Clean Sky 2 Information Day dedicated to the 8 th Call for Proposal (CfP08) Leonardo Helicopters

Transcription

1 Clean Sky 2 Information Day dedicated to the 8 th Call for Proposal (CfP08) FAST ROTORCRAFT IADP Topics related to FRC WP1 Next Generation Civil TiltRotor Project Leonardo Helicopters Brussels, 22/05/2018 Innovation Takes Off

2 MISSIONS FRC Overview Filling the Mobility Gap AIRFIELD Unprepared Area EMS, SAR, Helideck Coast guard Door-to-Door Disaster relief Oil & Gas offshore Helicopter Compound R/C Corporate Transport Air Taxi Heliport Local airfield Tilt-Rotor A/C Regional Airport Large Airport Turboprop Turbofan & CROR Local Transport Short range Medium Range Long Range TRANSPORT RANGE & PRODUCTIVITY Clean Sky 2 / FRC General Session 2

3 FRC Overview Clean Sky 2 Context Fast Rotorcraft Leonardo Helicopters Airbus HElicopters Leonardo Clean Sky 2 / FRC General Session 3

4 FRC Overview NextGenCTR Objectives and Challenges >320 kts Commercially attractive Payload Recurring and Direct Operational costs comparable to Conventional Helicopter ft VTOL/STOL Declared CleanSky 2 Objectives: Low environmental impact with high productivity and efficiency 4

5 Approach for NextGenCTR Program: 2 Phases NextGenCTR A 2-Phase Program Phase 1 Design, Build, Fly a Technology Demonstrator under CS2 NextGenCTR TD if the market is ripe on-going business case development 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 Phase 2 Develop & Certify a Product NextGenCTR Tailored for diverse missions State-of-the-art Technologies embedded Competitive RC & DOCs vs. Helicopters No Legacy with AW609 technologies

6 FRC IADP NGCTR-TD Objectives 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

7 FRC IADP NGCTR-TD Objectives New Technologies to be tested within CS2 for First Flight (TRL =6) New Wing (no dihedral and no swept) Integration (T-WING) Mast tilt for control improvement (LH) Advanced empennage configuration (LIFTT) Innovative fuel system (DigiFuel & DEFENDER) Distributed FCS system (LH) Flow through engine New control laws (LH) Splitted gearbox architecture to support non tilting engine (LH) 7

8 FRC IADP NGCTR-TD Objectives New Technologies to be tested within CS2 after First Flight (TRL =<6) Rotor system new material application (MMC,...) (LH) New tailcone & empennage material manufacturing (LIFTT) Active inceptors (Partner to be engaged) General System new applications (i.e. Electrical low pressure compressor,...) (Call to be assigned) Additive Manufacturing technology gearbox housing (AMATHO) 8

9 FRC IADP NGCTR-TD Work Package Structure WP 1 - NGCTR WP 1.1 NGCTR Management & Coordination WP 1.2 Air Vehicle Design & Development WP 1.3 Aircraft Final Assembly WP 1.4 Aircraft Test & Demonstration Task Program Management & Coordination Task Design Integration Task NGCTR Industrialisation Task Ground Test Task Partner Management & Coordination Task Tiltrotor System Design Task NGCTR Manufacturing Engineering & Tooling Task Flight Test Task Transmission Systems Task ATP Test Equipment Task Rotor Systems Task Final Assembly Line & Flight Line Task Airframe Structures T-Wing Task Electrical & Avionic Systems Task Airframe Systems

10 CS1 technology pull through to CS2 Technology transfer from CS1 to CS2 Accessibility of this technology is granted No direct accessibility of this technology: there is no impact on NGCTR-TD development No direct accessibility of this technology: it should be useful for NGCTR-TD development 10

11 GRC3 GRC2 GRC1 Technology transfer from CS1 to CS2 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 WP2.2 - NGCTR - TILTROTOR SYSTEM DESIGN WP2.2 - NGCTR - TILTROTOR SYSTEM DESIGN 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. 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 WP2.6 - NGCTR - ELECTRICAL and AVIONIC SYSTEMS WP2.6 - NGCTR - ELECTRICAL and AVIONIC SYSTEMS WP2.4 - NGCTR - ROTOR SYSTEMS 11

12 GRC6 GRC5 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 onboard 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. 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 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 12

13 NGCTR WBS - Clean Sky 2 Demonstrators Definition & Plan CO 2 and Noise Footprint reduction Reduced cost of ownership (operating & MRO) Fast Forward Speed High Efficiency, High Productivity D6 2. Efficient nacelle architecture D7 D10 4. Optimized Tail configuration D5 3. Advanced Wing architecture D4 1.Fixed-engine, Split gearbox drivetrain concept D9 D8 5. Advanced Modular, Distributed & Scalable FCS D1 D1 Wind Tunnel Model D2 TDH Tie Down Tilt Rotor D3 Flying Demo D4 Drive system and components D5 Wing Assembly D6 Engine-nacelle integration D7 Fuel system components D8 Flight control and Actuation systems and components (SaIL) D9 Digital Mock-Up (DMU) D10 Airframe Structural Components D2 D3

14 NGCTR WBS - Clean Sky 2 Demonstrators Definition & Plan Master Level 0 Plan Status: 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 SRR (4/2017) SFR (12/2017) A/C DEFINITION PRELIMINARY DESIGN REVISED LEVEL 0 PLAN ASSET AVAILABILITY FROM 609 PROGRAM 609 A/C FUSELAGE PREPARATION WING FINAL ASSY (CPW04) DEMO A/C FINAL SYSTEMS ATPs GTV ON THE RAMP (2 months) 4/2023 FIRST GROUND RUN TOOLING & RIGS DESIGN - Rotating Controls Trade D9 Studies D7 DETAILED DESIGN D6 6/ 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) PDR (12/2018) - 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) CDR (7/2020) TOOLING & RIGS PROCUREMENT/MANUFACTURING D1 PARTS PROCUREMENT/MANUFACTURING WIND TUNNEL TESTING - Interactional Aerodynamics (CfP06) - Low Speed Model - High Speed Model (CfP07) - Nacelle Large Model (CfP08) - Aeroelastic Dynamic Model (CfP09) D8 D10 FATIGUE, LAB & AVIONIC TESTING DEMO WING MFG (FROM CPW04 PARTNER) DEMO FLAPERON MFG (FROM CPW03 PARTNER) D4 D5 1/2022 3/2022 TRR (9/2022) Q4/2022 FRR (1/2023) D2 FIRST FLIGHT D3 (9/2021) A/C COMPLETION FOR FF (0,5 month) TECHNICAL PROGRAM TERMINATION FLIGHT TEST PHASE 2 FDR (6/2024) FLIGHT TEST ACTIVITY FLIGHT TEST PHASE 3 PROGRAM CLOSURE LEGEND: SCR : System Concept Review SRR : System Requirements Review SFR : System Functional Review PDR : Preliminary Design Review CDR : Critical Design Review TRR : Test Readiness Review FRR : Flight Readiness Review FDR : Flight Demonstration Review GTV : Ground Test Vehicle FLIGHT TEST PHASE 4 FLIGHT TEST PHASE 5 14

15 8 th Call for Proposal (CfP08) Fast RotorCraft IADP 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 CS2 Info Day CfP04, Brussels

16 FRC-01-18: Adoption of a Digital Transformation approach to improve NGCTR design and simulation Fast RotorCraft IADP 8 th Call for Proposal Open Day May 2018

17 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: 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

18 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

19 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 Clean Sky 2 Technology Demonstrator Flight Data RAW DATA DATA APPLIANCE Future TiltRotors Design Full Size A/C Certification

20 FRC-01-19: Certification by Simulation for Rotorcraft Flight Aspects (CSRFA) Fast RotorCraft IADP 8 th Call for Proposal Open Day May 2018

21 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.

22 FRC-01-19: Certification by Simulation for Rotorcraft Flight Aspects (CSRFA) 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.

23 FRC-01-19: Certification by Simulation for Rotorcraft Flight Aspects (CSRFA) 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).

24 FRC-01-20: Design, development and flight qualification of a supercritical composite shaft drive line for tiltrotor main drive system Fast RotorCraft IADP 8 th Call for Proposal Open Day May 2018

25 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: 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.

26 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;

27 FRC-01-21: Development of effective engine air intake protection system for Tilt Rotor Fast RotorCraft IADP 8 th Call for Proposal Open Day May 2018

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. 28

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. 29

30 FRC-01-22: Development of engine exhaust wake flow regulator for Tilt Rotor Fast RotorCraft IADP 8 th Call for Proposal Open Day May2018

31 FRC-01-22: Engine exhaust wake flow regulator for Tilt rotor 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. 31

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 32

33 FRC-01-23: Experimental characterization and optimization of the RH and LH Engine intakes configuration of the next generation Tilt Rotor Fast RotorCraft IADP 8 th Call for Proposal Open Day May 2018

34 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: 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.

35 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

36 FRC-01-23: Experimental characterization and optimization of the RH and LH Engine intakes configuration of the next generation Tilt Rotor 5. Icing and Snow analysis Workpackages 2/2 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.

37 FRC-01-24: High efficiency full electrical low pressure Compartment Pressure Control System for tilt-rotor applications Fast RotorCraft IADP 8 th Call for Proposal Open Day May 2018

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 modularbased 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. 38

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 39