SAT in the CS2Bruxelles,23th January 2013

January, 23th 2013

European Small Aircraft OEM Priority & Objectives for CS2

Presented By A. COZZOLINO

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European Small Aircraft OEM partnership

Piaggio Aero - P180 Mielec – PZL M28

Grob -G120 TP Evektor –EV55 Diamond –DA42

The European Small aircraft industry has a market position on the global general aviation and utility aircraft market both pistons and turboprops (excluding business jets and new category of Light Sport Aircraft) of around 33% in value (around 5 Billions Euro last ten Years).

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High level goals defined for small aircraft industry

Multimodality and passenger choice towards Flight path 2050

a. To provide accessible and affordable high speed mode of transport on European interregional network connections with low-intensity traffic

b. 90% of travelers within Europe are able to complete their journey, door-to-door within 4 hours

Revitalization of European small aircraft industry, more competitive EU

More safe and more efficient small aircraft operation

Lower environmental impact (noise abatement, fuel efficiency, energy saving production)

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HLO Priority Technology focus Quantitative target

• Operational Cost Reduction Airframe manufacturing & maintenance cost reduction Engine acquisition & maintenance cost reduction

Systems HM & More Electric 25-30% on Total Operating Cost

• Safety Improvement Systems for Pilot work load reduction 10 times fatal accident reduction • Cabin Improvement Noise, Thermal, Entertainment 80 dbA

Contributing to the ACARE Environmental Target:

• Reduce CO2 emission by 50%• Reduce NOX emission by 80%• Reduce noise perception by 50%

Small Aircraft OEM R&TD Priority (2020)

Major Research Area to be addressed Airframe

Areas below were defined by aircraft manufacturers

• WP A.1 - More affordable and green composite structures for small aircraft

• WP A.2 - More affordable and green metal structures for small aircraft

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Advanced out of autoclave (OOA) technologies More automation for low-volume composite production Improved process stability for non-prepreg composite technologies Advanced mould design and production Application of hybrid (metallic/GFRP/CFRP) materials to structures Application of integrated thermoplastic structural parts

Advanced design tool chain for OOA technologies (non handbook methods)

WP A.1 - More affordable and green composite structures for small aircraft

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Composite wing and empennage parts, hybrid float structure Airframe Subassemblies demonstrating advanced production processes,

production hardware (jigs/tools/moulds) and processes itself are parts of the demonstration.

WP A.1 - Airframe Integrated Structure – Composite ground demonstrator

Decrease of DOC & IOC BY 4%

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Increased structure performance by means of the latest generation materials tailored for low cost application:

Reduction of manufacturing and assembly cost increasing the application of integral structure concept and use of automated assembly processes (i.e. the friction stir welding, integrated machined parts, alternative joining technologies)

New concepts of assembly jigs and tools (robotic assisted assembly in low volume production)

Health monitoring systems for structures maintenance reduction and failures anticipation

WP A.2 - More affordable and green metal structures for small aircraft

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WP A.2 - More affordable and green metal structures for small aircraft

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Airframe Roadmap to Clean Sky 2

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Bruxelles, 23th January 2013 SAT in the CS2

WP E.1 - Reliable and more efficient operation of small turbine engines Major areas of interest are: Engine components - new alloys in aircraft engines, casting technologies for new superalloys,

use of ceramic cores for specific engine components, efficient machining technologies for critical engine parts (compressor, highly accurate gear wheels), optimized machining of heat resistant Ni/Co alloys, unconventional machining

Engine systems – control of engine (dual instruments, power lever), control system, fuel system including combustor

Engine designs / redesigns – aimed on improvements on engine efficiency, based also on safety analyses to meet safety/reliability requirements

Engines manufacturing and testing on ground and in flight - validation and integration of used technologies

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WP E.2 - Hybrid engine (piston/electric engine)

Major areas of interest are:

Design system components with ultra-light weight e.g. Inverter, E-Motor, E-Generator Design energy storage system e.g. battery suitable for airborne system in regards of safety and

weight Design of ultra-light weight propulsion systems with highest level of system integration Applying newest semiconductor technologies to address safety and reliability Develop system control platform to utilize maximum system availability Develop operational algorithm to maximize system efficiency according to different mission

profiles Drive market availability of key components e.g. energy storage systems for Aircrafts

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WP E.3 - Light weight and fuel efficient diesel engines

Thus the major areas of interest can be divided as follows: Engine – The engine weight optimization and high energy/mass design Turbocharging – application of new turbocharger design with use of new/alternative materials

and environmentally friendly parameters. Systems – control systems and fuel injection system redesign Engines manufacturing and testing on ground and in flight - validation and integration of used

technologies

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WP E.4 - Low noise efficient propeller

Innovations/improvements in the area: Noise abatement improved aerodynamics for better efficiency and therefore reduced fuel consumption advanced propeller a de-icing system for better efficiency and therefore reduced fuel

consumption and for reduced propeller system weight Improvement of total propulsion efficiency in conjunction with electric drives

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Small Aircraft Systems Peculiarity Small aircraft systems are different from large aircraft systems due to the ultimate need for low

weight, small dimensions, low cost and the severity to achieve these requirements on small dimension equipments together with reliability and performance.

The answer to many if this question is NO that’s why the need for an independent role in Clean Sky 2 for European Small Aircraft OEM.

MTM

E-ECS

Low Power deicing system

270 VDC Generator & Energy Management

Open Rotor

Have been the Small Aircraft priority taken into account? Are the technology directly

employable in Small Aircraft?

Are these technology directly/easily scalable?

Are the architecture applicable on small Aircraft dimensions?

EMA

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Major Research Area to be addressed JTI CS2 – ITD Systems

Areas below were defined by aircraft and systems manufacturers

• WP S1 - Efficient operation of small aircraft with affordable health monitoring systems

• WP S2 - More electric/electronic technologies for small aircraft

• WP S3 - Fly-by-wire architecture, modern cockpit and avionic solutions for small A/C

• WP S4 - Affordable SESAR operation, modern cockpit and avionic solutions for small A/C

• WP S5 - Comfortable and safe cabin for small aircraft

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The Condition Based Maintenance (CBM) is the state-of-the-art in the aviation industry (as well as other industries) next step is maintenance based on Prognostic Health Management (PHM)

The PHM strategy is founded on the possibility of monitoring the Systems, obtain information on their conditions and predict their evolution in the future.

WP S1 – Efficient operation of small aircraft with affordable health monitoring systems

Health monitoring System for small Aircraft will contribute to operational cost reduction & to safety improvement.

Reduction of the small aircraft Total operative cost of 9% is expected (50% reduction of total maintenance cost)

Costs• Unscheduled Maintenance• Scheduled Maintenance• Spare Parts• Warranty• Support• Fuel

Simplify• Better Visibility• Reduce logistics footprint• Fleet management

Operations• Improve Dispatch ability• Faster return to service • Greater availability• Avoid AOG

Higher Standard of Safety• Avoid and Mitigate failure• Flight Operations• Investigations• Training

Piaggio P180 Platform

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Aircraft electrical power consumption has dramatically increased in recent years. Technological advancements have led to the replacement of traditional hydraulic and pneumatic systems with electrically powered devices.

Forecasted new functions for small aircraft such as digital fly control system, electrical landing gear, de/anti-icing and entertainment systems will be added, which further increases the demand for electrical power.

Increasing use of electrical power is seen as the direction of technological opportunity for aircraft power systems based on rapidly evolving advancements in power electronics with fault tolerant power distribution systems and efficient power management.

WP S2 - More electric/electronic technologies for small aircraft

E-ECS

EMA

Reduction of the small aircraft Total Operative Cost of xx% is expected

270 VDC Generation & Energy Management System

E- Brake

Low Power deicing system

Mielec M28 Platform

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WP S3 – Fly-by-wire ArchitectureImproving safety by reduction of pilot workload in nominal and emergency conditions

Single pilot operability due overall reduced pilot workload (e.g. flight envelope protection)

Extensive flight automation capabilities to support or to substitute the pilot (optional pilot system)

Extended operational capability – all weather operation at regional airports with less ATC support

Diamond DA42 Platform

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WP S 4 – Affordable SESAR operation, modern cockpit and avionic solutions for small aircraft

In Avionics configuration of older commuter aircrafts with more than 10 passengers we observed mostly dual pilot cockpit even when aircraft are used for CARGO or low number of passengers operations only. It highly increase operation costs for these operations.

Goal of this WP is developing an universal cockpit and controls systems (i.e. Fly-By-Wire) which allows commuter airplanes effective operation depend on the user needs:

1. Single pilot operations for commercial Cargo and Passenger (up to 9 passengers – current regulations), 2. Dual pilot operations for commercial passenger transport (10 or more passengers),3. Single pilot operations for Cargo and Passenger (for 10 or more after increasing and proven safety level, pilot workload reduction and control systems enough to change regulations regulations).

The safety improvement trough the reduction of pilot workload developed by HMI research (software and hardware) on System Integration Lab and proven on M28 platform.

Mielec M28 PlatformSystem Integration Laboratory

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WP S5 – Comfortable and safe cabin for small aircraft Objective of this WP is to provide a step change in passenger comfort and safety addressing acoustic, air conditioning,

entertainment and crashworthiness issues specifically for small aircraft cabin.

The Introduction of smart passive damping devices and noise active control system can significantly reduce vibration and noise in the fuselage structures; this together with multifunction thermo-acoustic cabin interior makes a package to improve cabin comfort focused on small aircraft issue.

Innovative E-ECS air distribution will address small aircraft cabin environmental control issue improving the passenger individual comfort by appropriate management of cabin airflow and temperature.

New generation of „Slim“ seats will be accomodated to fulfill dynamic test requirements applied to small aircraft

The last but not least improving passenger comfort is the IFE system tuned for this size of aircraft operations. Therefore concepts and technologies will be developed and their proof of principle shown by simulation as well as hardware models in a most realistic test environment (including ground testing)

Evektor EV-55 Platform

active noise control Systemmultifunctional insulation

Slim dynamic seatsCabin IFE