Green RotorCraft ITD Closing event - Clean Sky · Green RotorCraft ITD Closing event Bruxelles, March 22nd 2017 GRC ITD presentation Innovation takes off Closing of Clean Sky 1 -

Green RotorCraft ITD Closing event

Bruxelles, March 22nd 2017

GRC ITD presentation

Innovation takes off

Closing of Clean Sky 1 - Wednesday 22 March

The Green Rotorcraft ITD gathers and structures all activities specifically concerned with the integration of technologies and demonstration on rotorcraft platforms (helicopters, tilt-rotor) which cannot be performed in platform-generic ITDs.

There are however technical links with activities conducted within the EcoDesign ITD, the Sustainable Green Engines ITD, the Systems for Green Operations ITD and with the Technology Evaluator.

With the goal to contribute to the overall objective of coming back within 20 years to the present global level of environmental impact while sustaining the expected growth of rotorcraft services, the Clean Sky initiative aims to reduce by half before year 2020, the specific impact of rotorcraft operations on the environment.

In detail, taking into account year 2000 as baseline, the objectives of the GRC ITD and concurrent activities in other Clean Sky ITDs were:

• reduce CO2 emissions by 26-40% and NOx emissions by 53-65%, according to vehicle and technologies used

• reduce average noise level by 10 dB

Position of GRC within the CS initiative


Main results, potential impact and contribution to CS

objectives – overview at start project


GRC ITD Consortium – A truly European Program


5 members, 18 associates, 68 partners in 17 countries

In order to achieve the global objectives, the project developed a new high compression power plant, innovative rotor blades, new aircraft configurations and Flight Paths Management.

The project is organized along six technological streams dedicated to key topics and one stream dedicated to technology evaluation:

(GRC1) Innovative rotor blades

(GRC 2) Drag reduction of airframe and non lifting rotating systems

(GRC3) Integration of Innovative Electrical Systems for Rotorcraft

(GRC4) Installation of a high compression engine on a light helicopter

(GRC 5) Environment friendly flight paths

(GRC6) Eco-design demonstrator (rotorcraft)

(GRC7) Technology evaluator for rotorcraft

The project includes also a management subproject (GRC0): it was jointly coordinated by LEONARDO SpA (ex Finmeccanica SpA, AgustaWestland) and Airbus Helicopters (AH).

Technical activities took place from July 1st, 2008 until December 31st, 2016

Initial objectives, long term vision and challenges


Work plan structure


Technology and impact results

GRC1

GRC3

GRC4

GRC6

GRC7

GRC2

GRC5

CO2 and NOx Reduction of Emission / Reduction of Fuel Consuption

Noise Reduction

REACH Compliance

Drag Reduction


8

GRC1: Innovative rotor blades Active Gurney Flap - Improved performance of highly loaded rotor

Aim - Identify technologies/methods to:

• Reduce rotor power consumption =>

Reduce CO2 /NOx

• Reduce audible signature

First “Ground Run” accomplished in Dec 2016

9

GRC1: Innovative rotor blades

INBOARD ACTIVE REGION

OUTBOARD ACTIVE REGION

Active Gurney Flap cross section

Active Trailing Edge donor blade

Cont.: Active Gurney Flap (Clean Sky GRC1) to provide rotor performance

enhancements (3-5%)

10

GRC1: Innovative rotor blades Innovative Rotors: Active Gurney Flap

Four stages programme

with Multiple Members

and Partners

Stage Members GAPs & Partners

Model Rotor ACCUBLADE, GUM AGF, COMROTAG

2D “Steady-State” aerodynamic test

PT656

2D “Oscillatory” aerodynamic test

DEMOS COMROTAG

Aircraft Demonstration

11

GRC1 - Innovative rotor blades GAP Results

Wind Tunnel model Rotor test

Confirmed AGF

capabilities

2D “Steady-State”

aerodynamic test

Gathered

2D Aerodynamic data

(tools development)

2D “Oscillatory”

aerodynamic test

Gathered

Performance data

12

GRC1 - Innovative rotor blades

Flight test

• Demonstrates safe operation

• Further flight test activities to follow

First “Ground Run” accomplished in Dec 2016

GRC 1.mp4

13

GRC2: Drag reduction of airframe and non lifting

rotating systems

Objective: Drag reduction of the rotor head and fuselage

HEAVY HELICOPTERS (AW101) • AW101 Optimized Main rotor hub

• AW101 Tail

• AW101 Rear fuselage drag reduction • Pulsed Jets

• Vortex generators

• AW101 Air intake drag reduction and engine installation

design optimization (GAP: HEAVYcOPTer)


TILT ROTOR (ERICA PLATFORM) • Drag reduction of a TILT-ROTOR fuselage, engine intake

and lift over drag increase of its wing and empennages

TEM (TWIN ENGINE MEDIUM HELICOPTERS - AW169) • AW169 Main rotor hub beanie optimization

14

HEAVY HELICOPTERS (AW101)


rotating systems

Baseline Optimized

Optimized AW101 Main rotor hub

AW101 Tail


15

flight tests on AW169 of the optimized hub beanie

Computational Fluid Dynamic

LIGHT TWIN HELICOPTERS


rotating systems


16

Tilt Rotor Erica wind tunnel tests

Objectives: drag reduction of a tilt-rotor fuselage and

lift over drag increase of its wing and empennages

TILT ROTOR


rotating systems

Particle Image

Velocimetry (PIV)


17

GRC 3: Integration of Innovative Electrical

Systems for Rotorcraft

Key benefits:

o Improve MTBF

o Permit rpm variation for power

saving in cruise and heading control

o Excellent power surge

o Reduced parts

o Reduced maintenance overhaul

target

GRC3 is focused on:

• Techniques for energy recovery

• Energy management

• Optimization of power generation and distribution (incl.power losses)

• Electrical technologies (power converter and energy storage for improved electrical system efficiency)

• Electric Tail Rotor (providing innovative concepts allowing better tail rotor power management)

Initial Ground Test accomplished in Dec 2016

Test Campaign is continuing in 2017

Key features:

o Tail rotor direct drive (no

gearboxes, no shafts, no joints)

o Air cooling (no liquid - oil

lubrication)

o High redundancy through

multiple machine winding (4X)

o Continuous variable speed

control

Electric Tail Rotor Drive


GRC 3.mp4

18

GRC3: Integration of Innovative Electrical Systems

for Rotorcraft - Main Contribution from GAPs

ELETAD led by

Technology: Electric Tail Rotor

Contributing Benefits:

System active weight optimised, proving technology in aircraft configurations (tail demonstration rig). Fault tolerance, Reliability, Safety, Maintainability, Non Hydraulic, Adaptable Design Concepts.

REGENESYS led by

Technology: DC High Voltage Power Converter, Control & Storage


System weight advantages, High voltage distribution, Multi use, Enables use of regenerative power sources. Reliability, Safety, Adaptability.

Technology: Regenerative Electrical Rotor Brake and Generator


System weight advantages, Multi use, Regeneration, Reliability, Safety, Maintainability, Non Hydraulic, Adaptability of control and use a brake and generator.

HERRB led by


19

GRC 5: Environment friendly flight paths

Objectives Key advancement Innovation

Demonstration of low-noise

VFR/IFR procedures for

helicopters and tiltrotors

Design and demo of procedures

• applicable in real operations

• validated noise abatement

Combination of available

acoustic numerical tools,

realistic operational constraints

and optimization algorithms

Demonstration of

guidance/monitoring systems for

low-noise procedures

Improvement of cues and reduction

of workload for pilots in flying

complex low-noise flight profiles

Integration (e.g. into the on-

board systems) and validation

in flight of suitable hardware

and software

Reduction of exhaust pollutants

Development and experimental

validation of computational tools for

engine gas emission prediction.

Fully predictive approach for

the emission estimation from

helicopter engines.

Innovation and Achievements


20

GRC 5: Environment friendly flight paths

Rotorcraft flight path optimization to minimize

noise & pollutant emissions


Integration of Flight

Management System

software models into

Leonardo simulator for

VFR real-time mission

guidance demonstration

Noise Abatement

Stee

pe

r

An

gle o

f ap

pro

ach

effect

Helicopter VFR & IFR Flight procedures developed

and validated through flight testing

Real-time mission guidance tool, including route

re-planning & display

TiltRotor - Air Traffic Management System coupled

simulations

Sequence 02.mp4

21

GRC 5: Environment friendly flight paths GAPs Contribution

Project

Acronym Leader Technology Result

EMICOPTER Development of computational

tools for engine gas emission

prediction

Fully predictive approach for the emission

estimation from helicopter engines.

Validation of the proposed approach against

experimental data in different engine operating

conditions (idle, take-off, cruise)

MAEMRO Development of methodology for

helicopter flue gas measurements

and flight measurement campaign

Measurements of pollutant concentrations in

exhaust gas have been carried out in different

ground and flight conditions

ANCORA Preliminary acoustic flight tests for

the tuning of simplified rotorcraft

noise models

Demonstration of the methodology to improve

the acoustic testing. Demonstration of

capability and advantages of the surface

microphones for on-board acquisition

TRAVEL Integrated ATC/TR simulation of

low-noise procedures for impact

evaluation on operators

Piloted sim demo of insertion of a tiltrotor in a

congested and complex air traffic scenario,

successfully achieved

MANOEUVRES

Innovative measurement and

monitoring system for accurate on-

board acoustic predictions during

rotorcraft approaches and

departures

Acoustic prediction; pilot acoustic indicator

development and PITL demo. Flapping

measurement system development; Integration

of measurements system on AW139.


22

GRC 5 Contribution from GAPs – one example

MANOEUVRES - Manoeuvring Noise Evaluation Using Validated Rotor State Estimation Systems

Goal: exploit Rotorcraft agility to perform VFR flight procedures with Real-Time Noise Footprint control

Pre-calculated helicopter noise database

(Validated through Flight Campaign)

Innovative Main Rotor Blade

contactless flapping sensor,

essential for real-time noise

estimation

(TRL6 – Flight Tested)

Pilot Acoustic Indicator display

(Validated through Flight Simulator

Tests)


23

GRC 5

Interaction with other project

ITD / TE Description of interaction Outputs / Results

GRC7/TE

Support to most of GRC7/TE technical

activities related to the acoustic analysis

and prediction

Production of acoustic data and low-

noise procedures for GRC7/TE generic

models, with benefits aligned to GRC5

demonstrations

Program Description of interaction Outputs / Results

SESAR, EASA, ATM stakeholders

GRC5 produced SESAR-compliant

simulation and flight test results relevant

to the demonstration of advanced GNSS-

based Instrument Flight Procedures, like

LPV steep approaches and Point-in-Space

procedures

Some GRC5 material shared, GARDEN-

CARE user forum organized,

demonstration by simulation of tiltrotor

IFR approach procedures to Milano

Malpensa airport with actual Air Traffic

Controllers involved

Operators Involvement of operators in final demo

definition and execution

Application of GRC5 low-noise VFR

trajectories to operators’ flight

procedures


24

GRC 6: Eco design demonstrators

COMPOSITE THERMOPLASTIC TAIL BOOM

Design

• Generic tail cone (compatible with AW169 aircraft) w/o

sandwich elements

Technologies

• Composite Thermoplastic panels

• Autoclave formed Skin (T=380 °C, P=7 Bar)

• Continuous compression moulding of Stringers

• Compression moulding of Frames

• Induction welding of Stringers to Skin

Tail cone demonstrator chosen as one of the most appropriate

“primary” structure to test new/novel technologies in lieu of

conventional ones (metallic or composite thermosetting)

Tail boom structural testing

accomplished


25

GRC 6

THERMOPLASTIC ROOF PANEL

Roof panel chosen to test material/technology appropriateness for

hot environment resistance of “secondary” structures

Design

• Light weight thermoplastic roof panel to fit

AW139, resistant to hot gas arising near

exhaust area.

Technologies

• Composite Thermoplastic panels

• Press moulded stringers

• Autoclave stringer + semipreg Co-Melt

process of Component (T=380 °C, P=7 Bar):

“one shot process”

Roof Panel Qualification tests began late 2016

Endurance flight tests are in progress


GRC6.mp4

26

GRC 6 : Eco design demonstrators / TGB

Green Surface Treatments, developed in EcoDesign ITD, applied on TGB

Support of Aluminium alloy with sulphuric anodising

Input Pinion: carburizing steel

with alkaline Zn-Ni

Tail Rotor Shaft: nitriding steel

with alkaline Zn-Ni

Case & Cover: Magnesium alloy with

“microarc” and “polimeric coatings”

TRL5 assessment accomplished on May 2016 Closing of Clean Sky 1 - Wednesday 22 March

Cadmium coatings

Crome exavalent

(anodising & coatings)

27

Main Objective: Development of technology & design for

GRC demonstrators

Main Outcome: Compression Moulding and Induction

welding solutions developed; EcoFair

design demonstrated

Sponson

GRC 6 : Eco-Design Demonstrators GAPs contribution

ECOFAIRs (GAP) led by………


Tooling for

sponson

28

Final Results simulation from Final Review

Rotorcraft

Class Version

Selected TE

Mission

Emission Reduction Target and Achieved at ATS Level

CO2 NOx

Noise Contour Area Reduction – Low Noise Procedure

(SEL dB(A))

Targets Results Targets Results Targets Results

Single Engine

Light [8] SEL_U2 Passenger

-10 to -25%

-21% -50 to -65%

-62 % -50% Reduction>60%

reached for noise levels > 85 dB

Twin Engine

Light [12] TEL_U2 EMS & Law

-25 to -40%

-13% -30 to -50%

-42% -50% Reduction >55%

reached for noise levels > 85 dB

Twin Engine

Medium [9] TEM_U1 SAR & Fire

-15 to -30%

-11% -55 to -70%

-42% -50% Reduction >50%

reached for noise level > 85 dB

Twin Engine

Heavy [13] TEH_U1 Oil & Gas

-15 to -35%

-21% -55 to -70%

-55% N/A N/A

High Compression Engine [10]

HCE_U1 Passenger,

Police & Training

to -40%

-67% per km flown*

to -65%

-68% per km flown*

N/A N/A

*comparison carried out against SEL_U2 Y2000R at mission level

Estimated as fully achieved

Estimated as partially achieved

GRC 7


GRC Dissemination: more than 200 Events

Main events

ERFs Clean Sky Conference & Exhibition

EU Aero Days AHS International Annual Forum &Technology Display

EASA Annual Helicopter Symposium

International Congress on Sound & Vibration

International Conference on Composites Materials

EASN WORKSHOP On Flight Physics And Propulsion

CFP Info Day IEEE International Conference on Industrial Technology

AAAF/AIAA Aircraft Noise and Emissions Reduction Symposium

EuroGNC Specialist Conference on Guidance, Navigation and Control

Years Number of

Actions (papers, articles, ..)

2008 2

2009 5

2010 12

2011 29

2012 28

2013 28

2014 47

2015 51

2016 26

TOTAL 228


Thanks for your attention

Innovation takes off

Many thanks to:

•CleanSky JU … for funding and support

•CleanSky partners … for all the help

•GAP partners …. for all the help


© 2017 by the CleanSky JU / Green Rotorcraft ITD (GRC) Members: Leonardo SpA (Ex AgustaWestland

Spa, Ex Finmeccanica Helicopter Division), Leonardo MV Ltd (ex AgustaWestland Ltd), Airbus Helicopters

(ex Eurocopter), Liebherr-Aerospace, Safran Electrical and Power (ex Hispano-Suiza and ex Labinal P.S.),

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, 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


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Green RotorCraft ITD Closing event - Clean Sky · Green RotorCraft ITD Closing event Bruxelles, March 22nd 2017 GRC ITD presentation Innovation takes off Closing of Clean Sky 1 -