Call info day - Clean Sky · Call info day Sébastien DUBOIS, Project Officer (rotorcraft) Green...

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Clean Sky –Info day/ 29th February 2012 in Madrid (SP)

Call info daySébastien DUBOIS,

Project Officer (rotorcraft)

Green Rotorcraft: 2012 workplan with topics presentation of Call 13

Paris, 6th July 2012

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Outlines

The Green Rotorcraft Project Environmental objectivesMembershipGRC at a glance2012 workplan and associated topics

proposedTopics currently openedQ&A

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Clean Sky / Green Rotorcraft : heading toward ACARE goals

REACH complianceREACH REACH compliancecompliance

Halving noise

Emissions reduction

Green Life Cycle

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ITD-leaders (< 50%)DLR (D)ONERA (F)PZL Swidnik (Pol)CIRA-SELEX ATS: cluster (I)

IGOR: cluster of 11 members (NL, B, D)Airborne Composite, Akustik Universiteit Twente

160M€ Total Budget: 10% of Clean Sky

Agusta-Westland (co-leader)Eurocopter

(co-leader)

Liebherr (D)Hispano-Suiza (F)Thales Avionics

Electrical Systems (F)

DLR (D)ONERA (F)PZL Swidnik (Pol)CIRA-SELEX ATS: cluster (I)

IGOR: cluster of 10 members (NL, B, D)Airborne Composite, Eurocarbon, Fibre Optic Sensors and Sensing Systems, LMS; Microflown Technologies, Micromega Dynamics, NLR, Technische Universiteit Delft, Universiteit Twente

Partners (>25%)

Associates (<25%)

Main Stakeholders of the domain presents in the ITD GRC:Helicopter Manufacturers, Research Institutes, Systems suppliers10 members composed of 23 legal entities

GRC: Participants & Global Shares

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GRC Master Plan

Legend

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2012 detailed workplan (GRC1)1. Innovative Rotor Blades

Active Twist: tests completion at component level, and confirmation of the full active twist blade design

Active blade deformation e.g. active twist Active Gurney Flap: design of the wind tunnel model incorporating Active Gurney Flaps (CDR early 2013), in parallel with the development of full scale rotor equipped with AGF (incl. actuation device, power transfer, control system & modified blades

Active control surface e.g. Gurney flap3D blade shape: Optimisation will continue, the detailed design process, including definition of the manufacturing process and tooling such as moulds will be conducted following the PDR

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2012 detailed workplan (GRC1)1. Innovative Rotor Blades: list of topics launched in call 13

Identification ITD - AREA - TOPIC VALUE

JTI-CS-GRC-01 Area-01 - Innovative Rotor Blades 1,650,000

JTI-CS-2012-3-GRC-01-011 Low cost design approach through simulation and manufacture of new mould concepts for very high tolerance composite components 400,000

JTI-CS-2012-3-GRC-01-012 Design and Manufacturing of an innovative oscillating airfoil provided with Gurney flap- Design of scaled systems representing the GRC1 technologies to be tested at wind tunnel facilities 900,000

JTI-CS-2012-3-GRC-01-013 Development and Correlation of CFD Methods to Model Active Gurney Flaps on Helicopter Main Rotor Blades 350,000

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2012 detailed workplan (GRC2)

2. Drag reduction, required power reductionRotor head drag reduction:

Wind tunnel tests of different h/c configurations (incl fuselage cabin, landing skids, or sponsons, and rotor head) will be completed. Aerodynamic and structural design of a new full scale hub cap for light helicopter will be completed.

Reduction of airframe drag:improved aerodynamic design of the common helicopter platform and of the ERICA tilt-rotor will be conducted, incorporating passive and/or active flow control systems remotely controlled horizontal stabiliser for the wind tunnel model of the helicopter common platform will be manufactured, together with the remote control system

Turbo shaft engine installation: Aerodynamic and noise propagation analysis about new side air intakes

integrations will continue for light and heavy helicopters.

The new nacelle configuration, will be designed for the ERICA tilt rotor model, while astudy for evaluation of emission, engine performance and noise will be accomplished.

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2012 detailed workplan (GRC2)2. Drag reduction, required power reduction: list of topics launched in call 13


JTI-CS-GRC-02 Area-02 - Reduced Drag of rotorcraft 600,000

JTI-CS-2012-3-GRC-02-008 Assessment of tiltrotor fuselage drag reduction by wind tunnel tests and CFD 600,000

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3. More electrical HelicopterArchitecure study & assessment:

The analysis, simulation and assessment of the integrated all-electrical helicopter architecture.The new system EPGDS technology architecture will be defined integrating energy management and the different applications under study.

Technology study:Preliminary design studies:

Multi-source regenerative systems power conversion (incl. storage device)Brushless 28VDC Starter-GeneratorElectrical driven tail rotor motor

Detailed design studies:EMA system for medium/heavy helicopter flight controlElectric taxiingHeat Energy recovery systemPiezo Power Supply module ( Active rotor blade demonstration)Rotor braking recoveryManagement of energy recovery

Demonstration performed at system level in a dynamic and representative way on the Copper Bird Test Bench


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2012 detailed workplan (GRC3)3. More electrical Helicopter: list of topics to be launched in 2012

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2012 detailed workplan (GRC4)4. Lean powerplant

To reduce drastically CO2 emission thanks to the very low fuel consumption of modern Diesel engine technology: -30% to -40% over full flight envelope

Using regular kerosene fuel (or biodiesel)

To integrate the engine minimising the potential adverse effects:

weight penalty

Vibration

Cooling system

In 2012:

PDR/ CDR of the diesel power pack and engine installation on H/C

Preliminary study of the next h/c generation powered with a diesel engine


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5. Environment-Friendly Flight Path

Low-noise on-board system

En-route optimised flight paths for the reduction of polluting emissions

IFR & VFR approach and departure procedures (noise footprint minimisation)

Low level VFR & IFR en route navigation (noise impact minimisation)

SNI shorter routes to minimise fuel emission and gas emission

Operational Requirements

Flight guidance systems

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• Doors & Structural– Recyclable composite parts – Surface preparation for composite-

metallic bonding– Bonding and painting– Repair– testing

Gear Box HousingCr6 free Magnesium protection & touch up AND paintingTesting

Transmission componentsCd free protectionRepair AND paintingtesting

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2012 detailed workplan (GRC6)6. EcoDesign: list of topics launched in Call 13


JTI-CS-GRC-06 Area-06 - Eco Design for Rotorcraft 300,000

JTI-CS-2012-3-GRC-06-005 Recycling of Metallic Materials from Rotorcraft Transmissions 300,000

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Green RotorCraft ITD – Info Day Call 12, Brussels 20 April 2012

Identification ITD - AREA - TOPIC topics VALUE MAX FUND

JTI-CS-GRC Clean Sky - Green Rotorcraft 5 2,550,000 1,912,500JTI-CS-GRC-01 Area-01 - Innovative Rotor Blades 1,650,000

JTI-CS-2012-3-GRC-01-011 Low cost design approach through simulation and manufacture of new mould concepts for very high tolerance composite components 400,000JTI-CS-2012-3-GRC-01-012 Design of scaled systems representing the GRC1 technologies to be tested at wind tunnel facilities 900,000JTI-CS-2012-3-GRC-01-013 Development and Correlation of CFD Methods to Model Active Gurney Flaps on Helicopter Main Rotor Blades 350,000

JTI-CS-GRC-02 Area-02 - Reduced Drag of rotorcraft 600,000

JTI-CS-2012-3-GRC-02-008 Assessment of tiltrotor fuselage drag reduction by wind tunnel tests and CFD 600,000JTI-CS-GRC-03 Area-03 - Integration of innovative electrical systems 0

JTI-CS-GRC-04 Area-04 - Installation of diesel engines on light helicopters 0JTI-CS-GRC-05 Area-05 - Environmentally friendly flight paths 0JTI-CS-GRC-06 Area-06 - Eco Design for Rotorcraft 300,000

JTI-CS-2012-3-GRC-06-005 Recycling of Metallic Materials from Rotorcraft Transmissions 300,000

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For further information:

[email protected]

Contact us

Clean Sky Info Day on 13th call for proposals, 6 July 2012, Paris

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Clean Sky Info Day on 7th call for proposals, 11 October 2010, Brussels

© 2010 by the CleanSky Leading Partners: Airbus, AgustaWestland, Alenia Aeronautica, Dassault Aviation, EADS-CASA, Eurocopter, Fraunhofer Institute, Liebherr Aerospace, Rolls-Royce, Saab AB, Safran Thales and the European Commission.

Permission to copy, store electronically, or disseminate this presentation is hereby granted freely provided the source is recognized. No rights to modify the presentation are granted.

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For further information:www.cleansky.eu

Sébastien DUBOISProject Officer

[email protected]

Contact us

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GRC2Assessment of tiltrotor fuselage drag reduction by wind tunnel tests and CFD

GRC2Assessment of tiltrotor fuselage drag reduction by wind tunnel tests and CFD

Green RotorCraft ITD – Info Day Call 13, Paris 6 July 2012

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JTI-CS-2012-03-GRC-02-008

Title: Assessment of tiltrotor fuselage drag reduction by wind tunnel tests and CFD

Expected start date : June 2013

Duration : 24 months


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Scope


Objectives:Wind-tunnel tests of a reference tiltrotor fuselage (no rotors)Wind-tunnel tests of an optimised design of a tilrotor fuselage (no rotors)

Optimized nose, sponsonsOptimized wing/fuselage and wing/nacelle fairingsOptimized empennage

Support GRC consortium in the CFD drag reduction assessment of the optimizeddesign with extension to full-scale of the wind tunnel data

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Scope

Background :Basic and optimized helicopter fuselage model (1/8 scaled) provided by GRC consortium(Main balance and supporting system not delivered by GRC: to be supplied by the Applicant)

• CAD file of the configuration (CATIA V5® format)

Tasks :Task 1 - Wind-Tunnel Tests on the Original and Optimized ConfigurationsTask 2 - CFD Computations


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Expected activities

Task 1: Wind-Tunnel Tests on the Original and Optimised ConfigurationsPerform wind-tunnel tests of the reference fuselagePerform wind-tunnel tests of the optimized fuselageSet-up configuration

The applicant can decide the best attachment system (vertical strut or rear sting). Model will be modified accordingly by the GRC Consortium. Supporting system to be provided by the Applicant.Main internal balance: fully compatible with the existing RUAG-192 SI (for interface reason). No modification is allowed to the internal box structure of the model. Balance to be supplied by the Applicant.

Main wind-tunnel requirementsModel size: Lenght=2.351 m, Span=2.175mWind-tunnel speed up to 50 m/s (with model into test section)Fuselage attitudes from -20° to +20° in both Pitch and Yaw

Expected measurementsGlobal Forces and MomentsAny other specific parameters able to support the drag evaluation


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GRC1Low cost design approach through

simulation and manufacture of new mould concepts for very high

tolerance composite components

GRC1Low cost design approach through

simulation and manufacture of new mould concepts for very high

tolerance composite components

Green RotorCraft ITD – Info Day Call 12, Brussels 20 April 2012

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Background

Current state of the art composite rotor blades are manufactured with prepreg technology.

Resin transfer moulding (RTM) is an attractive alternative due to:• Lower cost of materials (fibres and resin vs prepreg)• High product tolerances achievable

Challenges relevant to this CfP:• Low cost approach to mould design through virtual manufacturing(simulations)• Moulding solutions that enable both prepreg and RTM processing• Efficient and even heat-up/cooling of the moulds • Verification of simulations through use of in-mould sensors

One aim of the consortium is to explore alternative low-cost closed mould technologies to manufacture helicopter rotor blades. This CfP supports this aim by finding more efficient solutions to mould design than current trail-and-error approaches.

Green RotorCraft ITD – CFP13 Info day, Paris 6h July 2012

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bersModel blade details


Blade radius 1.1m

Blade chord 90mm

Blade twist 8°

Aerodynamic profile – full span NACA0012

Top view

Side view

Solid D-spar

Model rotor blades will house an active gurney flap system, integrated after manufacture (not part of scope)

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ObjectivesDelivery of a suite of tools that will enable the production of model helicopter blades through both prepregging and RTM technologies.

Suite of tools are:• preform tools • processing mould(s)• inserts

Namely, all tooling required in the production of the prepreg and RTM blades

Approach to achieving objectives:Full blade design will be provided by the topic manager at project

start (blade geometry already fixed)Set up and implementation of process simulations including flow

simulations and thermal modellingSetup of CAD models and design of toolingConsideration of necessary in-mould monitoring sensorsManufacture of the toolingVerification of simulations using in-mould monitoring sensors


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Scope

Setup and execution of the necessary process simulations to enable full design of the tooling

Design of suite of tools using CAD including:• method for opening and closing of moulds• method for heating and cooling of moulds• integration of in mould sensors

Manufacturing and delivery of the suite of tools

Process testing/shape monitoring to validate functionality of mould and requirements on model blades will be met

Assistance in the manufacture of one blade per manufacturing process as proof of mould functionality (at the Topic Manager’s site)

Dimensional measurements and non-destructive and destructive testing of the part

Verification of the simulations through results obtained with in-mould sensors.


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GRC6Recycling of Metallic Materials from

Rotorcraft Transmissions

GRC6Recycling of Metallic Materials from

Rotorcraft Transmissions

Clean Sky Info Day on 11th call for proposals, 20th January 2012, Brussels

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GRC-06-005: Recycling of Metallic Materials from Rotorcraft Transmissions

Green RotorCraft ITD – Info Day Call 13, Paris 06th July 2012

BACKGROUND

Helicopter power Transmissions consist of a set of Gear Boxes which transmit power from the engines to the rotors via a series of shafts.

Transmission parts are manufactured from metal alloys: high specification steels for Gears and aluminium or magnesium alloys for Housings.

Corrosion, wear and fatigue resistance of those parts is enhanced by the use of surface thermal and chemical treatments:

carburising or nitriding for steel working surfaces, hard metal plating (generally chromium or nickel),

sprayed ceramic coatings,polymeric coatings of various types.

Transmission components have a finite life after which they must be withdrawn from service and then disposed of.

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RECYCLING

Out of life components cannot be returned to service and must therefore be returned to the raw material market. The method to be defined for this must feature:

energy efficiency(to process parts and materials with minimum loss or expenditure of energy);

acceptable quality of Recycled Materials(without build up of contaminant elements for reuse by the general market);

clean removal and minimum waste of Surface Treatments;

environmentally sensitive Waste Products to be generated in minimum quantity;

substances listed in the REACH candidate list must not be used or generated.



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SCOPE OF WORK

To define and to apply existing modern recycling methods toaerospace materials and processes found in helicopter gearboxes

in a cost effective and environmentally efficient manner.

GRC 6 partners will provide details of demonstrator components and assemblies and also trial components as appropriate.

The partner/consortium shall:• provide expert knowledge and experience on recycling processes;• provide detailed analysis on the application of specific recycling methods to the

demonstrators of each ITD manager;• have access to facilities that are able to process trial components and to

manage and demonstrate the costs inherent in the process;• have the ability to measure the cost and efficiency of the selected processes.



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GRC 6.3 Tail gear box

Total weight 23 kg40% gears40% housings20% minor components

Lubrication oil inside

3/ Flange to shaft Welding

2/ Composite

TP Shaft

1/ Green surface protections on Magnesium and Steel

4/ Recycled Thermoplastics for obturators

3/ Flange to shaft Welding

2/ Composite

TP Shaft

1/ Green surface protections on Magnesium and Steel

4/ Recycled Thermoplastics for obturators

GRC 6.4 Intermediate

gear box

Support aluminium with sulphuric anodising

Input pinioncarburizing steel

with alk Zn-Ni

Case & Covermagnesium alloy with microarc and polimeric

coatings

Tail Rotor Shaft

nitriding steel with alk Zn-Ni

Protection coatings thickness:max 0.015 mm for steel partsmax 0.050 mm for light alloy parts



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TIMESCALES AND DELIVERABLES

Deliverable Description Due DateD1 Survey of gearbox components and suitability for recycling methods To +3 Months

D2 Detailed description of the dismantling methodology with steps:1 - Separate the different parts2 - Remove the surface treatments3 - Recycling the materials (with minimized energy consumption and maximum effectiveness)

To +6 Months

D3 Application of the dismantling methodology To +9 Months

D4 Evaluate the cost-effectiveness (operation cost and re-use percentage) To +12 Months



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