AIRFRAME ITD Call for Proposals #6

Clean Sky 2 AIRFRAME ITD Call for Proposals #6 Brussels, 22 nd February 2017

From Clean Sky towards Clean Sky 2 Greener Airframe Technologies More Electrical a/c architectures More efficient wing Novel Propulsion Integration Strategy Optimized Smart control Fixed surfaces Wing Aircraft Integrated Structures Smart high lift devices Re-think the wing Re-think the a/c architecture Re-think the cabin Re-think the fuselage Re-think the control Step changes in the efficiency of all airframe elements by the means of a systematic re-thinking 2

AIRFRAME Key General Objectives More Efficient Airframes Weight Drag Cabin Noise New Materials Maintenance Efficiency of the engineering & manufacturing process Manufacturing Cost Time to Market (lead Time) IADP/Integrated Demonstrators SUPPORT TO IADP: Maturate technologies up to TRL 6 REG High Performance & Energy Efficiency High Versatility & Cost Efficiency FRC Innovative Aircraft Architecture Advanced Laminarity High Speed Airframe Novel Control Novel travel experience Next generation optimized wing Optimized high lift configs. Advanced integrated structures Advanced Fuselage LPA AIR Bizjet REG FRC LPA SAT AIR Bizjet TRANSVERSE Eco-Design for Airframe & Modeling to certification ability SAT FUTURE: De-risk novel generation product in the prospect of changing step by 2030+

AIRFRAME ITD Interfaces Overview with other SPDs Leonardo Leonardo Airbus Helicopters IADPs AIRFRAME ITD Dassault SAAB - Airbus DS IADPs & SAT provide General Requirements Airframe technologies development up to TRL5/6 TRL6+ demonstrations in IADPs and SAT 4

Overall WBS and participants A - High Performance and Energy Efficiency B - High Versatility and Cost Efficiency TS A-0: Management & Interface TS A-1: Innovative Aircraft Architecture TS A-2: Advanced Laminarity TS A-3: High Speed Airframe TS A-4: Novel Control TS A-5: Novel travel experience TS B-0: Management & Interface TS B-1: Next Generation optimized wing box TS B-2: Optimized high lift configurations TS B-3: Advanced Integrated Structures TS B-4: Advanced Fuselage WP A-0.1 WP A-1.1 WP A-2.1 WP A-3.1 WP A-4.1 WP A-5.1 WP B-0.1 WP B-1.1 WP B-2.1 WP B-3.1 WP B-4.1 Wing for Optimal engine Multidisciplinary High wing / large Advanced Overall Smart mobile Ergonomic flexible Overall incremental lift & Rotor-less tail for integration on Laminar nacelle wing for high & Tprop nacelle Integration of Management control surfaces cabin Management transmission shaft Fast Rotorcraft rear fuselage low speed integration configuration syst. in nacelle WP A-0.2 WP A-1.2 WP A-2.2 WP A-3.2 WP A-4.2 WP A-5.2 WP B-0.2 WP B-1.2 WP B-2.2 WP B-3.2 WP B-4.2 Business Aviation OAD & config. Mgt CROR & UHBR configurations NLF smart integrated wing Tailored front fuselage Active load control Office Centered Cabin SAT OAD & configuration Mgt More affordable composite structures High lift wing All electrical wing WP A-0.3 WP A-1.3 WP A-2.3 WP A-3.3 WP B-0.3 WP B-1.3 WP B-3.3 WP B-4.3 LPA OAD & config. Mgt Novel high performance configuration Extended laminarity Innovative shapes & structure RotorCraft OAD & configuration Mgt More efficient wings technologies Highly integrated cockpit WP A-0.4 WP A-1.4 WP A-3.4 WP B-0.4 WP B-1.4 WP B-3.4 WP B-4.4 Eco-Design TA Link Virtual modelling for certification Eco-Design for airframe Regional a/c OAD & config. Mgt WP B-0.5 Eco-Design TA Link Flow & shape control More affordable small a/c manufacturing WP B-3.5 Advanced integration of syst. in small a/c WP B-3.6 New materials & manufacturing Pressurized fuselage for Fast Rotorcraft More affordable composite fuselage Low weight, low cost cabin 5 Technology Streams 4 Technology Streams Co-Leaders: Airbus D&S S.A.U. (CASA) Co-Leaders: DAv, SAAB Leaders: Airbus, FNM-VEL, FNM-HD/AW, Leaders: Airbus, Fraunhofer AH, Fraunhofer, SAAB, Evektor, Piaggio CP: NACOR, GAINS, ecotech, CASTLE, MANTA CP: NACOR, OUTCOME, ASTRAL, SHERLOC, OPTICOMS, PASSARO, SAT-AM, CASTLE, LIFTT(?) 5

Share of funding foreseen Participants to date Countries involved to date AIR ITD Family Leader 16.7% 4* 4 Part. Leaders Core Partners 23.2% 13* 6 30.0% 76* 12 Partners 30.1% 124 16 *incl. Affiliates and Third Parties

AIRFRAME ITD - CfP Status CfP06 Identificatio n Code CfP Title WP/Task Project HPE AIR-01-25 Improvement of the aerodynamic loads prediction at high Reynolds number A-1.4 AIR-01-26 Development of innovative and optimized stiffeners run-out for overall panel weight saving A-3.1 AIR-01-27 Innovative solutions for metallic ribs or fittings introduced in a composite box to optimally deal with thermomechanical A-3.1 effects AIR-01-28 Bigger cockpit windshields and associated trade-off between plugged design and load-bearing design A-3.2 AIR-01-29 Optimisation of Friction Stir Welding (FSW) and Laser Beam Welding (LBW) for assembly of structural aircraft parts A-3.3 Project HVC AIR-01-39 Ice tunnel Model & test for Induction system + Ice tunnel Model & test for Heat Transport system B-2.1/B- 3.2 AIR-01-40 Infusion manufacturing methodolodies for Aircraft complex composite components. B-2.2 AIR-01-41 All Electric Wing: Integrated electronics for actuator data and power management for Morphing Leading Edge B-1.4 / B- activities 3.2 AIR-01-42 Lay-up tools for Helicopter Shells B-3.3.10 AIR-01-43 Materials & Process : Low Cost Optical Wave Guide for Damage Detection & Data Transfer B-3.3.2 AIR-01-44 Adjustable high loaded rod B-3.3.2 AIR-01-45 Development and deployment of PLM Tools for A/C Ground Functional testing with Eco-design criteria. B-3.6 AIR-01-46 Auto testing technologies and more automated factories for Aircraft validation test process B-3.6 AIR-01-47 Part specific process optimization in SLM B-3.6 AIR-01-48 Development and validation of a portable, automated and jigless system for drilling and assembly of fuselage joints B-4.3 AIR-01-49 Development and validation of a self-adaptive system for automated assembly of major composite aerostructures B-4.3 AIR-01-50 Design and manufacturing of innovative toolings for large curved fuselage panel B-4.3 7

AIRFRAME ITD - CfP Status CfP06 AIB TS A-1: Innovative Aircraft Architecture WP A-1.1 WP A-1.2 WP A-1.3 Optimal engine integration on rear fuselage UHBR & CROR configuration Novel high performance configuration WP A-1.4 Virtual modelling for Certification 8

AIRFRAME ITD - CfP Status CfP06 BJ COMPOSITE WING ROOT DAV TS A-3: High Speed Airframe WP A-3.1 WP A-3.2 WP A-3.3 Multidisciplinary wing for high & low speed Tailored front fuselage Innovative shapes & structure WP A-3.4 Eco-Design for Airframe 9

AIRFRAME ITD - CfP Status CfP06 DAV TS A-3: High Speed Airframe WP A-3.1 WP A-3.2 WP A-3.3 Multidisciplinary wing for high & low speed Tailored front fuselage Innovative shapes & structure WP A-3.4 Eco-Design for Airframe 11 11

AIRFRAME ITD - CfP Status CfP06 DOOR DEMONSTRATOR DAV TS A-3: High Speed Airframe WP A-3.1 WP A-3.2 WP A-3.3 Multidisciplinary wing for high & low speed Tailored front fuselage Innovative shapes & structure WP A-3.4 Eco-Design for Airframe 12 12

AIRFRAME ITD - CfP Status CfP06 Anti Ice Induction Leading Edge Anti Ice Loop Heat Pipe Nacelle Demonstrator TS B-2: Optimized high lift configurations CASA TS B-3: Advanced Integrated Structures CASA WP B-2.1 High wing / large Tprop nacelle configuration WP B-2.2 High lift wing WP B-3.2 All electrical wing WP B-3.3 Advanced integrated cockpit WP B-3.4 More affordable small A/C manufacturing CASA CASA, PAI, EVE CASA, FHG CASA, Airbus, FHG EVE 13

AIRFRAME ITD - CfP Status CfP06 TS B-2: Optimized high lift configurations CASA WP B-2.1 WP B-2.2 High wing / large Tprop nacelle configuration CASA CASA, PAI, EVE WP B-2.2.1 CASA High lift wing Advanced composite external wing box DOOR DEMONSTRATOR 14

AIRFRAME ITD - CfP Status CfP06 TS B-3: Advanced Integrated Structures CASA WP B-3.2 All electrical wing CASA, FHG WP B-3.3 Advanced integrated cockpit CASA, Airbus, FHG WP B-3.4 More affordable small A/C manufacturing EVE 15

AIRFRAME ITD - CfP Status CfP06 17

AIRFRAME ITD - CfP Status CfP06 18

AIRFRAME ITD - CfP Status CfP06 TS B-3: Advanced Integrated Structures CASA WP B-3.3 WP B-3.4 WP B-3.5 WP B-3.6 Advanced integrated cockpit More affordable small A/C manufacturing Advanced int. of systems in small A/C New materials and manufacturing 19

AIRFRAME ITD - CfP Status CfP06 Full Scale Fuselage Structural Ground Demo TS B-4: Advanced Fuselage FNM VEL WP B-4.1 WP B-4.2 WP B-4.3 Roto-less tail for Fast Rotorcraft Pressurized fuselage for Fast Rotorcraft More affordable composite fuselage WP B-4.4 Affordable low weight, human centered cabin 22

AIRFRAME ITD - CfP Status CfP06 TS B-4: Advanced Fuselage FNM VEL WP B-4.1 WP B-4.2 WP B-4.3 Roto-less tail for Fast Rotorcraft Pressurized fuselage for Fast Rotorcraft More affordable composite fuselage WP B-4.4 Affordable low weight, human centered cabin 24

JTI-CS2-2017-CfP06-AIR-02-48 Title: Development and validation of a portable, automated and jigless system for drilling and assembly of fuselage joints WP Location: AIR ITD WP B-4.3 Objective: Development and validation of a flexible system for automated drill integrated holes inspection to be used for a regional aircraft composite fuselage assembly. Use of the system will allow a significant reduction of the overall production costs and flow. The system will consist in a compact equipment, movable on curved surfaces, and able, through a dedicated Part Program, to perform one-shot drilling and hole inspection for assembly of primary structures. This solution will address longitudinal/circumferential joint of fuselage sections.

JTI-CS2-2017-CfP06-AIR-02-48 Capability: The portable equipment shall be able to perform drilling and hole check for Composite regional aircraft fuselage longitudinal and orbital joints. Reference components are shown in pictures.

JTI-CS2-2017-CfP06-AIR-02-48 Tasks description: Task 1 - Trade-off Study and Tool Technical Specification The advanced technologies development for an automated drilling system on the Regional TurboProp fuselage shall be driven by the following key factors: increase of integration, reduction of assembly flow, reduction of assembling costs and increase of automation.. Task 2 Equipment design Equipment shall be designed as an integrated system of the three main components: drilling and measuring head, head moving equipment (both X and Y axis, moving on the fuselage, at specific locations for panels joint) and positioning and alignment system. Task 3 - Test Plan of the three main components and their integration After design, a Test Plan for each of the three main components shall be produced by the Applicant, listing and describing all the tests that have to be conducted to develop the process.

JTI-CS2-2017-CfP06-AIR-02-48 Tasks description: Task 4 - Equipment development and construction Equipment shall satisfy all design requirements. Tests required by plans shall be conducted during the equipment construction, thus supporting and orienting the development of the automatic equipment. Task 5 Pre-acceptance tests A pre-acceptance phase shall be conducted before equipment shipping to the Topic Manager plant in order to verify technology readiness and conformance to the requested performance level. Task 6 - Equipment Acceptance An acceptance task, similar but more in depth than pre-acceptance, shall be performed after final installation in the Topic Manager facility. A full-size demonstrator shall be successfully drilled, checked and assembled in order to validate the Equipment capabilities (6 longitudinal joints, 1 orbital joint). Task 7 - Fuselage Demonstrators Drilling and Fastening Equipment shall be tested on the final planned demonstrator. The partner shall provide the required operational and engineering support for drilling and assembly operations of one demonstrator (6 longitudinal joints and 1 orbital joint). Maintenance, technical assistance and spare parts shall be guaranteed by the partner until the completion of all the activities planned (2 full complete demonstrators, 12 panels).

JTI-CS2-2017-CfP06-AIR-02-48 Special skills: Skill 1: Proven competence in design and construction of equipment for aeronautical composite components assembly, by a documented experience in participating in actual aeronautical program. This competence shall include a strong knowledge of processes, quality, tooling, part programs for CN machines. Skill 2: Proven experience in experimental testing from coupon levels up to aeronautical full scale substructures. Evidence of qualification shall be provided. Skill 3: Proven experience in cost estimation at industrial level for aeronautical full scale composite structures. Indicative Funding Topic Value: 900 k Duration of the action: 24 Months T0 (Start): Q1 2018

JTI-CS2-2017-CfP06-AIR-02-49 Title: Development and validation of a self-adaptive system for automated assembly of major composite aerostructures WP Location: AIR ITD WP B-4.3 Objective: Development and validation of self-adaptive system for automated assembly of major composite aerostructures of a regional aircraft composite fuselage which will allow a significant reduction of the overall production costs and flow. The system will consist in a anthropomorphic automatic robot equipped with end effector for drilling/countersinking, sealing and fastener insertion.

JTI-CS2-2017-CfP06-AIR-02-49 Capability: This solution will be applied for the assembly of stiffened panel skins, frames, window frames and door surround components. Recognition of actual position and shape of sub structure is performed by a dedicated camera system, so that a specific algorithm will elaborate the 3D model holes pattern on the basis of the actual structure position and profile. Camera system and algorithm shall be able to perform visual and dimensional checks by matching the actual data with requirements and providing report. Reference components is shown in figure 1. Figure 1 -generic stiffened after frame/ shear tie clips installation.

JTI-CS2-2017-CfP06-AIR-02-49 Tasks description: Task 1 - Trade-off Study and Tool Technical Specification The advanced technologies development for an automated drilling system on the Regional TurboProp fuselage shall be driven by the following key factors: increase of integration, reduction of assembly flow, reduction of assembling costs and increase of automation.. Task 2 Equipment design Equipment shall be an integrated system of the three main components: drilling and fastening (sealing and insertion) head, moving equipment and vision, analysis, positioning and alignment system, Task 3 - Test Plan of the three main components and their integration After design, a Test Plan for each of the three main components shall be produced by the Applicant, listing and describing all the tests that have to be conducted to develop the process.

JTI-CS2-2017-CfP06-AIR-02-49 Tasks description: Task 4 - Equipment development and construction Equipment shall satisfy all design requirements. Tests required by plans shall be conducted during the equipment construction, thus supporting and orienting the development of the automatic equipment. Task 5 Pre-acceptance tests A pre-acceptance phase shall be conducted before equipment shipping to the Topic Manager plant in order to verify technology readiness and conformance to the requested performance level. Task 6 - Equipment Acceptance An acceptance task, similar but more in depth than pre-acceptance, shall be performed after final installation in the Topic Manager facility. A full-size demonstrator shall be successfully drilled, checked and assembled in order to validate the Equipment capabilities (6 panels assembly). Task 7 - Fuselage Demonstrators Drilling and Fastening Equipment shall be tested on the final planned demonstrator. The partner shall provide the required operational and engineering support for drilling and assembly operations of one demonstrator (6 panels). Maintenance, technical assistance and spare parts shall be guaranteed by the partner until the completion of all the activities planned (2 full complete demonstrators, 12 panels).

General system architecture Capability of part/ hole pattern adaptation through a vision, analysis, re-positioning and alignment system (See Fig.2 for general system architecture); JTI-CS2-2017-CfP06-AIR-02-49 Fig. 2

JTI-CS2-2017-CfP06-AIR-02-49 General system architecture Re-positioning algorithm approach is shown in fig. 3. Fig. 3

JTI-CS2-2017-CfP06-AIR-02-49 Special skills: Skill 1: Proven competence in design and construction of equipment for aeronautical composite components assembly, by a documented experience in participating in actual aeronautical program. This competence shall include a strong knowledge of processes, quality, tooling, part programs for NC machines. Skill 2: Proven experience in experimental testing from coupon levels up to aeronautical full scale substructures. Evidence of qualification shall be provided. Skill 3: Proven experience in cost estimation at industrial level for aeronautical full scale composite structures. Skill 4: Proven experience in vision and inspection technology at industrial level. Indicative Funding Topic Value: 2000 k Duration of the action: 30 Months T0 (Start): Q1 2018

Any questions? Info-Call-CFP-2017-01@cleansky.eu Last deadline to submit your questions: 29 th March 2017 Innovation Takes Off

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