Green RotorCraft ITD Closing event - Clean Sky · Green RotorCraft ITD Closing event Bruxelles,...
Transcript of Green RotorCraft ITD Closing event - Clean Sky · Green RotorCraft ITD Closing event Bruxelles,...
Green RotorCraft ITD Closing event
Bruxelles, March 22nd 2017
GRC ITD presentation
Innovation takes off
Closing of Clean Sky 1 - Wednesday 22 March
The Green Rotorcraft ITD gathers and structures all activities specifically concerned with the integration of technologies and demonstration on rotorcraft platforms (helicopters, tilt-rotor) which cannot be performed in platform-generic ITDs.
There are however technical links with activities conducted within the EcoDesign ITD, the Sustainable Green Engines ITD, the Systems for Green Operations ITD and with the Technology Evaluator.
With the goal to contribute to the overall objective of coming back within 20 years to the present global level of environmental impact while sustaining the expected growth of rotorcraft services, the Clean Sky initiative aims to reduce by half before year 2020, the specific impact of rotorcraft operations on the environment.
In detail, taking into account year 2000 as baseline, the objectives of the GRC ITD and concurrent activities in other Clean Sky ITDs were:
• reduce CO2 emissions by 26-40% and NOx emissions by 53-65%, according to vehicle and technologies used
• reduce average noise level by 10 dB
Position of GRC within the CS initiative
Closing of Clean Sky 1 - Wednesday 22 March
Main results, potential impact and contribution to CS
objectives – overview at start project
Closing of Clean Sky 1 - Wednesday 22 March
GRC ITD Consortium – A truly European Program
Closing of Clean Sky 1 - Wednesday 22 March
5 members, 18 associates, 68 partners in 17 countries
In order to achieve the global objectives, the project developed a new high compression power plant, innovative rotor blades, new aircraft configurations and Flight Paths Management.
The project is organized along six technological streams dedicated to key topics and one stream dedicated to technology evaluation:
(GRC1) Innovative rotor blades
(GRC 2) Drag reduction of airframe and non lifting rotating systems
(GRC3) Integration of Innovative Electrical Systems for Rotorcraft
(GRC4) Installation of a high compression engine on a light helicopter
(GRC 5) Environment friendly flight paths
(GRC6) Eco-design demonstrator (rotorcraft)
(GRC7) Technology evaluator for rotorcraft
The project includes also a management subproject (GRC0): it was jointly coordinated by LEONARDO SpA (ex Finmeccanica SpA, AgustaWestland) and Airbus Helicopters (AH).
Technical activities took place from July 1st, 2008 until December 31st, 2016
Initial objectives, long term vision and challenges
Closing of Clean Sky 1 - Wednesday 22 March
Work plan structure
Closing of Clean Sky 1 - Wednesday 22 March
Technology and impact results
GRC1
GRC3
GRC4
GRC6
GRC7
GRC2
GRC5
CO2 and NOx Reduction of Emission / Reduction of Fuel Consuption
Noise Reduction
REACH Compliance
Drag Reduction
Closing of Clean Sky 1 - Wednesday 22 March
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GRC1: Innovative rotor blades Active Gurney Flap - Improved performance of highly loaded rotor
Aim - Identify technologies/methods to:
• Reduce rotor power consumption =>
Reduce CO2 /NOx
• Reduce audible signature
First “Ground Run” accomplished in Dec 2016
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GRC1: Innovative rotor blades
INBOARD ACTIVE REGION
OUTBOARD ACTIVE REGION
Active Gurney Flap cross section
Active Trailing Edge donor blade
Cont.: Active Gurney Flap (Clean Sky GRC1) to provide rotor performance
enhancements (3-5%)
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GRC1: Innovative rotor blades Innovative Rotors: Active Gurney Flap
Four stages programme
with Multiple Members
and Partners
Stage Members GAPs & Partners
Model Rotor ACCUBLADE, GUM AGF, COMROTAG
2D “Steady-State” aerodynamic test
PT656
2D “Oscillatory” aerodynamic test
DEMOS COMROTAG
Aircraft Demonstration
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GRC1 - Innovative rotor blades GAP Results
Wind Tunnel model Rotor test
Confirmed AGF
capabilities
2D “Steady-State”
aerodynamic test
Gathered
2D Aerodynamic data
(tools development)
2D “Oscillatory”
aerodynamic test
Gathered
Performance data
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GRC1 - Innovative rotor blades
Flight test
• Demonstrates safe operation
• Further flight test activities to follow
First “Ground Run” accomplished in Dec 2016
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GRC2: Drag reduction of airframe and non lifting
rotating systems
Objective: Drag reduction of the rotor head and fuselage
HEAVY HELICOPTERS (AW101) • AW101 Optimized Main rotor hub
• AW101 Tail
• AW101 Rear fuselage drag reduction • Pulsed Jets
• Vortex generators
• AW101 Air intake drag reduction and engine installation
design optimization (GAP: HEAVYcOPTer)
Closing of Clean Sky 1 - Wednesday 22 March
TILT ROTOR (ERICA PLATFORM) • Drag reduction of a TILT-ROTOR fuselage, engine intake
and lift over drag increase of its wing and empennages
TEM (TWIN ENGINE MEDIUM HELICOPTERS - AW169) • AW169 Main rotor hub beanie optimization
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HEAVY HELICOPTERS (AW101)
GRC2: Drag reduction of airframe and non lifting
rotating systems
Baseline Optimized
Optimized AW101 Main rotor hub
AW101 Tail
Closing of Clean Sky 1 - Wednesday 22 March
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flight tests on AW169 of the optimized hub beanie
Computational Fluid Dynamic
LIGHT TWIN HELICOPTERS
GRC2: Drag reduction of airframe and non lifting
rotating systems
Closing of Clean Sky 1 - Wednesday 22 March
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Tilt Rotor Erica wind tunnel tests
Objectives: drag reduction of a tilt-rotor fuselage and
lift over drag increase of its wing and empennages
TILT ROTOR
GRC2: Drag reduction of airframe and non lifting
rotating systems
Particle Image
Velocimetry (PIV)
Closing of Clean Sky 1 - Wednesday 22 March
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GRC 3: Integration of Innovative Electrical
Systems for Rotorcraft
Key benefits:
o Improve MTBF
o Permit rpm variation for power
saving in cruise and heading control
o Excellent power surge
o Reduced parts
o Reduced maintenance overhaul
target
GRC3 is focused on:
• Techniques for energy recovery
• Energy management
• Optimization of power generation and distribution (incl.power losses)
• Electrical technologies (power converter and energy storage for improved electrical system efficiency)
• Electric Tail Rotor (providing innovative concepts allowing better tail rotor power management)
Initial Ground Test accomplished in Dec 2016
Test Campaign is continuing in 2017
Key features:
o Tail rotor direct drive (no
gearboxes, no shafts, no joints)
o Air cooling (no liquid - oil
lubrication)
o High redundancy through
multiple machine winding (4X)
o Continuous variable speed
control
Electric Tail Rotor Drive
Closing of Clean Sky 1 - Wednesday 22 March
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GRC3: Integration of Innovative Electrical Systems
for Rotorcraft - Main Contribution from GAPs
ELETAD led by
Technology: Electric Tail Rotor
Contributing Benefits:
System active weight optimised, proving technology in aircraft configurations (tail demonstration rig). Fault tolerance, Reliability, Safety, Maintainability, Non Hydraulic, Adaptable Design Concepts.
REGENESYS led by
Technology: DC High Voltage Power Converter, Control & Storage
Contributing Benefits:
System weight advantages, High voltage distribution, Multi use, Enables use of regenerative power sources. Reliability, Safety, Adaptability.
Technology: Regenerative Electrical Rotor Brake and Generator
Contributing Benefits:
System weight advantages, Multi use, Regeneration, Reliability, Safety, Maintainability, Non Hydraulic, Adaptability of control and use a brake and generator.
HERRB led by
Closing of Clean Sky 1 - Wednesday 22 March
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GRC 5: Environment friendly flight paths
Objectives Key advancement Innovation
Demonstration of low-noise
VFR/IFR procedures for
helicopters and tiltrotors
Design and demo of procedures
• applicable in real operations
• validated noise abatement
Combination of available
acoustic numerical tools,
realistic operational constraints
and optimization algorithms
Demonstration of
guidance/monitoring systems for
low-noise procedures
Improvement of cues and reduction
of workload for pilots in flying
complex low-noise flight profiles
Integration (e.g. into the on-
board systems) and validation
in flight of suitable hardware
and software
Reduction of exhaust pollutants
Development and experimental
validation of computational tools for
engine gas emission prediction.
Fully predictive approach for
the emission estimation from
helicopter engines.
Innovation and Achievements
Closing of Clean Sky 1 - Wednesday 22 March
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GRC 5: Environment friendly flight paths
Rotorcraft flight path optimization to minimize
noise & pollutant emissions
Closing of Clean Sky 1 - Wednesday 22 March
Integration of Flight
Management System
software models into
Leonardo simulator for
VFR real-time mission
guidance demonstration
Noise Abatement
Stee
pe
r
An
gle o
f ap
pro
ach
effect
Helicopter VFR & IFR Flight procedures developed
and validated through flight testing
Real-time mission guidance tool, including route
re-planning & display
TiltRotor - Air Traffic Management System coupled
simulations
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GRC 5: Environment friendly flight paths GAPs Contribution
Project
Acronym Leader Technology Result
EMICOPTER Development of computational
tools for engine gas emission
prediction
Fully predictive approach for the emission
estimation from helicopter engines.
Validation of the proposed approach against
experimental data in different engine operating
conditions (idle, take-off, cruise)
MAEMRO Development of methodology for
helicopter flue gas measurements
and flight measurement campaign
Measurements of pollutant concentrations in
exhaust gas have been carried out in different
ground and flight conditions
ANCORA Preliminary acoustic flight tests for
the tuning of simplified rotorcraft
noise models
Demonstration of the methodology to improve
the acoustic testing. Demonstration of
capability and advantages of the surface
microphones for on-board acquisition
TRAVEL Integrated ATC/TR simulation of
low-noise procedures for impact
evaluation on operators
Piloted sim demo of insertion of a tiltrotor in a
congested and complex air traffic scenario,
successfully achieved
MANOEUVRES
Innovative measurement and
monitoring system for accurate on-
board acoustic predictions during
rotorcraft approaches and
departures
Acoustic prediction; pilot acoustic indicator
development and PITL demo. Flapping
measurement system development; Integration
of measurements system on AW139.
Closing of Clean Sky 1 - Wednesday 22 March
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GRC 5 Contribution from GAPs – one example
MANOEUVRES - Manoeuvring Noise Evaluation Using Validated Rotor State Estimation Systems
Goal: exploit Rotorcraft agility to perform VFR flight procedures with Real-Time Noise Footprint control
Pre-calculated helicopter noise database
(Validated through Flight Campaign)
Innovative Main Rotor Blade
contactless flapping sensor,
essential for real-time noise
estimation
(TRL6 – Flight Tested)
Pilot Acoustic Indicator display
(Validated through Flight Simulator
Tests)
Closing of Clean Sky 1 - Wednesday 22 March
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GRC 5
Interaction with other project
ITD / TE Description of interaction Outputs / Results
GRC7/TE
Support to most of GRC7/TE technical
activities related to the acoustic analysis
and prediction
Production of acoustic data and low-
noise procedures for GRC7/TE generic
models, with benefits aligned to GRC5
demonstrations
Program Description of interaction Outputs / Results
SESAR, EASA, ATM stakeholders
GRC5 produced SESAR-compliant
simulation and flight test results relevant
to the demonstration of advanced GNSS-
based Instrument Flight Procedures, like
LPV steep approaches and Point-in-Space
procedures
Some GRC5 material shared, GARDEN-
CARE user forum organized,
demonstration by simulation of tiltrotor
IFR approach procedures to Milano
Malpensa airport with actual Air Traffic
Controllers involved
Operators Involvement of operators in final demo
definition and execution
Application of GRC5 low-noise VFR
trajectories to operators’ flight
procedures
Closing of Clean Sky 1 - Wednesday 22 March
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GRC 6: Eco design demonstrators
COMPOSITE THERMOPLASTIC TAIL BOOM
Design
• Generic tail cone (compatible with AW169 aircraft) w/o
sandwich elements
Technologies
• Composite Thermoplastic panels
• Autoclave formed Skin (T=380 °C, P=7 Bar)
• Continuous compression moulding of Stringers
• Compression moulding of Frames
• Induction welding of Stringers to Skin
Tail cone demonstrator chosen as one of the most appropriate
“primary” structure to test new/novel technologies in lieu of
conventional ones (metallic or composite thermosetting)
Tail boom structural testing
accomplished
Closing of Clean Sky 1 - Wednesday 22 March
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GRC 6
THERMOPLASTIC ROOF PANEL
Roof panel chosen to test material/technology appropriateness for
hot environment resistance of “secondary” structures
Design
• Light weight thermoplastic roof panel to fit
AW139, resistant to hot gas arising near
exhaust area.
Technologies
• Composite Thermoplastic panels
• Press moulded stringers
• Autoclave stringer + semipreg Co-Melt
process of Component (T=380 °C, P=7 Bar):
“one shot process”
Roof Panel Qualification tests began late 2016
Endurance flight tests are in progress
Closing of Clean Sky 1 - Wednesday 22 March
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GRC 6 : Eco design demonstrators / TGB
Green Surface Treatments, developed in EcoDesign ITD, applied on TGB
Support of Aluminium alloy with sulphuric anodising
Input Pinion: carburizing steel
with alkaline Zn-Ni
Tail Rotor Shaft: nitriding steel
with alkaline Zn-Ni
Case & Cover: Magnesium alloy with
“microarc” and “polimeric coatings”
TRL5 assessment accomplished on May 2016 Closing of Clean Sky 1 - Wednesday 22 March
Cadmium coatings
Crome exavalent
(anodising & coatings)
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Main Objective: Development of technology & design for
GRC demonstrators
Main Outcome: Compression Moulding and Induction
welding solutions developed; EcoFair
design demonstrated
Sponson
GRC 6 : Eco-Design Demonstrators GAPs contribution
ECOFAIRs (GAP) led by………
Closing of Clean Sky 1 - Wednesday 22 March
Tooling for
sponson
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Final Results simulation from Final Review
Rotorcraft
Class Version
Selected TE
Mission
Emission Reduction Target and Achieved at ATS Level
CO2 NOx
Noise Contour Area Reduction – Low Noise Procedure
(SEL dB(A))
Targets Results Targets Results Targets Results
Single Engine
Light [8] SEL_U2 Passenger
-10 to -25%
-21% -50 to -65%
-62 % -50% Reduction>60%
reached for noise levels > 85 dB
Twin Engine
Light [12] TEL_U2 EMS & Law
-25 to -40%
-13% -30 to -50%
-42% -50% Reduction >55%
reached for noise levels > 85 dB
Twin Engine
Medium [9] TEM_U1 SAR & Fire
-15 to -30%
-11% -55 to -70%
-42% -50% Reduction >50%
reached for noise level > 85 dB
Twin Engine
Heavy [13] TEH_U1 Oil & Gas
-15 to -35%
-21% -55 to -70%
-55% N/A N/A
High Compression Engine [10]
HCE_U1 Passenger,
Police & Training
to -40%
-67% per km flown*
to -65%
-68% per km flown*
N/A N/A
*comparison carried out against SEL_U2 Y2000R at mission level
Estimated as fully achieved
Estimated as partially achieved
GRC 7
Closing of Clean Sky 1 - Wednesday 22 March
GRC Dissemination: more than 200 Events
Main events
ERFs Clean Sky Conference & Exhibition
EU Aero Days AHS International Annual Forum &Technology Display
EASA Annual Helicopter Symposium
International Congress on Sound & Vibration
International Conference on Composites Materials
EASN WORKSHOP On Flight Physics And Propulsion
CFP Info Day IEEE International Conference on Industrial Technology
AAAF/AIAA Aircraft Noise and Emissions Reduction Symposium
EuroGNC Specialist Conference on Guidance, Navigation and Control
Years Number of
Actions (papers, articles, ..)
2008 2
2009 5
2010 12
2011 29
2012 28
2013 28
2014 47
2015 51
2016 26
TOTAL 228
Closing of Clean Sky 1 - Wednesday 22 March
Thanks for your attention
Innovation takes off
Many thanks to:
•CleanSky JU … for funding and support
•CleanSky partners … for all the help
•GAP partners …. for all the help
Closing of Clean Sky 1 - Wednesday 22 March
© 2017 by the CleanSky JU / Green Rotorcraft ITD (GRC) Members: Leonardo SpA (Ex AgustaWestland
Spa, Ex Finmeccanica Helicopter Division), Leonardo MV Ltd (ex AgustaWestland Ltd), Airbus Helicopters
(ex Eurocopter), Liebherr-Aerospace, Safran Electrical and Power (ex Hispano-Suiza and ex Labinal P.S.),
Thales Avionics Electrical Systems, Wytwornia Sprzetu Komunikacyjnego PZL Swidnik, Office National
d'Etudes et de Recherches Aérospatiales, Deutsches Zentrum für Luft- und Raumfahrt, Centro Italiano
Ricerche Aerospaziali, Airborne Composites, Alphei Pueschel Roesler - Akustik Technologie Goettingen,
Eurocarbon, Fibre Optic Sensors and Sensing Systems, LMS International, Microflown Technologies,
Micromega Dynamics, Stichting Nationaal Lucht- en Ruimtevaartlaboratorium, Technische Universiteit
Delft, Universiteit Twente
All rights reserved. This presentation material is provided for information of parties/persons invited to
the meeting as indicated herewith. No information contained in this material may be disclosed to any
other party/person, nor reproduced in whole or in part, nor used without the prior written consent of
the specific GRC member(s) to which the information belong(s).
Clean Sky JU / Green RotorCraft ITD
Closing of Clean Sky 1 - Wednesday 22 March