRL Progress

GRC6 - Eco-Design for Helicopters

TRL Progress

H/C design, test and validation

Passive Rotor Blade

Drag Reduction

(Hub & Fuselage)

Engine Installation

Engine Development

Active Rotor Blade

2014 2015 20162008 2009 2010 2011 2012 2013

Test & Evaluation

Technology Review

Full-scale blade design

Preliminary Design Detailed Design Ground Test

2 CoDR PDR CDR 4 5

Whirl Tower test

Ground test: full scale rotor blade

Design & manufacturing Whirl Tower test

Technology Review

Manufacturing

Preliminary Design Detailed Design Final TestsCoDR PDR CDR

sub-assembly design & validation (WTT)

3 6

Flight test (Hub)

WTT (fuselage)

Numerical aerodynamics optimization Design & manufacturing Flight test

H/C Requirements Equipments & Systems development /from SGO & ED) Ground Test

3 4SR

6

WTT

Test

Test

Test

(Copper Bird on EDS)

H/C pre-design, engine requirements Preliminary Design, detailed design, developmt. Ground Test

Engine Design Development

FlightTest

SR

2

2 3 CoDR PDRCDR 5 6

Test

Test

H/C adaptation design & development Test

<= depending on budget

Def.phase: flight rules analysis, requirement & tools Tools development for in-flight

environmental measures

Procedure & Guidance Systems Development

SR

2 3

PDR CDR

5 6

CoDR

Flight Test

Design

3PDR

Manufacturing Recycling

4CDR

3

2 4 5

5

2 5 6

GRC-ITD Demonstration schedule

37

37


GRC-ITD Environmental Goals

38

38


© 2012 by the CleanSky JU / Green Rotorcraft ITD (GRC) Members: AgustaWestland, Eurocopter,

Liebherr-Aerospace, Hispano-Suiza, Thales Avionics Electrical Systems, Wytwornia Sprzetu

Komunikacyjnego PZL Swidnik, Office National d'Etudes et de Recherches Aérospatiales, Deutsches

Zentrum für Luft- und Raumfahrt, Centro Italiano Ricerche Aerospaziali, SELEX Sistemi Integrati,

Airborne Composites, Alphei Pueschel Roesler - Akustik Technologie Goettingen, Eurocarbon, Fibre

Optic Sensors and Sensing Systems, LMS International, Microflown Technologies, Micromega Dynamics,

Stichting Nationaal Lucht- en Ruimtevaartlaboratorium, Technische Universiteit Delft, Universiteit

Twente,

All rights reserved. This presentation material is provided for information of parties/persons invited to

the meeting as indicated herewith. No information contained in this material may be disclosed to any

other party/person, nor reproduced in whole or in part, nor used without the prior written consent of

the specific GRC member(s) to which the information belong(s).

Clean Sky JU / Green RotorCraft ITD

Documents

GRC ITD TOPICS FOR CFP#12 - Clean · PDF fileOptimised helicopter fuselage design provided by GRC consortium Existing reference model components and ... inside a simulated aircraft