Eco-Design ITD ECO-DESIGN ITD DESCRIPTION OF WORK SUMMARY

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1 ECO-DESIGN ITD DESCRIPTION OF WORK SUMMARY 1. INTRODUCTION The global objective of the Eco-Design ITD is to reduce the product environmental impact while keeping competitiveness of the aeronautic industry. The Eco-Design ITD is composed of two parts: the Eco-Design for Airframe application (EDA) and the Eco-Design for small aircraft Systems application (EDS). The EDA part addresses the full A/C life cycle, with a particular focus on the A/C design & production and A/C withdrawal phases, let say the out of operation phases. The EDS part only addresses the A/C Use & Maintenance phase. In both parts, the usual performance and cost criteria will strongly guide all the R&D activities all along the project. The coordinator in terms of Grant Agreement is Aviation. The last contract of Clean Sky will cover the period 2013 to The purpose of this document is a general description of the work performed in the frame of the Eco-Design ITD along this period. This description is a first draft technical input to the related Annual Implementation Plan (AIP). 2. INDUSTRIAL ORGANISATION Aviation and -Gesellschaft are the co-leaders of the ITD team which includes: 8 other ITD leaders: Airbus, AgustaWestland, Alenia, EADS CASA, Eurocopter, SAFRAN, Thales 5 Associates: EADS IW, HAI, IAI, a Swiss cluster (RAC) led by RUAG and a Netherland cluster (NLC) led by Fokker Aerostructure Partners winner of CfPs complement this list. 1 / 13

2 WP A.2 WP A.1 WP A.3 Eco-Design ITD 3. ECO-DESIGN FOR AIRFRAME 3.1 Development Logic The work is organised according to the following logic flow: Period Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 LCA current techno. State of the Art Specifications Trade-Off - Roadmaps LCA tools LCA current technologies Simplified LCA Tools and database Advanced LCA Tool and database Selection of the technologies to be developed (environmental impact, TRL, etc.) LCA new technologies Synthesis / TE Scoping Technology Development WP A.4 Demonstrator definition WP A.5 Equipment Ground Demonstration Preparation WP A.6 Equipment Ground Demonstration Figure 1: Development Logic After the initial evaluation of current technologies (WP A.3), a set of requirements for the future technologies has been established (WP A.1). These requirements have been used to select green technologies to be developed in the frame of EDA (WP A.2). Then the most promising technologies will be evaluated and matured through a life cycle demonstration (WP A.4, A.5 and A.6). After extrapolation to real industrial conditions, a final eco-statement will be conducted in WP A.3 to evaluate the environmental impact of newly developed technologies and to benchmark them against current technologies evaluated in WP A.3 Current Eco-Statement. The activity is conducted for the production, maintenance and withdrawal phases of the aircraft lifecycle ( non operation phases ). 2 / 13

3 3.2 Statement of Work for the period Work Breakdown Structure The logic described in above section can be translated into a WBS as shown on Figure 2 hereafter. On this figure the WP not active on the period are greyed. ED A Eco-Design for Airframe DAv/FhG ED A.1 Alternative Requirements ED A.2 Technologies Development ED A.3 Application Studies ED A.4 Life Cycle Demo. Def. ED A.5 Life Cycle Demo. Prepa. ED A.6 Life Cycle Demonstration ED A.1.1 Materials & Surfaces Eurocopter ED A.2.1 Materials & Surfaces EADS IW ED A.3.1 Eco-Statement Airbus ED A.4.1 Equipped Airframe HAI ED A.5.1 Equipped Airframe HAI ED A.6.1 Equipped Airframe HAI ED A.1.2 Manufacturing ED A.2.2 Manufacturing RUAG Cluster ED A.3.2 Extrap. to Industrial Cond. Alenia ED A.4.2 Equipment SAFRAN ED A.5.2 Equipment SAFRAN ED A.6.2 Equipment SAFRAN ED A.1.3 Long Life Structure AgustaWestland ED A.2.3 Long life Structure IAI ED A.3.3 Eco-Design Guidelines ED A.1.4 End of life ED A.2.4 End of Life Airbus ED A.1.5 Societal Figure 2: EDA WBS Scope of Technical Work WP A.2 Technology Development General objective of this WP is to define and mature alternative solutions consistent with WP A.1 Requirements. In each of the 4 sub-wps, i.e. Materials and Surfaces, Manufacturing, Long Life Structure and End of Life, the development of the technology will be finalised by October 2013 to reach TRL 4 prior to enter into the demonstration step to reach TRL 6 by the end of Clean Sky WP A.3 Application Studies The objectives of the WP are as follows: To quantify the environmental benefits associated with new technologies by comparison with baseline technologies from a life cycle perspective (WP 3 / 13

4 A.3.1). This includes deployment of evaluation tools, evaluation of current technology a/c and evaluation of Clean Sky technology future a/c. The development and deployment of simplified tool is finalised mid of The enhance tool will be deployed by mid The evaluation (LCA) of current technologies will be finalised by October 2103 and the evaluation of new technologies developed in the frame of WP A.2 will be performed up to beginning of To analyse the technologies developed in the WP A.2 and demonstrated in WP A.6 in a prototype context in terms of industrial repercussion consequent to their possible adoption in the manufacturing plants of the future (WP A.3.2). This task will be closed end of To develop an Eco-Design Guideline to optimize the a/c design, production, and end of life phase from an overall environmental perspective (WP A.3.3) WP A.4/5/6 Lifecycle Demonstration The last phase of activities will include a proof of eco-design demonstration through a full lifecycle demonstration of aircraft representative components. The list of components will cover most of the critical items highlighted through the initial ecostatement. The aim of the lifecycle demonstration definition is: Starting from the Technology Development WP A.2, to select the technologies which have to be matured to the readiness level that will allow their application to future aircraft and rotorcraft programmes; With the selected technologies, to define with a cost effective approach the demonstrators and the means to be used for the demonstration; these elements will be defined based on the outcome of the first years of research activities. The demonstration is structured around 2 groups of demonstrators: The Equipped Airframe demonstrators covering the structure demonstrators and the cabin interior demonstrators (WP A.4.1, 5.1, 6.1) The Equipment demonstrators (WP A.4.2, 5.2, 6.2). WP A.4 is the definition of the demonstration to be finalised on WP A.5 is the preparation of the demonstration to take place on 2012 and 1 st half of The demonstration (WP A.6) will be performed up to mid Structure Demonstrators This type of demonstrator is dedicated to tests for use/maintenance phase demonstration. Test articles will be manufactured and then, if relevant, duty cycled under representative aircraft/rotorcraft environment. Subscale test articles and/or structural subcomponent constituting intrinsic item of a validation article are candidates to become part of this topic. An example of such a demonstrator is presented on Figure 3 hereafter. 4 / 13

5 Figure 3 Example of Airframe Demonstrator Fuselage panel Cabin Interiors Demonstrators This type of demonstrator is aimed at performing tests for cabin furnishings. Test articles will be manufactured and then dismantled. The materials will be recycled, eliminated or stored if relevant and possible. An example of such a demonstrator is shown on Figure 4. Figure 4: Example of cabin interior demonstrator - Cabin lining panel Equipment Demonstrators Additional demonstrators could be necessary for items demonstrated as critical through the initial eco-statement. Examples of such items are: rotorcraft blade, turbine blade, tyres, engine components, and microelectronics This type of demonstrator is dedicated to manufacturing and tests for use phase demonstration. Test articles will be manufactured and then, if relevant, duty cycled under representative equipment environment (engine/aircraft/rotorcraft) to evaluate 5 / 13

6 their ability to be used first in the development of the equipment and further in its use phase. Example of such a demonstrator is presented on Figure 5: Figure 5 Example of equipment demonstrators - Turbine wheel Master Plan The programme of work extends to 7 years and has been structured to allow adequate consideration of the technical options in each area within the proposed timescales. Figure 6 below shows the EDA master plan. The plan identifies interactions with the Clean Sky Technology Evaluator. Figure 6: EDA Master Plan 6 / 13

7 4. ECO-DESIGN FOR SYSTEMS (SMALL AIRCRAFT) 4.1 Development Logic The primary objectives of this part of the Eco-Design ITD are: To reduce the direct, weight and drag-induced non renewable energy consumptions of vehicle systems, To reduce dependency on noxious fluids through an evolution towards electric technologies, To reduce ground and flight tests with innovative concepts and technologies. Secondary objectives are: To develop and validate an aircraft design methodology for the optimisation of integrated vehicle systems architecture and the associated tools. To develop and validate innovative technology models and simulations to reduce amount of H/W testing (towards the virtual a/c: clean design and development). The work will be organised according to the following logic flow: Clean Sky Technology Evaluator WP S.1 Common Architecture Studies (Generic Arch.) Requirements Modelisation, simulations, validations Technologies ECS, anti / de-icing Actuators Electrical generators, Starters... WP S.2 Bizjet Arch. Trade-off Regional Arch. Trade-off Rotorcraft Arch. Trade-off Eco-Design ITD SGO ITD GRA ITD Electrical & Thermal Benches definition WP S.3, S.4 Global Test Bench Electrical Bench Thermal bench GRC ITD Figure 7: EDS Logic Flow The logic is based on the 2 sequential steps: common architecture studies to develop and validate the a/c optimisation methodology followed by the specific a/c trade-off studies to optimise the all electric aircrafts and demonstrate benefits of the concept. On the figure appears a first overview of the links between 4 ITDs as shown by the colour code: 7 / 13

8 Common activities using the generic architecture are performed in the frame of the Eco-Design ITD. The Systems for Green Operation ITD (noted SGO ITD) develop electric and thermal technologies in the frame of the Energy Management part of the ITD. It produces H/W components, models and data to be used by the Eco-Design ITD at a/c architecture level, for test and analysis. Trade-off and ecolonomic analysis on specific architectures for business jet, regional and rotorcraft a/c are performed respectively in the frame of the EDS, GRA and GRC ITDs. 4.2 Statement of Work for the period Work Breakdown Structure The WBS is derived from the above logic flow and is represented on Figure 8 hereafter. WP S.2 is dedicated to the specific a/c Vehicle Systems architecture activities for the business jet. The activities for the regional and the rotorcraft a/c are hosted by the related ITD. On this figure the WP not active on the period are greyed. ED S Eco-Design for Systems (Small aircraft) DAv/FhG ED S.1 Common Activities ED S.2 Business Jet ED S.3 Ground Electrical Tests Activities ED S.4 Ground Thermal Tests Activities ED S.1.1 Methods & Tools ED S.2.1 A/C Requirements Business Jet ED S.3.1 Ground Electrical Bench Def. ED S.4.1 Ground Thermal Bench Def. ED S.1.2 Concepts & Technology Cand. ED S.2.2 A/C Architecture Candidates ED S.3.2 Ground Electrical Tests Def. ED S.4.2 Ground Thermal Tests Def. ED S.1.3 Generic Architecture Alenia ED S.2.3 S/S Architecture Candidates ED S.3.3 Ground Electrical Bench Manuf. ED S.4.3 Ground Thermal Bench Manuf. ED S.1.4 Ground tests & Benches reqts ED S.2.4 BJ S/S Reqts & Dev. Follow-up ED S.3.4 Ground Electrical Bench Integr. ED S.4.4 Ground Therm. Bench Integr. ED S.1.5 S/S Reqts & Dev. Follow-up Eurocopter ED S.2.5 BJ Models & Data ED S.3.5 Ground Electrical Tests & Valid. ED S.4.5 Ground Thermal Tests & Valid. ED S.1.6 Generic Arch. Models & Data ED S.2.6 BJ Architecture Trade-off Figure 8: EDS WBS 8 / 13

9 4.3 Scope of Technical Work WP S.1 - Common activities Only WP S.1.6 (Generic Architecture Models & Data) will be active in the period up to mid The objectives of this WP S.1.6 are: The elaboration of the models by using the tools and the completion of the data base for the generic architecture. The validation of the methodology and the models through confrontation to electrical and thermal test results WP S.2 - A/C VS Architecture Business Jet This WP is dedicated to the activities specific to the a/c of business jet type. The general objective is the demonstration of benefits from the all electric VS concept by using the methodology validated through WP S.1, S.3 and S.4. WP S.2.1 and S.2.2 are respectively the a:c requirements and the definition of architecture candidates for business jet application. These WP have been closed on WP S S/S Architecture Candidates WP S.2.2 has provided a definition of the a/c level VS architecture candidates. The objective of this WP is to define the architecture candidates at subsystem level for each of the architecture candidate, including the baseline. This WP is to be closed by end of The WP is split within 5 sub-wps corresponding to different functions / subsystems (WP S to 2.3.6): Electrical generation/distribution, ECS & Ice protection, FCS, Utilities & fuel system, SPS, same activity for the engine. WP S S/S Requirements and Development Follow -up The objective of this WP is to derive from the architecture definition, output of WP S.2.3, the basic requirements of the components of the architecture. These components include the engine as well as subsystems and equipments. In addition the WP hosts airframers tasks related to follow-up and support to equipment suppliers WP S.2.3 activities. This WP is closed by end of WP S.2.5 Models & Data This WP is equivalent to WP S.1.6 but for business jet application. The models and database will be elaborated for the VS architectures of the limited set, output of WP S.2.2. As for the generic architecture the models will be obtained through the integration of sub-models of subsystems and equipments. 9 / 13

10 WP S.2.6 Architecture Trade-off This is the last step of the activities toward the proof of concept and benefits demonstration for the business jet application. The process of a/c optimisation will apply for the limited set of VS architectures. The output will be the corresponding set of a/c definitions to be compared through the ecolonomic analysis. The expected result will be the highlighting of the best future architecture based on the all electric concept. Then, through the comparison with the baseline, the benefits gotten from the new concept will be quantified and demonstrated. This task will start beginning of 2014 and will be completed by the end of EDS WP S.3 - Ground Electrical Test Bench Activities The objective of this high level WP is to validate the methodology and associated modelling for the electrical side. The test bench is based on the test bench developed in the frame of the Power Optimised Aircraft (POA) European project, the so called Copper Bird test bench (see Figure 9 hereafter). The following activities conducted from the tests and bench requirements to the models validation are: Definition of the ground test bench on the basis of adaptation of the Copper Bird (WP S.3.1). This task is closed end of Detailed definition of the test from the requirements to the procedures (WP S.3.2). Most of the tests will be conducted on the generic architecture and will be common to the 3 vehicle types. Some specific tests could be added for the different vehicle types. This task is closed on Test bench ancillaries and specific components manufacturing (WP S.3.3). This task is closed on the second half of Test bench integration of representative a/c equipment, test rigs and ancillaries (WP S.3.4) to be performed on the first half of Tests performing for the generic configuration and for the specific configuration if necessary and test results analysis and models fittings leading to the expected modelling methodology validation (WP S.3.5). This task is from mid 2013 to the end of EDS. 10 / 13

11 Figure 9: Copper Bird WP S.4 - Ground Thermal Test Bench Activities The steering of this WP is similar to WP S.3. The thermal tests and bench requirements are elaborated in WP S and S on The objective of this high level WP is to validate the methodology and associated modelling for the thermal side. It is based on the use of representative fuselage sections (Falcon aircraft) including various typical areas to cover the problems encountered for the thermal modelling. The major requirement of the test bench is to be representative in terms of various heat transfer types: convective, radiative and conductive (see The test will be performed by using the FhG low pressure flight test facility (FTF) in Holzkirchen, Germany. The same activities will be conducted from the test and bench requirements analysis to the thermal modelling validation: Definition of the ground test bench on the basis of the use of existing mock-up (e.g. mechanical mock-up of a Falcon a/c) (WP S.4.1). The task is closed on Detailed definition of the test from the requirements to the procedures (WP S.4.2). This task is closed by the end of Test bench ancillaries and specific components manufacturing (WP S.4.3) and integration (WP S.4.4). Thes task should be closed by end of Tests performing and test results analysis and models fittings leading to the expected modelling methodology validation (WP S.4.5). The activity is performed from beginning of 2013 to mid / 13

12 Figure 10: Thermal test bench overview Master Plan A simplified master plan is provided on the following Figure 11. Figure 11: EDS Master Plan 12 / 13

13 5. CALL FOR PROPOSAL The estimated total budget dedicated to CfPs for is 2,2 M for EDA topics and no topic for EDS topics. Table 1: CfP ED Topics list, gives le ED topics list to be presented at the last CfPs on 2013 (CfP 14 and 15) as available at the time of this current document issue. Table 1: CfP ED Topics list CfP /1 JU Ref. JTI-CS-ECO-01 ECO ECO ECO ECO ECO ECO ECO CfP /2 JU Ref. JTI-CS-ECO-01 JTI-CS ECO JTI-CS ECO JTI-CS ECO JTI-CS ECO CfP Title Area-01 Extrapolation and Technical and economical study of a LBW technology Manufacturing by DMLS and machining of a titanium fan wheel. Comparison with casting process Manufacturing of high temperature composite parts for air cooling unit by filament winding Manufacturing and optimisation of a PEEK scroll or body by fusible core injection molding for a Motorized Turbo Compressor (MTC) in an Electrical-Environmental Control System (E-ECS) Characterization of metallurgical joining technologies for Mg Al and Mg Al-Li joints Application of sol gel technologies on low weight green metallic fuselage section Design and Modification of existing spraying facilities for automated sol gel application. CfP Title Area-01 Manufacturing optimisation of a plenum with GFRP cyanate ester-based prepreg Protection of an aluminium valve body by micro-arc oxidation: thick coating against wear on ring face, thin coating against corrosion elsewhere Manufacturing and surface treatment of a magnesium scroll or body for a Motorized Turbo Compressor (MTC) LCA of low weight green metallic fuselage panel(s) including physical dismantling and recycling Est. budget [k ] Total 1600 WP / Task 150 A A.6.2 / H1 200 A.6.2 / H1 250 A.6.2 / C2 200 A.6.1 / B2 300 A.6.1 / B2 300 A Est. budget [k ] WP / Task 200 A.6.2 / C2 100 A.6.2 / H1 100 A.6.2 / H1 200 A.3.1, A.6.1 / B2 dem. Total / 13