aerodays2015

Brusseles, Belgium, October 20 – 22, 2015

Pavel WOLF

Presentation of ESPOSA project

aerodays2015

Brusseles, Belgium, October 20 – 22, 2015

Pavel WOLF

Presentation of ESPOSA project

Project overview

• 41 partners (incl. 11 SMEs)

• 20 industrials, 11 research centres,

10 universities

• 15 countries :

CZ(7), PL(5), DE(5), ES(1), IT(5),

HU(1), RO(2), FIN(1), UK(1),

BE(3), NL(2), SVK(1),

UKRAINE(2), RU(1), TR (3)

Title : ESPOSA = Efficient Systems and Propulsion for Small Aircraft

level 2 project of 4th call of FP7, (ACP1-GA-2011-284859-ESPOSA)

Duration: 48+9M, start: Oct 2011 – end: June 2016

Website: www.esposa-project.eu

Coordinator : PBS Velká Biteš, a.s.

Administrator : VZLU

Consortium:

ENGINES

• turbo propeller and turbo shaft

gas turbine engines

• two power categories

(160250 kW and 300550 kW)

FLYING VEHICLES

• small turboprop aircraft, light helicopters

• transport utility aircraft, small commuter

aircraft (CS-23)

• unmanned aircraft systems for civil use

Future impact

Technical areas

RTD AREAS

New technologies and concepts for

key engine parts as compressor,

turbine, combustion chamber

and gear box.

New low costs manufacture

technologies for engine components

machining, casting and for coating.

Affordable solutions for electronic

engine control up to FADEC level,

tailored engine health monitoring

system for small aircraft operation…

Advanced and reliable simulation

tools and design methodologies for

mechanical, aerodynamic,

aeroacustic, thermal and aeroelastic

integration of engine into aircraft

structure…

RTD AREAS

New technologies and concepts for

key engine parts as compressor,

turbine, combustion chamber

and gear box.

New low costs manufacture

technologies for engine components

machining, casting and for coating.

Affordable solutions for electronic

engine control up to FADEC level,

tailored engine health monitoring

system for small aircraft operation…

Advanced and reliable simulation

tools and design methodologies for

mechanical, aerodynamic,

aeroacustic, thermal and aeroelastic

integration of engine into aircraft

structure…

PROJECT

OBJECTIVES

Modern gas turbine engine

affordability.

Reduction of DOCs by 10-

15%.

Pilot workload

PROJECT

OBJECTIVES

Modern gas turbine engine

affordability.

Reduction of DOCs by 10-

15%.

Pilot workload

PROJECT

AREAS

Optimal engine components.

Lean manufacture.

Modern engine systems.

Engine/aircraft integration.

PROJECT

AREAS

Optimal engine components.

Lean manufacture.

Modern engine systems.

Engine/aircraft integration.

C O

M P

E T

I T

I V

E N

E S

S

C O

M P

E T

I T

I V

E N

E S

S

• Project activities will include extensive

validation on the test rigs (validation on

component level)

• The most promising technologies (value/cost

benefit) will be selected and integrated into

higher functional complexes and further

evaluated on the engine test beds (validation

on engine level)

Demonstration activities

• The functionality of certain project outcomes will also be demonstrated and

validated in flight conditions to reach higher TRL level (validation on aircraft

level)

Objectives / Engines

The target for “BE2” engine

(measured in DOC) :

• Reduction of depreciation costs - by

1,5 3%

• Reduction of fuel consumption

(fuel costs) – by 2,55%

• Reduction of maintenance and MRO

related costs – by 6%

The target for “BE1” engine :

• About 60% price reduction compare to

the gas turbine engine currently available

• Lower maintenance costs (TBO

prolongation) compare to piston engines.

• EECU (engine control system)

• Create new engine segment

Reduction of

maintenance cost

by 40%

Reduction of fuel

consumption (fuel

costs) – by 1015%

Reduction of

depreciation costs

by 15 20%

Reduction of engine

waight and mass

Reduction DOC

by 10 -14 %

SP1 start technical activities with definition of high

level requirements (airframers - req. on propulsion

unit, engine producers - req. on engine

components / systems)

SP2 and SP3 work comprises performance

improvements of key engine components, their

improved manufacture in terms of costs and

quality.

SP4 is dedicated to novel modern electronic

engine control based on COTS, pioneering the

engine health monitoring for small engines and

providing advanced more electric solutions for fuel

control systems.

SP5 summarizes particular achievement of

SP2,3,4 in functional complex and provides the

space for their validation on engine test benches

SP6 addresses problematic design areas

connected with turboprop/shaft engine installation

into airframe structure, including the use of

composite materials. The work will be conducted

taking into account specifics of different aircraft

configurations.

SP7 validates not only installation technologies

developed in SP6 but also selected engine in

operational conditions

SP1 Requirements on Propulsion Units

Performances

SP2 Optimal Engine

Components

SP3 Lean

Manufacture Technologies

SP4 Reliable “COTS” Based Systems

for Small Engine

SP0 Consortium and Project Management

Engine

Technologies

SP5 - Engine and Systems Integration and Validation

SP6 - Advanced Design Methods for Engine/Airframe Integration

SP7 - Validation of Engine/Airframe Integration and In-Flight Demonstration

SP8 - Assessment of Small GTE Potential for Air Transport

ENGINE PRODUCERS‘

ROADMAP

AIRFRAMERS‘

ROADMAP

Overall assessment of project outputs and

perspectives for future small GTE propulsion

Validation of

design tools &

methods in real

conditions

New technical concepts for engine

components & engine systems / Innovative

manufacture

Inputs & Engine

Requirements

Validation of new engine systems in real

conditions

Components & systems integration

and validation on test rigs (on engines)

Definition and

acquisition of

parameters for

BE1, BE2 engine

installations

New design tools &

methodologies for

engine/airframe

integration

Project work flow

SP1 - Technical activities with definition of high level requirements of air framers requirements on propulsion unit, engine producers requirements on engine components and systems)

• Review of existing power units for small size aircraft – technological and economical challenges

• Forecast of technological and economical challenges for small size aircraft engine based on requirements for future small air transport system

• Specification of Baseline Engine BE1/2 and components for both units

• Enhanced BE1 and BE2 engine matematical modeling

SP1 Requirements on Propulsion

units performances

Periodic Review Meeting – 5-6 November 2014, Vienna

•PBS – BE1 engine data - outputs from altitude baro chamber in CIAM

•TUD – development of mathematical modeling calculation for BE1

•NLR – development of mathematical modeling calculation for BE2

Input

Output

API

e.g. BE2 model

Enhanced BE1/2 engine model

Work comprises performance improvements of key

engine components, their improved manufacture in terms

of costs and quality.

• In ESPOSA project are implemented

two types of Engines BE2 and BE1

SP2 Optimal Engine Components

BE1 –TP / TS 100 (PBS)

• Optimal small compressor

• Advanced low-cost small turbine

• Efficient NGV – cooled blades

• Efficient combustion concept proposal for a new combustion chamber (JETIS, RQL)

• Efficient combustion nozles concept

• Advanced dynamic modelling of high speed turbomachinery on the gearbox

• Advanced automatic control system for small GTE

• BE1 platform

EB2 – AI450 S2 (IVCHENKO)

• Preparation of potential technologies for use in next-generation engine

• Optimal Small Compressor

• Advanced Cooled Small Turbine

• Streamlining the production function and the combustion chamber and nozzles

• Cooling diffuser blade wheels

• Optimization of transmission

• Analysis of the dynamic conduct of the engine

BE2 platform

• High pressure ratio and high efficiency small centrifugal compressor according to its optimal weight, thermal and strength criteria is almost done

• Flow temperature and stresses fields acquisition for strength and clearance values evaluation in centrifugal compressor;

• Outlet system optimization in order to reach an impeller-outlet system matching is done;

• Developing an system of measurement gaps in centrifugal compressor is still in process

WP21 Optimal small compressor

• Advanced Small Cooled High Pressure Turbine aerodynamic investigations

• Advanced Small Cooled High Pressure Turbine Optimization

• Low Pressure Turbine optimization

• Investigation and design of a high efficiency inter-turbine duct (optimization)

• Advanced turbine CFD throughflow calculations with optimized components-

HPT, LPT, inter-turbine diffuser

• Simple cooling for vanes of small turbine (BE1)

• Turbine blades linear cascade experimental study

• Experimental Aerodynamic investigations of Advanced small turbine

• Experimental Research of Advanced small turbine Cooling system

• Turbine radial clearance measurement system in process

WP 2.2 - Advanced Cooled Small

Turbine

• BE1 injector - design of final RQL fuel nozzles with acceptable

parameters - done

• BE1 JETIS FANN sectors experimental verification – in process

• BE1 RQL FANN planar sector experimental verification - done

• BE1 RQL/JETIS LES simulation - done

• BE1 FANN JETIS combustion chamber delivered to WP5.1- in process

• BE1 FANN RQL combustion chamber delivered to WP5.1 – in process

WP 2.3 - Efficient combustion

concept BE1

• Research of original fuel injector with swirlers – done

• Optimized combustor numerical research finished – done

• Designed ecological parameters weren‘t achieved – swirler

optimization designed – done

• Test rig modification for installation of Advanced combustor - done

WP 2.3 - Efficient combustion

concept BE1

• Gearbox enhancement guidelines definition - done

• Gearbox dynamic loads and inputs - done

• Gearbox key components production – again in production (finalization of 2pc

pinion without modification and 2 sets of modified wheels A10, A20, A30, A40)

• Gearbox components measurement

• Gearbox assembly and Gearbox pre-test operations

• Gearbox testing and post processing

WP 2.4 - Optimum Gearbox

Concept

• Design of different low-cost machining strategies for BE1-impeller -

followed by evaluation using reference process A - done

• Design of low-cost machining strategy for BE2-compressor-stage -

followed by evaluation using reference process B – done

• Development of mathematical software for tool design - done

• Testing of BE2/BE1-compressor-stage on internal engine test bench in

SP5 - in process

WP 3.1 - Low-cost machining for

compressors

913 915

612

676

555596

405 420

293

639690

471

Machining t ime [min] Preparat ion t ime [min] Cut t ing tool costs [€]

Summary of ent ire process chain

Areference-Process C1-Process DPBS-Process DComot i-Process

-26 %

- 55%

- 30 %-39 %

- 54 % - 25 %

-2 %

- 52 % - 23 %

Main objectives: • Development of design of castings – ceramic shells

• Development of casting technology

• Casting of turbine wheels, Casting of guide wheels

• Testing of mechanical properties of materials

Task planned: • Ceramic shells development for casting of Hf containes alloys.

• Casting of turbine wheels from MAR-M 247 for BE1 demonstrator.

• Preparation of specimens from MAR-M 247 and CM247LC for material testing

• Testing of material properties (tensile, creep, LCF, HCF).

• Introduction of result from turbine wheels in to the guide wheels.

WP 3.2 - Precise and low-cost

casting technologies for turbine

wheels

Development of new TBC configurations

for turbine vanes and combustion chamber. Development of wear resistant

coatings for bearings mountain seats on engine shaft and compressor rotor blades

roots. Testing of lab-scale components under standard conditions for the aerospace

sector.

• Specifications on coating requirements

• TBCs for turbine nozzle guide vanes

• TBCs for flame tube elements of the combustion chamber

• Wear resistance coatings for bearings mountain seats

(engine shaft)

• Anti-fritting coatings for compressor rotor blade roots.

• Characterization / validation procedures for

coatings in BE2

• Specification on testing of proposed material

systems for combustor

WP 3.3- Development of

progressive coating solutions

• Development of low cost manufacturing technologies for gear wheels: contour induction hardening as an alternative to gas carburizing, superfinishing, manufacturing of CURVIC couplings. Validation of the new technology through a component test campaign (pitting / scuffing/ bending)

Main objective of the task:

• To evaluate the applicability of CIH, actually used for splines and/ or bearing seats, as an alternative to carburizing for case hardening of accessory gear.

• To identify a suitable steel for CIH

• To validate this technology through a component test campaign

Advantages of CIH

• Green Process: Contour hardening allows

removing the galvanic operation of copper

plating and de-plating.

• Copper plating-related costs

• Process-related costs

• Increase of productivity

WP3.4 - Low-cost gearbox

manufacturing and test

SP4-Contributions to new design

Reliable “COTS” Based Systems for Small Engine

New technologies for EEC/FADEC using COTS‐based HW/SW

control components, MEMS technology for energy harvesting and

scavenging, wireless sensors, reusable HW/SW components and

embedded reliable real time operation systems (RTOS), MBD

development, obsolescence management of electronic component

New technologies and components for smart health monitoring

system (HUMS “light”) based on wireless sensor network (WSN)

• Advanced automatic control system for

small engines

• Smart Health Monitoring Systém

• Affordable more electric solution for fuel and propeller control

systems

BE1/BE2/EEC I/EEC II – modular

concept

Vibration

Module EMM

Module

EEC-II

Channel

B

EEC-II

Channel

A

BLDC

Channel

A - B

BE2 BE1

WP4.1 - EEC I for BE1

BLDC

CH A / B

BLDC

CH A / B

Senzors

BLDC

CH A / B

Senzors

BLDC

CH A / B

WP4.1 - EEC II for BE2

BE1/BE2/EEC I/EEC II – MBD

synergi

Configuration of GSP for BE2 BE2 model in Matlab/Simulink

BE1 model in Matlab/Simulink

Configuration of GSP for BE1

WP.4.3 Fuel and Propeller Control

WP 5.1 - Validation of BE1 on Test Rig

- Validation of new components (compressor, turbine, combustor, control

system) and its development tests

- Acknowledgement of BE1 parameters and overall functionality

WP 5.2 - Validation of BE2 on Test Rig

- Validation of new components (compressor, HP and LP turbine, combustor,

control system) and its development tests

- Definition of BE2 parameters and updated mathematical model

WP 5.3 - Validation of BE2 in Altitude Test Chamber

- Verification of BE2 mathematical model through bench tests

- Main and operational characteristics of the BE2 engines will be verified in a

wide range of external conditions

SP5 Engine and System

Validation and Integration

BE1 PBS

Test components and

test rig technical

requirements review

Test plans for engine

and components

validation

Test rig specification and

design

Test rig preparation:

-special equipment

- test engines

- software

Test rig preparation

process

SP

3

SP

2

SP

4

WP 5.1 - Validation of BE1 and

BE2 on Test Rig

BE2 Ivchenko - Progres

WP 5.2 WP 5.3

Test components and

test rig technical

requirements review

Test plans for engine

and components

validation

Test rig specification and

design

Test rig preparation:

-special equipment

- test engines

- software

Test rig preparation

process

SP

3

SP

2

SP

4

WP 5.1 - Validation of BE1 and

BE2 on Test Rig

• Mapping of power unit installation requirements

• Application of innovative analysis technologies for engine integration

• Application of innovative technologies for power unit mechanical

integration in W7.1, WP7.2

WP OBJECTIVES/OUTPUTS

• Mapping of power unit installation requirements for selected aircraft

configurations and engines (ACC TR1, ACC PU2, ACC TR2, ACC HE1

and ACC HE2)

• DMU level 0 – first design of engine installation and inputs for

modification

• Creation of optimization of engine integration methodology in WP6.2, 6.3,

6.4 and WP6.5

• Application and verification of optimization methodology

• Creation of PDR (DMU L1) for ACC TR1, PU2, TR2, HE1 and HE2

All activites are done

WP6.1 - Innovative methods of

design solution and integration

of the engine to the airframe

DMU Level 0

DMU L1

DMU Level 0

WP6.1 - Twin TP engine

integration in tractor modification

(TR2) Aircraft: Twin TR – EV 55 (EVECTOR) CZ, DMU - L1 - done

Benefits •Reduced weight (15% less)

•Reduced production cost (45% less standard production)

•Possibility of outer shape optimization

•Minimization of engine maintenance time

DMU Level 0

WP6.1 – Sing.TP engine

integration in tractor modification

(TR1)

• Reduced weight

• Accessibility of engine

• Mount and accessibility of accessories

• Technology

• Minimization of development time and cost

Benefits • Minimization of air inlet drag

• Optimization of article separation

• Minimization of development time and cost (reducing of mistake during installation with influence to

preparing redesign of engine installation and production

tools and requirements for development tests)

Aircraft: TR – I31T (ILOT) PL, DMU - L1 - done

DMU Level 0

WP6.1 - Twin TP engine

integration in pusher

modification (PU2) Aircraft: ORKA (M&M) PL, DMU L1 – done

• Reduced weight

• Accessibility of engine

• Mount and accessibility of accessories

Benefits • Minimization of air inlet drag

• Optimization of particle separation

• Minimization of development time and cost (reduction of mistake during installation with influence to

preparing redesign of engine installation and production

tools and requirements for development tests)

DMU Level 0

WP6.1 - TS engine integration in

light helicopter (HE1)

• Reduced weight

• Accessibility of engine

• Mount and accessibility of accessories

Benefits • Minimization of air inlet drag

• Optimization of IFB

• Minimization of development time and cost (reduction of mistake during installation with influence to

preparing redesign of engine installation and production

tools and requirements for development tests)

B250, WINNER Helico (Belgie), DMU L1 – done

DMU Level 0

WP6.1 - TS engine integration in

ultra light helicopter (HE2)

Benefits • Minimization of air inlet drag

• Optimization of IFB

• Minimization of development time and cost (reduction of mistake during installation with influence to

preparing redesign of engine installation and production

tools and requirements for development tests)

T- line, IRI (Italy), DMU L0, L1 done

WP6.2 Reliable design

technology for aerodynamic

engine/airframe integration

• Effect of non uniform inflow on propeller performances

• Aerodynamic design methodology of nacelle external shape

• Innovative technologies and aerodynamic design methodology for air

inlet and internal nacelle duct

• Aero-Acoustic and aerodynamic assessment and methodologies

Method and tool for the unsteady aerodynamics of propeller - models and SW

tool for aeroelastic interference considering fatigue effects (INCAS)

WP 6.3 - Tools for engine and

nacelle integration "Whirl Flutter"

• Detailed structural model

• Modeling of the propeller dynamics

using MSC rotor dynamics

• Obtaining the global load spectrum

• Select critical location for Principal

Structural Elements

• Calculate nominal stress levels for PSEs

and local stress levels at critical

locations

• Calculate fatigue life and Margin of

Safety

For TR1 Aircraft:

• Oil Cooler Analysis (on ground and in air)

• Nacelle Thermal Analysis (cruise operation, engine

shutdown, climb operation)

• Nacelle Thermal Stress Evaluation (cruise operation)

• Exhaust Jet Analysis (on ground, cruise and climb

conditions)

For PU2 Aircraft:

• Oil Cooler Analysis (on ground and in air)

• Nacelle Thermal Analysis (cruise operation, engine

shutdown, climb operation)

• Nacelle Thermal Stress Evaluation (cruise operation)

• Exhaust Jet Analysis (on ground, cruise and climb

conditions)

For TR2 Aircraft:

• Oil Cooler Analysis (on ground and in air)

• Nacelle Thermal Analysis (cruise operation, engine

shutdown, climb operation)

• Nacelle Thermal Stress Evaluation (cruise operation)

• Exhaust Jet Analysis (on ground, cruise and climb

conditions)

For HE1 Helicopter:

• Oil Cooler Analysis

WP6.4 Reliable simulation tools

for engine thermal integration

WP6.5 New design and

manufacturing approaches for

"hot" composite nacelles

• Most suitable composite materials and processes

• Process windows and material properties.

• Design engineering approach

• Understanding “benefits”

• Validated new technology

• Provide technology to WP7.1

• All activities are focused to I31T (ILOT) and P180 (PIAGGIO)

• Objectives

WP6.1

T6.5.1 T6.5.2

T6.5.3

T6.5.4

SP7

A

B

C

WP6.4

2nd nacelle: • Adapted bagging • Adapted location resin reservoirs • Generally results

WP6.5 New design and

manufacturing approaches for

"hot" composite nacelles

WP7.1 Validation of integration design methodologies Validation of complex design methodology for engine integration within various

airframes Engine/airframe installation for different kind of aircraft – knowledge.

WP7.2 Qualification Activities for Flight Testing The engine ground tests and qualifications of the engine for flight Main operational characteristics of the BE1 engine verified and

aircrafts (I-23, ORKA, Rotorcraft Winner, Rotorcraft IRI) prepared for flight demonstration.

WP7.3 Overall Demonstration in In- flight Conditions Demonstration of the results developed engine technologies in in-flight conditions

and validation of complex design tools and methodologies for BE1 engine integration within various airframes.

Results of flight tests for airplanes: I-23, ORKA & rotorcrafts with new powerplant and validation flight performance of the BE1 engines for four aircraft platforms

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SP7 Validation of Engine

/Airframe Integration

and In-Flight Demonstration

Institute of Aviation ILOT - TR-1 Margański & Mysłowski PU-2

WINNER HELICO HE-1 IRI HE-2

Innovative Aircraft Demonstrator

Platforms of ESPOSA

WP7.2 Qualification Activities for Flight Testing

• The engine ground tests and qualifications of the engine for flight

BE1 life testing according to the typical flight profile for EM-11C Orka airplane

• Finished second 500 hour period – target for ESPOSA project (1000 hours)

achieved

Measurement in altitude test chamber

Measurement on the ground test bench

• Test verification of MTV-25 propeller for I-31T airplane

• test with the same propeller

• lower vibration, lower noise,engine faster acceleration

WP 7.2 Qualification Activities for

Flight Testing

Water ingestion test

• realized within the EM-11C Orka approval process

• test cycle defined to fulfill CS-E 790, CS-23.901 – worst case: 4% of water

• engine operation during the test was stable without surge indication

WP 7.2 Qualification Activities for

Flight Testing

Czechowice – Dziedzice, Poland 22 Oct 2014 – first engine run

13 February 2015 – first flight

WP7.1 PU-2 Progress

Czechowice – Dziedzice First engine run on 4 March

2015

10 June 2015 – first flight

WP7.1 TR-1 Progress

Sorinnes –Chassis

WP7.1 HE-1 Progress

WP7.1 HE-2 Progress

Summary of ESPOSA project

The project ESPOSA should encourage both aircraft

and engine producers in using new solutions for their

aircrafts and gas turbine engines by demonstrating their

feasibility and by proving their advantages.

Thank you for your attention !

The project ESPOSA should encourage both aircraft

and engine producers in using new solutions for their

aircrafts and gas turbine engines by demonstrating their

feasibility and by proving their advantages.

Thank you for your attention !