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This document is the property of one or more Parties to the Clean Sky 2 AIRFRAME ITD consortium and shall not be distributed or reproduced without their formal approval Clean Sky 2 SYSTEMS ITD Call for Proposals #6 Brussels, 22 nd February 2017

SYSTEMS ITD Call for Proposals #6 - Clean Sky (f)- SYS... · Objectives: The applicant has to ... The evaluation of those prototypes aims at demonstrating ... Analysis and trade-off

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Page 1: SYSTEMS ITD Call for Proposals #6 - Clean Sky (f)- SYS... · Objectives: The applicant has to ... The evaluation of those prototypes aims at demonstrating ... Analysis and trade-off

This document is the property of one or more Parties to the Clean Sky 2 AIRFRAME ITD consortium and shall not be distributed or reproduced without their formal approval

Clean Sky 2

SYSTEMS ITD Call for Proposals #6

Brussels, 22nd February 2017

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JTI-CS2-2017-CfP06-SYS-01-04 - Manufacturing process for ultimate performance inertial MEMS Accelerometer

▌Key information

Topic: Manufacturing Process for ultimate Performance

Inertial MEMS Accelerometer

Call: Call for Partners Wave 6

Duration: 2 years, starting Q3 2017

Indicative funding value : 1 500 K€

Context:

In the context of the Modular Advanced Inertial System Development, the introduction of Silicon

Very High Performances MEMS Accelerometers Technology is targeted. Based on an existing

design, the challenge of the topic is to develop an industrial Silicon MEMS manufacturing process to

meet the performances, reliability and reproducibility level required by inertial systems applications.

Objectives:

The applicant has to demonstrate the capability to produce prototype components in a

production relevant environment (MRL5). The evaluation of those prototypes aims at demonstrating

full accelerometer performances in relevant environment (TRL5).

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▌Main Challenges

Identify and master a high accuracy etching technology on SOI silicon substrate for

manufacturing of in-plane capacitive structure

Develop a technology with minimum build-in stress from dissimilar material; Ideally a fully

monocrystalline silicon solution is targeted (with a few silicon oxide layers admitted)

Materials and technology shall be compatible with extended temperature range : -

55/+105°C

Technology shall include wafer level packaging functions for chip connections and

assembly

Proposed solutions for MEMS manufacturing and packaging shall be compatible with

more than 30 years lifetime.

As targeted applications are Inertial Systems requiring very high safety and reliability

level, applicant shall be able to deliver process failure mode analysis as most process

failure and drift will induce accelerometer failure. A full traceability monitoring system is

also mandatory.

JTI-CS2-2017-CfP06-SYS-01-04 - Manufacturing process for ultimate performance inertial MEMS Accelerometer

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Tasks

Ref. No. Title – Description Due Date

WP1 Definition of the target MEMS manufacturing process M3

WP2 Setup of the MEMS manufacturing process M10

WP3

Manufacturing of 20 MEMS Accelerometers and delivery

to the Topic Manager for evaluation in relevant

environment

M14

WP4 Optimisation of the MEMS manufacturing process based

on WP3 results. M20

WP5

Manufacturing of 40 MEMS Accelerometers and delivery

to the Topic Manager for validation in relevant

environment (TRL5)

M24

JTI-CS2-2017-CfP06-SYS-01-04 - Manufacturing process for ultimate performance inertial MEMS Accelerometer

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▌Key information

Topic: Voice interaction towards natural crew assistant

Call: Call for Partners Wave 6

Duration: 21 months, starting Q3 2017

Indicative funding value : 1100 k€

Context:

Intelligent personal assistants have been successful in the world of portable phones. They are based

on natural language user interface to make recommendations, answer requests, and perform

actions. The proposed activity aims at investigating whether this kind of assistant could be

implemented in a cockpit environment.

Objectives:

The aim of the proposed activity is to develop and/or integrate the technologies required to

implement an intelligent system such as the “natural crew assistant” in a cockpit environment.

A natural crew assistant is an intelligent system capable of listening to all communications occurring

in the cockpit (either between crew members or between crew and ATC), recognizing and

interpreting speech content, interacting with crew and fulfilling crew requests, such as to simplify

crew tasks.

JTI-CS2-2017-CfP06-SYS-01-05 - Solutions for voice interaction towards natural crew assistant

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▌Main Challenges

Provide audio evaluation environment

− Representative bench of the audio environment of a cockpit.

− Allowing to evaluate the sound listening, voice recognition and natural crew assistants.

Solutions for basic cockpit sound listening / voice recognition system

− develop solution for a sound listening / voice recognition system

− integrate solution in the evaluation bench

− evaluate solution with scenarios and expected behavior provided by the topic manager

Note: iterative approach is highly recommended.

Solutions for the natural crew assistants

− develop solution for a natural crew assistant

− integrate assistant with the cockpit voice recognition system in the evaluation bench

− evaluate solution with scenarios and expected behavior provided by the topic manager

− Note: iterative approach is highly recommended.

Solutions shall be compatible with aircraft environments and constraints

− embedded, autonomous or connected, noisy environment

JTI-CS2-2017-CfP06-SYS-01-05 - Solutions for voice interaction towards natural crew assistant

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Q1 Q2 Q3 Q4 Q5 Q6 Q7

Project Management

WP1 – Audio evaluation environment

WP2 – Sound Listening/Voice recognition systems

WP3 – Designing/evaluating solutions for the natural crew assistants

JTI-CS2-2017-CfP06-SYS-01-05 - Solutions for voice interaction towards natural crew assistant

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CfP06 Info Days

Recent regulatory and Technological development now enables the next step in Vision & Awareness Systems

Needed: An Affordable Multi-spectral Electro-Optic Sensor Unit (LRU) to TRL5 with image Algorithms providing a video stream covering visual to Long-wave IR bands based on non-export restricted technology

To be used in the next generation Vision and Awareness: • Enhanced Vision System (video presented on a HUD)

• Obstacle Awareness System (detecting ground obstacles)

• Sense and Avoid systems (detecting other moving objects, e.g. UAV’s)

• Image based navigation (Final approach phase)

Certification Expertise not required, can be by Integrator

Proprietary to one or several SYSTEM ITD Member – do not disclose 8

JTI-CS2-2017-CfP06-SYS-01-06 - Affordable Electro - Optical Sensor Cluster/Assembly Unit (LRU) for Vision & Awareness enabling Enhanced Vision, Sense & Avoid, and Obstacle Detection Systems for Aeroplane and Helicopter All-weather Operations and enhanced safety

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CfP06 Info Days Proprietary to one or several SYSTEM ITD

Member – do not disclose 9

Provide a cost effective and ITAR free Unit. Use Affordable (uncooled) IR sensors (Visual, NIR to LWIR) for System integration and flight evaluation. • Visual, NIR and LWIR (SWIR TBC), FoW 45⁰ * 30⁰, IR Bands resolution ≥ 640

x 480 Frame rate: ≥30 Hz, Latency <30ms, weight < 2kg

To define an optical solution for the sensors.

Develop an efficient mechanical and electrical build for the required functions.

Define and implements algorithms for the image data stream.

Use a standard digital interface for the output image data stream.

Test, validate and qualify the Unit in relevant environment, TRL5.

Use a process that will allow/enable a system integrator to certify the LRU as part of a Enhanced Vision System, Obstacle Awareness System, and Sense & Avoid System.

Provide units for Aircraft System integration, evaluation and demonstration. Saabs Development Aircraft

JTI-CS2-2017-CfP06-SYS-01-06 - Affordable Electro - Optical Sensor Cluster/Assembly Unit (LRU) for Vision & Awareness enabling Enhanced Vision, Sense & Avoid, and Obstacle Detection Systems for Aeroplane and Helicopter All-weather Operations and enhanced safety

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CfP06 Info Days Proprietary to one or several SYSTEM ITD

Member – do not disclose 10

T+01 T+02 T+03 T+04 T+05 T+06 T+07 T+08 T+09 T+10 T+11 T+12 T+13 T+14 T+15 T+16 T+17 T+18 T+19 T+20 T+21 T+22 T+23 T+24

Tasks

T01 - Specification finalization phase

T02 - Design Phase

T03 - Production of EOS LRU

T04 - Integration and run-up

T05 - Environmental and functional test

T06 - Hand-over to system integration & Flight

T07 - Integration & Evaluation Support

Deliveries

D0 - Final EOS LRU specification

D1 - HW Design data package

D2 - Algorithm Definition / Implemented

D3 - Produced LRU (2 for external hand-over)

D4 - Operational LRU

D5 Hand-over to system integration

Milestones

System specification (input)

EOS LRU Final specification

Design review w.r.t. certifiability

Hand-over

Year 2 - Q4Year 2 - Q3Year 1 - Q1 Year 1 - Q2 Year 1 - Q2 Year 1 - Q3 Year 2 - Q1 Year 2 - Q2

JTI-CS2-2017-CfP06-SYS-01-06 - Affordable Electro - Optical Sensor Cluster/Assembly Unit (LRU) for Vision & Awareness enabling Enhanced Vision, Sense & Avoid, and Obstacle Detection Systems for Aeroplane and Helicopter All-weather Operations and enhanced safety

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▌Key information

Topic: Next generation of power module for a scalable and modular electric taxiing

system

Call: 6th Call for proposal CFP 06/ JTI-CS2-2017-CfP06-SYS-02-30/ JTP WP 4 – Landing

Gear Systems

Duration: 45 monthes, starting Q1 2018

Indicative funding value : 800 K€

Context:

Studies for the electric taxi system have shown significant fuel savings (and emissions reductions) for

single aisle aircraft. The studies have also indicated fuel and emissions reduction opportunities in

other aircraft types ranging from helicopters, business jets and regional jets, up to a short-haul wide

body aircraft.

The current demonstration system can achieve higher benefits on weight and size, efficiency, cost,

and integration when optimizing energetic streams between the A/C power sources and green

taxiing loads during drive and recovery phases.

.

Objectives:

To enhance Green Taxiing performances, modularity and scalability through the development of a

new generation of power module (Power converter & Energy Storage System).

JTI-CS2-2017-CfP06-SYS-02-30 - High density energy storage module for an electric taxi

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▌Main Challenges

At System level, identification of

− The best architecture for an optimal integration, scalability and modularity of the Electric Taxiing

System

At product level (power module considered)

− Bi-directional operation for storage and recycling energy

− Energy storage capability – The energy storage capability module shall be able to store up to

700Wh (2500kJ) (target mass for storage technology is at least 30Wh/kg, target mass for power

electronics is at least 2kW/kg)

− Power: The power module shall be able to manage up to 50kW power regenerated from wheel

actuator (target mass for the whole unit is 40kg).

− Bus voltage – The power module shall operate from the +/-270V DC bus

− Compliance to Aeronautical environments D0-160 standard

At technological level, identification of:

− Innovative energy storage chemistry (high energy & power density for the application

30kWh/kg)

− Adapted topologies for Power converter/Energy storage

− Optimized control algorithms and balance monitoring system

JTI-CS2-2017-CfP06-SYS-02-30 - High density energy storage module for an electric taxi

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Tasks 2018 2019 2020 2021 Ref. No. Title – Description Due Date

[T0+m] Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12 Q13 Q14 Q15

T4.1.2.4.01 Support analysis of the overall system requirements and definition of power module detailed requirements

T0+3

T4.1.2.4.02 Support analyses and trade-off studies of storage technologies T0+9

T4.1.2.4.03 Analysis and trade-off studies of buck/boost converter topologies, and filtering approach

T0+9

T4.1.2.4.04 Analysis and trade-offs of mechanical integration approaches, including packaging and cooling

T0+9

T4.1.2.4.05 Support identification and analysis of potential additional functional requirements such as balance monitoring system

T0+9

T4.1.2.4.06 Definition of interface requirements and integration procedures T0+9

T4.1.2.4.07 Power module architecture definition T0+9

T4.1.2.4.08 Power module safety and reliability analysis T0+9

T4.1.2.4.09 Development of the Power module to TRL4 T0+21

T4.1.2.4.10 Laboratory evaluation of the Power module critical functions T0+21

T4.1.2.4.11 Power Module integration simulation model development T0+26

T4.1.2.4.12 Development of the Power Module to TRL6 T0+33

T4.1.2.4.13 Laboratory testing and evaluation of the Power Module T0+33

T4.1.2.4.14 DO 160 compliance testing T0+39

T4.1.2.4.15 Laboratory demonstrator integration T0+45

T4.1.2.4.16 Laboratory testing T0+45

TRL4

TRL6

JTI-CS2-2017-CfP06-SYS-02-30 - High density energy storage module for an electric taxi

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Not legally binding

Context and applications :

With increasing electrical power on the MEA, oil cooling and lubrication systems are the preferred solution for electrical generators, enabling higher power density and minimized bearing maintenance comparing to air cooled generator solutions.

The objective of this call is to develop innovative oil pump solution for the generator internal cooling system.

Technical Target in the project: To develop, manufacture and test an innovative oil pump for electrical generators, in the objective of: - easing integration inside the generator to decrease the weight impact of the cooling system (e.g.

by suppressing the need of an intermediate gear reducer between the generator shaft and the pump),

- increasing durability and avaibility, - higher efficiency The innovative oil pump will contribute to realize weight and maintenance cost savings on the A/C electrical starting and generation system.

Timeframe and funding:

Foreseen start : Feb-2018 Indicative Funding Topic Value Foreseen end : Aug-2020 800K€

©THALES

JTI-CS2-2017-CfP06-SYS-02-31 - Innovative pump architecture for cooling electrical machine

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Not legally binding

Context and applications : Future aircrafts request more electrical power on board and weight saving is necessary to reach technical targets of More Electrical Aircraft (MEA) or All Electrical Aircraft (AEA).

Integrated Modular Power Electronic (IMPEC) shall contribute to weight reduction by replacing discrete power components and electro mechanical contact, by giving greater degree of integration and consequently by increasing the power density of electronic products.

Technical Targets in the project: • To perform a Trade-Off comparing flexible topology of the power semiconductor device to allow

the achievement of three different applications relaying on series-parallel combinations: – full-bridge HVDC,

– bidirectional matrix contact HVDC,

– half-bridge LVDC .

• To select a topology then to make and validate a mock-up in accordance with preliminary design (i.e. PCB and discrete components assembly ≈ TRL4).

• To make and validate a TRL6 maturity level demonstrator (according to environmental requirements).

Timeframe and funding:

Foreseen start : Dec-2017 Indicative Funding Topic Value Foreseen end : mid-2019 500K€

JTI-CS2-2017-CfP06-SYS-02-32 – Power Module

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▌Key information

Topic: Development of functionalizable materials

Call: Call for Partners Wave 6

Duration: 2 years, starting Q1 2018

Indicative funding value : 600 K€

Context:

Mainly due to their low specific weight, relative good mechanical properties, and comfort to

implement, use of composites in aeronautics is constantly increasing, including in structure of

electrical cabinets.

Currently, in the aim to reduce cost of production and to functionalize structure of cabinets,

investigations are conducted for integration of structural and/or thermal and/or electrical

components directly into core material composing the structure.

Objectives:

Aim of the project is to develop breakthrough material constituting structure of electrical cabinets,

and able to integrate mechanical and/or electrical and/or thermal elements. The expectation is to

develop material(s), compliant with aeronautical application specification, and associated

manufacturing processes.

JTI-CS2-2017-CfP06-SYS-02-33 – Development of functionalizable materials

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▌Main Challenges

The objective of this project will be to specify and develop functionalizable materials

and associated manufacturing processes, in accordance with aeronautical

specifications.

Material(s) and processes developed in the frame of this project must be:

− REACh compliant.

− optimised in terms of weight, volume and cost.

− FAR25 compliant relative to Fire Smoke Toxicity requirements.

− compliant with -55°C / +90 °C temperature.

A detailed specification will be provided at the beginning of the project.

Additional requirements… - Fire resistance 1100°C (5 min) - Peak maximum operating condition 150°C (30 min) - Resistance to aeronautics fluids (water, skydroll, kerosene, de-icers,…)

JTI-CS2-2017-CfP06-SYS-02-33 – Development of functionalizable materials

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Ref. No. Title - Description Due Date

Proposition of Materials to answer to the TM specification

The objective of this activity is to define sample geometries and associated

qualification test plan (QTP)

Samples manufacturing

The main objective of this activity consists of manufacturing the tests samples

Tests on non complex samples

This activity consists of performing the QTP on Samples for verification of

their conformity to specifications related to T1.

Prototype design

The main objective of this task is to check if properties obtained on non

complex samples are reproducible on representative prototype.

Full CAD definitions shall be provided.

Prototype manufacturing

The main objective of this activity consists of manufacturing the prototype(s)

in order to provide validation samples tests.

T6 Final prototype(s) delivery T0+22

Final report of the project

The main objective of this activity consists of detailing optimized process(es)

and material(s) used for realization of prototype(s), limits of the process, and

feedback on manufacturing.

T4 T0+12

T5 T0+21

T7 T0+23

Tasks

T1 T0+3

T2 T0+6

T3 T0+10

Milestones (when appropriate)

Ref. No. Title – Description Type* Due Date

M1 Answer to the TM specification with proposition of functionalizable material(s)

Note T0+3

M2 Tests report on samples and selection of candidate Report T0+12

M3 Design of prototype for demonstration of technology maturity Note T0+14

M4 Prototype delivery Prototype T0+22

M5 End of project Review T0+24

JTI-CS2-2017-CfP06-SYS-02-33 – Development of functionalizable materials

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▌Key information

Topic: Development of autonomous, wireless, smart and low cost current sensor for

monitoring of electrical lines

Call: Call for Partners Wave 6

Duration: 3 years, starting Q1 2018

Indicative funding value : 900 K€

Context:

In Aircraft, thousands of sensors, mostly non critical, are equipped with embedded systems for data

processing and required wiring for power supply and data exchanges implying several hundred

kilometers of wiring and subsequently weight. In the context of the MEA, this wiring complexity will

continue to grow-up.

Sometimes sensors cannot be installed on aircraft due to wiring constraints (accessibility). The use of

wireless sensors, contributes to the reduction of wiring for power and data transmission, the limitation of

weight increase and the reduction of Electrical Wiring Interconnection System (EWIS) complexity.

Objectives:

The objective of the proposed activity is to develop an autonomous wireless sensor

able to measure current level using local energy (no additional power supply

interface), then to transmit the measured data to a remote equipment using

wireless communication.

JTI-CS2-2017-CfP06-SYS-02-34 – Development of autonomous, wireless, smart and low cost current sensor for monitoring of electrical lines

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▌Main Challenges

The possibility to embed autonomous sensor in aircraft will offer considerable possibilities for the aeronautical domain. However several problems need to be solved that are related to:

Wireless data transmission:

− contained metallic space is not favorable for electromagnetic signal propagation,

− interferences from and on other systems shall be avoided,

− data exchange has to be secured,

Power supply interface: current solutions of energy harvesting does not provide enough power for aeronautical sensor application,

Electronic design: considering the advantages of wiring (low cost and reliability), the innovative equipment has to comply with a high level of reliability, aeronautical environmental

harsh constraints and a challenging cost margins.

develop an autonomous wireless sensor able to measure current level (nominal 100 Amps, pic 400 Amps, with an accuracy of 1%, compatible with DC and AC current (Freq. up to 1kHz)), using local energy (example: inductive coupling technology or alternative solutions), then to transmit the measured data to a remote equipment using

wireless communication compatible with aeronautical constraints (range 4,2 – 4,4 GHz).

A detailed specification will be provided at the beginning of the project.

The network communication dimension is out of scope of this activity, but design

constraint shall be taken into account for the proposed design of the Wireless

communication module.

The final prototype has to reach TRL5 maturity

JTI-CS2-2017-CfP06-SYS-02-34 – Development of autonomous, wireless, smart and low cost current sensor for monitoring of electrical lines

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Milestones (when appropriate)

Ref. No. Title – Description Type* Due Date

M1 Answer to the TM specification with proposition of functionalizable material(s)

Note T0+3

M2 Tests report on samples and selection of candidate Report T0+12

M3 Design of prototype for demonstration of technology maturity Note T0+14

M4 Prototype delivery Prototype T0+22

M5 End of project Review T0+24

Ref. No. Title - Description Due Date

Functional requirement specification

Objective is to define requirements for the final prototype

Wireless communication module

Objective is to develop a wireless communication solution compliant with use case

requirements and aeronautical qualification constraints. The module power consumption will

be also an important factor to consider.

Power supply module

Objective is to develop an energy harvesting solution that allows powering the sensors without

use of A/C power

Current sensor

Objective is to develop a sensor able to measure different current types (AC / DC; variable

frequency; different value) in aeronautical environment

Autonomous current sensor based on modules developed in previous tasks

Objective is to realize a demonstrator that integrates all modules developed in tasks 2, 3 and 4

Remote equipment allowing tests of solution

Objective is to realize an equipment centralizing communication from sensors network.

Integration tests and final validation

Objective is to create a sensor (from task 5) network integrated with the remote equipment so

as to validate the compliance of the solution to the initial specification.

Tasks

T3

T1 T0+4

T4

T0+32

T0+36

T0+14

T2 T0+24

T0+16

T5 T0+32

T6

T7

JTI-CS2-2017-CfP06-SYS-02-34 – Development of autonomous, wireless, smart and low cost current sensor for monitoring of electrical lines

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SYS TEM WBS

Although, Fly-By-Wire is well established in large aircraft, this technology has not found its way into small aircraft. Today’s technology provides well-designed network standards which fulfill the data integrity and performance requirements of flight safety critical systems at reasonable effort. The use of low-cost avionics backbone networks could enable the creation of state-of-the-art Integrated Modular Avionics (IMA) systems for small aircraft to support a Fly-by-Wire system.

JTI-CS2-2017-CfP06-SYS-03-09 – Computing Node for Safety Critical Applications

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Not legally binding

Context and applications : Scope of this call is the definition of an Integrated Modular Avionics (IMA) architecture and the related basic building blocks to implement a highly scalable system for safety critical applications. The proposed solution should meet the requirements of low costs and data integrity in flight safety critical systems and should be specific for SAT. This architecture will be based on a single Line-Replaceable Unit (LRU) providing the capabilities to communicate with other equipment of the system through a deterministic and robust communication bus based on Ethernet protocol and a general purpose I/O interface to provide connectivity.

Technical Target in the project: Definition of an Integrated Modular Avionics (IMA) infrastructure which will be the basic building block of an highly

scalable system for safety critical applications.

Infrastructure based on a single Line-Replaceable Unit (LRU) providing the capabilities to communicate with other equipment of the system through a deterministic and robust communication bus based on Ethernet protocol and a general purpose I/O interface to provide connectivity.

The computational unit shall also provide the capability to connect directly with other equipment by means of standard serial line (EIA-422 and/or CAN) and it shall provide Discrete Input/Output interfaces as interlock for test/download/debug modes.

The computational unit shall be capable to support ARINC-653 compliant Real-Time Operating Systems.

Immediate application is to obtain an affordable computing platform suitable to be used as flight control computer for small aircrafts.

Timeframe and funding:

Foreseen start : January-2018 Foreseen Duration: 36 Months

Indicative Funding = 1000kE

JTI-CS2-2017-CfP06-SYS-03-09 – Computing Node for Safety Critical Applications

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Not legally binding

Proposed WBS To be refined by applicant

Tasks

Ref. No. Title - Description Due Date

T01 System Requirements Review T0+2m

T02 Conceptual Design T0+6m

T03 Detailed Design T0+12m

T04 Implementation

T0+18m

T05 Acceptance Test and Verification T0+20m

T06 Support to System Integration T0+36m

JTI-CS2-2017-CfP06-SYS-03-09 – Computing Node for Safety Critical Applications

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Not legally binding

Special skills, Capabilities, Certification expected from the Applicant(s) • Previous experience in development and design of advanced technologies in the field of

Embedded Computing. • Proven experience in international R&T projects cooperating with industrial partners,

institutions, technology centers, universities. • Quality and risk management capabilities demonstrated through participation in

international R&T projects and/or experience in the industrial environment • Proven experience in the use of design, analysis and configuration management tools of

the aeronautical industry • Good knowledge of industrial air vehicle developments with experience in “in-flight”

components and laboratory set-up for aeronautical certification. • HW/SW development and integration capacity • Knowledge and capabilities in test rig design • Instrumentation data acquisition, recording and monitoring capabilities.

JTI-CS2-2017-CfP06-SYS-03-09 – Computing Node for Safety Critical Applications

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▌Key information

Topic: Electrocoating process for Cr6-free surface treatment of aluminium parts

/ JTI-CS2-2017-CfP06-SYS-03-10

Call: Call for Partners Wave 6

Duration: 2 years, starting Q3 2017

Indicative funding value : 350 K€

Context:

Nowadays most landing gear parts made of aluminium alloys of 7000 series are

protected against corrosion by surface anodising and an additional painting.

Anodising is a very complex and time intensive process that often contains hazardous

substances for health and environment, which means high disposal costs.

Objectives:

e goal of this topic is to develop an anaphoretic coating process (also known as

electrocoating or e-coat) for aluminium alloys of 7000 series including the optimal

pretreatment processes.

The developed process shall respect the aeronautical standards. For example the E-

Coat must be compliant with DO-160G.

JTI-CS2-2017-CfP06-SYS-03-10 – Electrocoating process for Cr6-free surface treatment of aluminium parts

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▌Main Challenges

process shall lead to a reduction of emissions and wasted paint and potentially increase

corrosion resistance

process is to be REACH compliant

adhesion of the anaphoretic coating shall be better than the adhesion of traditional

painting system on the anodised aluminium thanks to adapted pretreatment processes

corrosion resistance of e-coated aluminium alloys without painting shall aim to be better

than anodised aluminium alloys with traditional primer plus top coat

lifetime of anaphoretic coating shall be longer than the one of traditional painting

system

Influence of the coating and of the pretreatment processes on the mechanical

properties of the base material shall also be minimized in order to increase the

endurance of landing gear parts

JTI-CS2-2017-CfP06-SYS-03-10 – Electrocoating process for Cr6-free surface treatment of aluminium parts

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Deliverables

Ref. No. Title - Description Type Due Date

D1 Feasibility study, screening results and solution

selection

Doc T0 + 3M

D2 Test Matrix for process development Excel Doc T0 + 4M

D3 Coated and tested coupons Hardware T0 + 13M

D4 Test results of the small specimens Doc T0 + 13M

D5 Coated and tested big specimens Hardware T0 + 17M

D6 Test results of the big specimens Doc T0 + 17M

D7 Cost and application Study Doc T0 + 18M

D6 Final Report & Project Closure with process

description

Doc T0 + 18M

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▌Key information

Topic: Assessment of Partial Discharge and breakdown behaviour of electric insulation

materials for very high voltage gradients / JTI-CS2-2017-CfP06-SYS-03-12

Call: Call for Partners Wave 6

Duration: 2 years, starting Q4 2017

Indicative funding value : 400 K€

Context:

The use of high speed switching devices is expected to support the development of

power electronic systems with lower losses and improve power densities. However,

devices based on technologies such as SiC produce voltage gradients that will have

a negative impact on the performance of high voltage insulation systems.

Objectives:

Analysis and experimental assessment of state-of-the-art insulation materials.

Develop methods for the verification of insulation materials considering aerospace

environmental conditions.

Make recommendations for design guidelines and design optimization.

JTI-CS2-2017-CfP06-SYS-03-12 – Assessment of Partial Discharge and breakdown behaviour of electric insulation materials for very high voltage gradients

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▌Main Challenges

modelling techniques to assess the voltage gradients and magnitudes observed in

insulation systems for typical converter – cabling – machine systems.

examine the impact of key parameters such as the number of turns, the winding

method used and the stator length

identify measures that can be taken to reduce the voltage gradient at the electrical

machine without negative impact on the performance

understanding of the performance of electrical insulation materials

identify the insulation types best suited to managing high voltage gradients

identify methods for the verification and qualification of new insulation systems

quantify the impact of higher voltage gradients on the lifetime of electrical machines,

wiring and insulation material

Equipment suitable of assessing the partial discharge behaviour of insulation systems

exposed to high slew rates (up to 20kV/µs) and at pressures down to 10,000Pa

combined with temperatures between -50⁰C and 150⁰C

Capability to model and, if required, experimentally verify the distribution of voltage

gradients and magnitudes within a typical aerospace power electronic system

JTI-CS2-2017-CfP06-SYS-03-12 – Assessment of Partial Discharge and breakdown behaviour of electric insulation materials for very high voltage gradients

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Deliverables

Ref. No. Title - Description Type* Due Date

D1

Modell to assess voltage gradient and magnitudes

within insulation systems including related report of

T1 results

R T0 + (12 months)

D2

Report of PD and breakdown behaviour of

components exposed to high voltage gradients

including verification methods; including results of

T2

R T0 + (18 months)

D3

Report of lifetime characterization of components

exposed to high voltage gradients including design

recommendations; including results of T3

R T0 + (24 months)

*Types: R=Report, D-, HW=Hardware

JTI-CS2-2017-CfP06-SYS-03-12 – Assessment of Partial Discharge and breakdown behaviour of electric insulation materials for very high voltage gradients