clean sky 2 information day dedicated to the 4th call for proposal … cs2cfp08id... · frc...

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


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)


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


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


• WP2.7 - NGCTR - AIRFRAME SYSTEMS


• 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


• WP2.4 - NGCTR - ROTOR SYSTEMS


Company General Use 12


• 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


• WP4 - NGCTR - AIRCRAFT TEST and DEMONSTRATION

• WP2.4 - NGCTR - ROTOR SYSTEMS






• 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


• 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


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


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)


Open Day May 2018

Company General Use


• Topic Manager: Andrea Ragazzi

• Collab.: Implementation Agreement

• Indicative Funding Value: 3 M€


• 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.


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-01-20: Design, development and flight qualification of a supercritical composite shaft drive line for tiltrotor main drive system


Open Day May 2018

Company General Use







• 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


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


Open Day May 2018

Company General Use

28

FRC-01-21: Development of integrated engine air intake and protection systems for Tilt Rotor






• 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


Open Day May2018

Company General Use

31






• 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


Open Day May 2018

Company General Use






• 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


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


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


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






• 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

clean sky 2 information day dedicated to the 4th call for proposal … cs2cfp08id... · frc...

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