clean sky 2 information day dedicated to the 4th call for proposal … cs2cfp08id... · frc...
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Company General Use
Innovation Takes Off
Brussels, 22/05/2018
Clean Sky 2 Information Day dedicated to the
8th Call for Proposal (CfP08)
FAST ROTORCRAFT IADP Topics related to FRC WP1 – Next Generation Civil TiltRotor Project
Leonardo Helicopters
Company General Use
2
FRC Overview Filling the Mobility Gap
TRANSPORT RANGE & PRODUCTIVITY
Unprepared Area Helideck
Door-to-Door
Large Airport
Regional Airport
Heliport Local airfield
Local Transport Short range Medium Range Long Range
Helicopter
Compound R/C
Tilt-Rotor A/C
Turboprop
Turbofan & CROR
EMS, SAR, Coast guard
Disaster relief Oil & Gas offshore
Corporate Transport Air Taxi
MISSIONS AIRFIELD
Clean Sky 2 / FRC – General Session
Company General Use
3
FRC Overview Clean Sky 2 Context
Leonardo
Clean Sky 2 / FRC – General Session
Fast Rotorcraft
Leonardo Helicopters Airbus HElicopters
Company General Use
25000 ft
Declared CleanSky 2 Objectives: Low environmental impact with high productivity and efficiency
Commercially attractive Payload Recurring and Direct Operational costs comparable to Conventional Helicopter
VTOL/STOL
FRC Overview NextGenCTR Objectives and Challenges
>320 kts
4
Company General Use
NextGenCTR
A 2-Phase Program
Design, Build, Fly a
Technology Demonstrator under CS2
NextGenCTR TD
Phase 1
if the market is ripe on-going business case development
Develop & Certify a Product
NextGenCTR
Phase 2
De-risk program, expand current TR capability
Prove Architecture, Technologies, Operations
Supported by external funding
Develop collaborations and partnerships
Sow the seeds for future technologies &
products
Technology exploitation and dissemination
Tailored for diverse missions
State-of-the-art Technologies embedded
Competitive RC & DOCs vs. Helicopters
No Legacy with AW609 technologies
Approach for NextGenCTR Program: 2 Phases
Company General Use
Key objectives will be pursued within CS2 by a Technology Demonstrator focusing on the Design & Development effort of Key Enabling Technologies:
1. Fixed-engine, Split Gearbox Drivetrain concept
2. Efficient Nacelle architecture
3. Advanced Wing architecture
4. Optimized Tail configuration
5. Advanced Modular, Distributed & Scalable Flight Control System
Throughout this effort the development and validation of predictive models and tools for air vehicle performance (including environmental), efficiency and productivity
6
FRC IADP NGCTR-TD Objectives
Company General Use
New Technologies to be tested within CS2 for First Flight (TRL =6)
7
New Wing (no dihedral and no swept) Integration (T-WING)
Mast tilt for control improvement (LH)
Splitted gearbox architecture to support non tilting engine (LH)
Advanced empennage configuration (LIFTT)
Innovative fuel system (DigiFuel & DEFENDER)
Distributed FCS system (LH)
New control laws (LH)
Flow through engine
FRC IADP NGCTR-TD Objectives
Company General Use
New Technologies to be tested within CS2 after First Flight (TRL =<6)
8
Rotor system new material application (MMC,...)
(LH)
General System new applications (i.e. Electrical low pressure
compressor, ...) (Call to be assigned)
Additive Manufacturing technology gearbox housing –
(AMATHO)
New tailcone & empennage material manufacturing (LIFTT)
Active inceptors (Partner to be engaged)
FRC IADP NGCTR-TD Objectives
Company General Use
WP 1.1 NGCTR Management &
Coordination
Task 1.1.1 Program Management &
Coordination
Task 1.1.2 Partner Management &
Coordination
WP 1.2 Air Vehicle Design &
Development
Task 1.2.1 Design Integration
Task 1.2.2 Tiltrotor System Design
Task 1.2.3 Transmission Systems
Task 1.2.4 Rotor Systems
Task 1.2.5 Airframe Structures
Task 1.2.6 Electrical & Avionic
Systems
Task 1.2.7 Airframe Systems
WP 1.3 Aircraft Final Assembly
Task 1.3.1 NGCTR Industrialisation
Task 1.3.2 NGCTR Manufacturing Engineering & Tooling
Task 1.3.3 ATP Test Equipment
Task 1.3.4 Final Assembly Line &
Flight Line
WP 1.4 Aircraft Test & Demonstration
Task 1.4.1 Ground Test
Task 1.4.2 Flight Test
FRC IADP NGCTR-TD Work Package Structure
WP 1 - NGCTR
T-Wing
Company General Use
Technology transfer from CS1 to CS2
10
No direct accessibility of this technology: there is no impact on NGCTR-TD development
Accessibility of this technology is granted
No direct accessibility of this technology: it should be useful for NGCTR-TD development
CS1 technology pull through to CS2
Company General Use
Technology transfer from CS1 to CS2
11
• LamBlade - Development and provision of a numerical model to solve laminar turbulent boundary layer transition and boundary layer velocity profiles for unsteady flow conditions
• COMROTAG - Development and supply of an advanced numerical model suitable for commercial code (Fluent) to investigate complex unsteady interational phenomena
GR
C1
• TP13 - Optimised geometry of the common tiltrotor platform.
• TILTOp - Contribution to the study of the air intake and exhaust integration into a tiltrotor nacelle.
• TETRA - Assessment of optimized tiltrotor engine intake performance by wind tunnel tests.
• TP10 - Optimised turboshaft installation of the common tiltrotor platform.
• CODE-Tilt - Contribution to design optimisation of tiltrotor for drag (fuselage/wing junction, nose, landing gear, empennage).
• DREAm-TILT - Assessment of tiltrotor fuselage drag reduction by wind tunnel tests and CFD.
GR
C2
• WP2.2 - NGCTR - TILTROTOR SYSTEM DESIGN
• WP2.2 - NGCTR - TILTROTOR SYSTEM DESIGN
• WP2.7 - NGCTR - AIRFRAME SYSTEMS
• WP2.2 - NGCTR - TILTROTOR SYSTEM DESIGN
• ELETAD - Electrical Tail Rotor Drive – Modelling, Simulation and Rig Prototype Development
• REGENESYS - Multi‐source regenerative systems power conversion
• HERRB - Innovative Dynamic Rotor Brake GR
C3
• WP2.6 - NGCTR - ELECTRICAL and AVIONIC SYSTEMS
• WP2.6 - NGCTR - ELECTRICAL and AVIONIC SYSTEMS
• WP2.4 - NGCTR - ROTOR SYSTEMS
• WP2.2 - NGCTR - TILTROTOR SYSTEM DESIGN
Company General Use 12
Technology transfer from CS1 to CS2
• EMICOPTER - Development of computational tools for engine gas emission prediction Tools required to perform the emissions analysis and evaluation methodology
• MAEM-RO - Development of methodology for helicopter flue gas measurements and flight measurement campaign Tools required to perform the emissions analysis and evaluation methodology, experimental support
• ANCORA - Preliminary acoustic flight tests for the tuning of simplified rotorcraft noise models
• TRAVEL - integrated ATC/TR simulation of low-noise procedures for impact evaluation on operators
• MANOEUVRES - Innovative measurement and monitoring system for accurate on-board acoustic predictions during rotorcraft approaches and departures. Sensoring and cockpit monitoring to reduce noise in manoeuvring flight.
• TP1 - Eco-flight VFR Procedure.
• TP2 - Eco-flight IFR Procedure.
• TP4 - Eco-Flight Planner.
GR
C5
• WP1.5 - CS2 FRC WP4 - Technology Evaluator Methodology
• WP1.5 - CS2 FRC WP4 - Technology Evaluator Methodology
• WP4 - NGCTR - AIRCRAFT TEST and DEMONSTRATION
• WP2.4 - NGCTR - ROTOR SYSTEMS
• WP2.6 - NGCTR - ELECTRICAL and AVIONIC SYSTEMS
• WP4 - NGCTR - AIRCRAFT TEST and DEMONSTRATION
• WP1.5 - CS2 FRC WP4 - Technology Evaluator Methodology
• WP2.2 - NGCTR - TILTROTOR SYSTEM DESIGN
• WP4 - NGCTR - AIRCRAFT TEST and DEMONSTRATION
• ECOfairs - "Manufacturing of Thermoplastic Structural Demonstrators. Development of technology & design for demonstrator“
• REMART - End-of-life solutions for metallic structures - Recycling of Metallic Materials from Rotorcraft Transmissions G
RC
6
• WP2.5 - NGCTR - AIRFRAME STRUCTURES
• WP3 - NGCTR - AIRCRAFT INDUSTRIALISATION and ASSEMBLY
• WP1.4 - CS2 FRC WP3 - Eco-Design Implementation
• WP2.5 - NGCTR - AIRFRAME STRUCTURES
• WP3 - NGCTR - AIRCRAFT INDUSTRIALISATION and ASSEMBLY
Company General Use
D1 Wind Tunnel Model
D3 Flying Demo
D4 Drive system and components
D7 Fuel system components
D8 Flight control and Actuation systems and components (SaIL)
D6 Engine-nacelle integration
D5 Wing Assembly
D2 TDH – Tie Down Tilt Rotor
D9 Digital Mock-Up (DMU)
D3
4. Optimized Tail
configuration
3. Advanced Wing
architecture
1 .Fixed-engine, Split gearbox
drivetrain concept
5. Advanced Modular,
Distributed & Scalable FCS
2. Efficient nacelle
architecture
D1
D8
D5
D7 D6
D10
D4
NGCTR WBS - Clean Sky 2 Demonstrators
Definition & Plan
D10 Airframe Structural Components
D2
D9
CO2 and Noise Footprint reduction Reduced cost of ownership (operating & MRO) Fast Forward Speed High Efficiency, High Productivity
Company General Use
2017_1 2017_2 2018_1 2018_2 2019_1 2019_2 2020_1 2020_2 2021_1 2021_2 2022_1 2022_2 2023_1 2023_2 2024_1 2024_2 2025_1 2025_2
REVISED LEVEL 0 PLAN
ASSETAVAILABILITY
FROM 609 PROGRAM (9/2021) A/C COMPLETION
FOR FF
(0,5 month)
609 A/C FUSELAGE
PREPARATION
PROGRAMCLOSURE
FDR (6/2024)
SYSTEMSATPs
4/2023FIRST GROUND RUN
GTV ON THE RAMP
(2 months)
DEMO A/C FINAL
WING FINAL
ASSY (CPW04)
FLIGHT TEST ACTIVITY
FLIGHT TEST PHASE 2
FLIGHT TEST PHASE 3
FLIGHT TEST PHASE 4
FLIGHT TEST PHASE 5
A/C DEFINITION
PRELIMINARY DESIGN
TOOLING & RIGS DESIGN
DETAILED DESIGN
- Wing Detailed Design (CPW04)
- Tail Detailed Design (CPW03)
- Drive System detailed Design
- Rotor head & Rotating Ctrs Detailed Design
- FCS Detailed Design
- Wiring Detailed Design
- Fuel System Detailed Design (CfP02, CfP03)
TOOLING & RIGS PROCUREMENT/MANUFACTURING
PARTS PROCUREMENT/MANUFACTURING
FATIGUE, LAB & AVIONIC TESTING
LEGEND:
SCR : System Concept ReviewSRR : System Requirements Review
SFR : System Functional ReviewPDR : Preliminary Design Review
CDR : Critical Design ReviewTRR : Test Readiness Review
FRR : Flight Readiness Review
FDR : Flight Demonstration ReviewGTV : Ground Test Vehicle
CDR (7/2020)
PDR (12/2018)
- Interactional Aerodynamics
(CfP06)
- Low Speed Model
- High Speed Model (CfP07)
- Nacelle Large Model (CfP08)
- Aeroelastic Dynamic Model
(CfP09)
- Rotating Controls Trade
Studies 6/2023FIRST FLIGHT
Q4/2022
3/2022
1/2022
- Wing Prelmiminary Design (CPW04)
- Tail Preliminary Design (CPW03)
- Drive System Preliminary Design
- Rotor head & Rotating Ctrs Preliminary design
- FCS Preliminary Design
- Wiring Preliminary Design
- Fuel System Preliminary Design (CfP02, CfP03)
WIND TUNNEL TESTING
DEMO WING MFG
(FROM CPW04 PARTNER)
TECHNICAL PROGRAM
TERMINATIONTRR (9/2022)
FRR (1/2023)
SRR (4/2017) SFR (12/2017)
DEMO FLAPERON MFG (FROM CPW03 PARTNER)
Master Level “0” Plan Status:
14
NGCTR WBS - Clean Sky 2 Demonstrators
Definition & Plan
D2 D3
D1
D9
D4
D6
D10
D5
D7
D8
Company General Use
CS2 Info Day CfP04, Brussels 22.06.2016 15
• FRC-01-18: Adoption of a “Digital Transformation” approach to improve NGCTR design and simulation
• FRC-01-19: Certification by Simulation for Rotorcraft Flight Aspects (CSRFA)
• FRC-01-20: Design, development and flight qualification of a supercritical composite shaft drive line for tiltrotor main drive system
• FRC-01-21: Development of effective engine air intake protection system for Tilt Rotor
• FRC-01-22: Development of engine exhaust wake flow regulator for Tilt Rotor
• FRC-01-23: Experimental characterization and optimization of the RH and LH Engine intakes configuration of the next generation Tilt Rotor
• FRC-01-24: High efficiency full electrical low pressure Compartment Pressure Control System for tilt-rotor applications
8th Call for Proposal (CfP08) – Fast RotorCraft IADP
FRC-01-18: Adoption of a “Digital Transformation” approach to improve NGCTR design and simulation
Fast RotorCraft IADP 8th Call for Proposal
Open Day May 2018
Company General Use
FRC-01-18: Adoption of a “Digital Transformation” approach to improve NGCTR design and simulation
• Topic Manager: Leonardo Helicopters ;
• Collab.= Implementation Agreement
• Indicative Funding Value: 1.750 M€ ;
• Duration: 60 Months
• Type of Action: RIA
• Overview: Leverage on new technologies and methods ( Big data and AI algorithms) to sustain the development of the NGCTR-TD.
• Objectives:
Increase efficiency and accuracy in flight data analyses
Improve design choices
Optimize flight campaigns
Company General Use
FRC-01-18: Adoption of a “Digital Transformation” approach to improve NGCTR design and simulation
Build the Big Data Appliance:
Computational power to explore complex, large and heterogeneous data-sources
Advanced data processing and visualization capabilities
Implementation of new algorithms, aimed at:
Automate data anomalies detection
Perform event recognitions
Predict aircraft behavior
Build predictive models learning from data
Company General Use
Clean Sky 2
FRC-01-18: Adoption of a “Digital Transformation” approach to improve NGCTR design and simulation
The project will use the existing Tiltrotors data to train the system and NextGen tilt-rotor as application case
To facilitate the Flight Data Analysis for TD;
To feed simulation activity
To support future full size Tiltrotors design and Certification process
RAW DATA DATA
APPLIANCE
Technology Demonstrator
Flight Data
Future TiltRotors
Design
Full Size A/C Certification
FRC-01-19: Certification by Simulation for Rotorcraft Flight Aspects (CSRFA)
Fast RotorCraft IADP 8th Call for Proposal
Open Day May 2018
Company General Use
FRC-01-19: Certification by Simulation for Rotorcraft Flight Aspects (CSRFA)
• Topic Manager: Andrea Ragazzi
• Collab.: Implementation Agreement
• Indicative Funding Value: 3 M€
• Duration: 36 Months
• Type of Action: IA
• Overview: the aim of this topic is to bring together the rotorcraft industry, the certification authority and simulation excellences to define a virtual certification process for rotorcraft flight aspects.
• Objectives:
to improve from the current case-by-case to a more standard approach;
to improve safety;
to reduce program costs;
to increase insight into design;
to reduce environmental impacts.
Company General Use
Simulation has three big advantages: safety + economy + effectiveness.
Flight simulation requires: simulation models that satisfy real-time constraints; simulation hardware that provides adequate cues.
The research activity shall:
identify the areas of the certification process/rules that can be substituted/supported by simulation;
define guidelines for acceptable CSRFA simulation models fidelity; define guidelines for acceptable CSRFA simulator cueing systems fidelity study for each rule the approach using the above simulation assets.
To maximize the benefits for rotorcraft industries (especially smaller ones)
CSRFA will consider both high-level and affordable technology, possibly scaling the use of simulation in place of real flight with the fidelity level.
FRC-01-19: Certification by Simulation for Rotorcraft Flight Aspects (CSRFA)
Company General Use
The research shall address helicopters and tilt-rotors.
CSRFA results will use the NextGen tilt-rotor as application case To facilitate the Permit to Fly release for TD; To support future full size Tiltrotors design and
Certification process
The project shall use Leonardo Helicopters simulation models and simulation facility (with the possibility to modify it to support this research).
FRC-01-19: Certification by Simulation for Rotorcraft Flight Aspects (CSRFA)
FRC-01-20: Design, development and flight qualification of a supercritical composite shaft drive line for tiltrotor main drive system
Fast RotorCraft IADP 8th Call for Proposal
Open Day May 2018
Company General Use
FRC-01-20: Design, development and flight qualification of a supercritical composite shaft drive line for tiltrotor main drive system
• Topic Manager: Leonardo Helicopters ;
• Collab.= Implementation Agreement
• Indicative Funding Value: 0.400 M€ ;
• Duration: 42 Months
• Type of Action: IA
• Overview: Design, development and flight qualification of a supercritical composite shaft drive line for tiltrotor main drive system
• Objectives:
• design a supercritical composite drive shaft line for a tilt rotor drive system, whose architecture should conceive suitable supports, damping behaviour into the whole operating range, capability of coping with angular deflections
• innovative monitoring and diagnostic system able to properly and timely detect possible damages of the whole drive line.
Company General Use
FRC-01-20: Design, development and flight qualification of a supercritical composite shaft drive line for tiltrotor main drive system
Capability of properly transmitting design torque not operating continuously at a critical whirling speed;
the use of composite material technology can allow to realize non–isotropic shaft, tailoring the shaft design such that it can withstand the torque load while having proper flexible bending properties
Use of suitable active bearings to control the stability and vibration of the highly flexible driveline
Capability of accommodating flexural curvature to allow for the effects of wing deflection and possible misalignment of the support bearings;
Usage and health monitoring system performances (i.e. embedded sensors)
Light and compact design;
FRC-01-21: Development of effective engine air intake protection system for Tilt Rotor
Fast RotorCraft IADP 8th Call for Proposal
Open Day May 2018
Company General Use
28
FRC-01-21: Development of integrated engine air intake and protection systems for Tilt Rotor
• Topic Manager: Leonardo Helicopters ;
• Collab.= Implementation Agreement
• Indicative Funding Value: 2.5 M€ ;
• Duration: 60 Months
• Type of Action: IA
• Overview: Design, manufacturing, testing and flight qualification of an integrated engine air intake protection system for Tilt Rotor.
• Objectives:
Design and development of engine air inlet with barrier filter for VTOL and high speed operations.
Integration of anti-ice system, compressor washing system and filter self/easy cleaning system.
Computational fluid dynamic analysis of the entire air intake system.
System testing for icing conditions and bird strike.
Company General Use
29
FRC-01-21: Development of integrated engine air intake and protection systems for Tilt Rotor
Development of an intake protection system for harsh Tilt Rotor operating environment. Design optimization process for the integration of the intake sub-systems and the compliance with aircraft operational requirements.
Validation of the air intake system for Flight Clearance against inadvertent icing, vibrations and bird strike damage.
FRC-01-22: Development of engine exhaust wake flow regulator for Tilt Rotor
Fast RotorCraft IADP 8th Call for Proposal
Open Day May2018
Company General Use
31
• Topic Manager: Leonardo Helicopters ;
• Collab.= Implementation Agreement
• Indicative Funding Value: 1.6 M€ ;
• Duration: 60 Months
• Type of Action: IA
• Overview: Design, manufacturing, testing and flight qualification of an engine exhaust with variable geometry and active engine bay cooling system.
• Objectives:
Development of an exhaust system able to convert residual gas energy into thrust.
Development of an innovative system for bay cooling by directing the secondary pressurized flow to the exhaust.
Computational fluid dynamic and structural analysis to support the entire design phase.
FRC-01-22: Engine exhaust wake flow regulator for Tilt rotor
Company General Use
32
FRC-01-22: Engine exhaust wake flow regulator for Tilt rotor
Optimization process for tiltrotor performance during both hovering and level flight conditions. Design of a two-position primary nozzle
to improve turboprop cycle (max expansion efficiency) in VTOL and turbojet cycle (max thrust efficiency) in airplane mode
VTOL mode
Airplane mode
FRC-01-23: Experimental characterization and optimization of the RH and LH Engine intakes configuration of the next generation Tilt Rotor
Fast RotorCraft IADP 8th Call for Proposal
Open Day May 2018
Company General Use
FRC-01-23: Experimental characterization and optimization of the RH and LH Engine intakes configuration of the next generation Tilt Rotor
• Topic Manager: Leonardo Helicopters ;
• Collab.= Implementation Agreement
• Indicative Funding Value: 3.500 M€ ;
• Duration: 30 Months
• Type of Action: RIA
• Overview:
To test in wind tunnel the datum engine intake configuration, to optimize and test the internal ducts and to make an analytical assessment of the icing and snow effects on the configuration.
• Objective:
To experimentally provide the datum intake performances for NGCTR-TD and to address the optimized configurations suitable for the NGCTR aircraft.
Company General Use
FRC-01-23: Experimental characterization and optimization of the RH and LH Engine intakes configuration of the next generation Tilt Rotor
Workpackages 1/2
1. Numerical assessment of the datum configuration (NGCTR-TD) CFD analysis in different flight conditions of the datum configuration as supplied by the ITD
leader
Rotor effects shall be included
2. Design, manufacturing and wind tunnel testing of the datum configurations (NGCTR-TD) Accomplishment of wind tunnel test on a scaled model (rotating parts not required) to support
and confirm the CFD prediction in the previous WP1 (performances, distorsion, losses, etc.)
3. Optimization of the internal ducts CFD optimization of the internal ducts of datum configuration aimed to maximize intake
efficiencies in different flight conditions (airplane mode and helicopter mode)
4. Design, manufacturing and wind tunnel testing of the optimized configurations Accomplishment of wind tunnel test on a scaled model (rotating parts not required) to support
and confirm the CFD optimzation in the previous WP3 aimed to address the NGCTR configuration
Company General Use
FRC-01-23: Experimental characterization and optimization of the RH and LH Engine intakes configuration of the next generation Tilt Rotor
Workpackages 2/2 5. Icing and Snow analysis
Analysis of the datum configuration (NGCTR-TD) in terms of ice accretion in order to identify possible criticalities.
Investigation of the intake characteristics into snow environments
Activities not related to the TD but fundamental to support the NGCTR development that exploits the same intake concepts
Expected capabilities from the Applicant
Proven skills in internal duct analysis and optimization
Wind tunnel tests management, test conduction and experimental data analysis on similar subject (proprotor nacelles)
Qualified and demonstrated skills in both numerical multi-objective optimization and simulation (CFD) for fixed and rotating (blade/propeller) components, wind tunnel testing and icing prediction.
FRC-01-24: High efficiency full electrical low pressure Compartment Pressure Control System for tilt-rotor applications
Fast RotorCraft IADP 8th Call for Proposal
Open Day May 2018
Company General Use
38
FRC-01-24: High efficiency full electrical low pressure compartment pressure control system for tilt-rotors applications
• Topic Manager: Leonardo Helicopters ;
• Collab.= Implementation Agreement
• Indicative Funding Value: 1.2 M€ ;
• Duration: 48 Months
• Type of Action: IA
• Overview: Development, testing and qualification of a full electrical modular-based low pressure compartment pressure control system .
• Objectives:
Development of the best architecture and hardware for a bleedless pressurized system.
Development of an integrated system composed by the electrical air compressor, cabin pressurization system components and management.
Company General Use
39
FRC-01-24: High efficiency full electrical low pressure compartment pressure control system for tilt-rotors applications
Development of an electric compressor to enable the bleedless engine architecture pursuing the philosophy of the More Electric Aircraft.
Optimization of energy supply modulation: ability to provide energy as necessary