GRC - Clean Sky

GRC ITD TOPICS FOR CFP#12 

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

Giornata ACARE Italia 

Torino, 17 th May 2012 

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Green RotorCraft ITD: Top Level WBS 

GRC1: 

Innovative 

Rotor Blades 

Technology 

Evaluator 

GRC0: Management 

Technology Developments & Demonstrations 


Reduced Drag 

of Airframe & 

Dynamic 

Systems 

Engines / 

SAGE 5 


Integration of 

Innovative 

Electrical 

Systems 


Installation of a 

Diesel Engine 

on a Light 

Helicopter 

EcoDesign for 

Systems 

SGO / Energy 

Management 

GRC7: Preparation of T.E. 

for Rotorcraft 

Green RotorCraft ITD - Giornata ACARE Italia – GRC Topics for CFP#12, 17th May 2012 Torino 


Environment- 

Friendly Flight 

Paths 

Contribution from/to 

transversal ITDs 


EcoDesign 

Demonstrators 

(Rotorcraft ) 

EcoDesign for 

Airframe 

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GRC - List of topics for CFP#12 

5 topics split in 4 sub-projects 

� GRC1: Innovative Rotor Blades 

Low weight, high energy efficient tooling for rotor blade manufacturing 710 k€ 

� GRC2: Drag Reduction of Airframes and DynamicSystems 

Wind tunnel tests on a common helicopter platform and contribution to its 

optimised aerodynamic design 800 k€ 

� GRC3: Innovative Electrical Systems 

Design and Implementation of a Load Simulator Rig and Ground Test Bench 

Adaptation Kit for a HEMAS Test Rig 1000 k€ 

� GRC5: Environment-friendly Flight Paths 

Sensoring and cockpit monitoring to reduce noise in manoeuvring flight 1500 k€ 

Curved SBAS-guided IFR procedures for low noise rotorcraft operations 580 k€ 


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GRC1 

Low weight, high energy efficient tooling 

for rotor blade manufacturing 


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© 2012 – CSJU/GRC-ITD Members 

Low weight, high energy efficient tooling for 

rotor blade manufacturing 

Status 

� manufacturing of helicopter rotor blades with composite materials use 

currently metallic moulds with self heated technology or external heating by 

heat presses or ovens 

� the mould weight for a light helicopter (~5,0 meters long) is likely above 5tons 

� Curing temperature is, for rotor blades, above 135°C 

� High energy consumption and poor handling capabilities 

Path 

� Change to new manufacturing processes (e. g. preforming and liquid 

composite moulding, LCM) 

� Use of innovative, energy efficient and light toolings for preforming and 

injection with short turnaround times in industrial manufacturing 


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© 2012 – CSJU/GRC-ITD Members Objective 



Find new and innovative tooling for helicopter rotor blades manufacturing with 

composite materials based on low energy and green aspects 

Steps that should be performed by the applicant 

Develop, design and manufacture of preform- and curing tools 

� Light and easy to handle 

� Easy to heat up and cool down > short cycle times 

� Less energy consumption / heat exchange device 

� Heat up range up to 135°C curing or activation temperature 

� Homogenous heat transfer and distribution 

� Stiff and closed mould for injection (up to 3bar) 

� Applicable to use with special impregnation technologies (e.g. LCM) 

� Light, one sided, fast heatable preform tools 


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or consortium) 

� Knowledge to develop, design and manufacture new tooling concepts with 

respect to green aspects 

� Heat and energy management for toolings 

� Able to collect LCA-data 

As we intend to take a new approach regarding tooling design and manufacturing 

we are open to any proposal. A specific certification for aerospace and 

airworthiness items is not required from the possible applicants. 

Rotor blade manufacturing process details (e.g. position of injection line, preform 

technology,…) will be defined by topic manager. 

© 2012 – CSJU/GRC-ITD Members Skills and capabilities required from the applicant (single organisation 


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� Project duration: 

� 18months (January 2013 – June 2014) 

� Maximum Total Cost: 

� € 710.000 


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Wind tunnel tests on a common helicopter 

platform and contribution to its optimised 

aerodynamic design 


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Wind tunnel tests on a 

common helicopter platform 

� Title: Wind tunnel tests on a common helicopter platform and contribution to 

its optimized aerodynamic design 

� Expected start date : January 2013 

� Duration : 30 months 


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Scope 

� Objectives: 

o Support of GRC consortium in benefit assessment process for a heavy-weight class H/C by: 

� Wind-tunnel tests of a reference helicopter fuselage 

� Wind-tunnel tests of optimised design of several 

elements of the common helicopter fuselage 

o The work comprises: 

� Background : 

� Design and manufacturing of some model components 

� Wind tunnel test preparation, execution and results post-processing 

� Optimised helicopter fuselage design provided by GRC consortium 

� Existing reference model components and wind-tunnel test results 

� Tasks : 

Wind tunnel tests on a common helicopter platform 

� Task 1 - Preparation of the Original and Optimised Models 

� Task 2 - Wind-Tunnel Tests on the Original and Optimised Configurations 

� Task 3 - CFD Analysis (optional) to address mount effects on fuselage aerodynamics 


Reference fuselage 

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Expected activities (1/3) 

� Task 1: Preparation of the Original and Optimised Models 

� Manufacture additional components for the reference configuration 

� Sponsons, hub cap, blade stubs. 

� Manufacture optimised components 

� to be finalised during the numerical optimisation phase 

� Instrumentation of reference and optimised components 


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� Task 2: Wind-Tunnel Tests on the Original and Optimised Configurations 

� Perform wind-tunnel tests of the reference fuselage 

� Perform wind-tunnel tests of the optimised fuselage 

� Two set-up configurations 

� Strut configuration: for rotor head investigations (with/without rotation) 

� Upside down configuration: for fuselage backdoor ramp investigations 

� Main wind-tunnel requirements 

� Model size: L=4.097m, S frontral=0.55m² 

� Wind-tunnel speed > 40 m/s 

� fuselage angle of attack from -20° to +20° 

� rotating rotor-hub using suitable driving system (around 1000rpm expected) and 

monitoring system 

� Expected measurements 

� Global forces 

� Surface static pressure (~ 300 taps) 

� Surface unsteady pressure (~ 20 transducers) 


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� Task 3: CFD Analysis (optional) 

� Numerical assessment of the drag reduction of the optimised design 

� Investigation of wind-tunnels effect (strut, walls) 

� Numerical/experimental correlations 


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Skills and capabilities required 

� Qualified and demonstrated skills in WT testing (appreciated previous experience in 

WT testing on helicopter configurations) 

� Wind Tunnel: 

� wind speeds at least 40 m/s 

� fuselage angle of attack from -20° to +20° (both mount systems) 

� fuselage angle of side-slip from -20° to +20° (both mount systems) 

� rotating rotor-hub using suitable driving system 

� Measurement capabilities 

� global loads through an internal or external balance, all six components 

� surface static pressures (~300 pressure taps in a full configuration) 

� surface unsteady pressures (~20 unsteady pressure transducers in a full 

configuration) 

If the applicant offers CFD work in task 3, the following skills are encouraged 

� mandatory 

� CFD code solving the RANS equations 

� Optional 

� CFD code solving the URANS equations 

� Moving body capabilities for rotating rotor head 


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� Expected planning, assuming (T0 at Jan. 2013) 

N° Task Nr. Task Name 

1 1 W T Test of the original geometry 

2 1.1 Input01: CATIA file of the original model delivered to the Partner 

3 1.2 Manufacturing of new elements 

4 1.3 Input02 & Input03: Existing model delivered to the Partner 

5 1.4 Model adjustment 

6 1.5 Input05: Specifications for the original configuration wind-tunnel tests 

7 1.6 Wind tunnel test of the original configuration 

8 1.7 Data analysis 

9 1.8 Input04: CATIA file of the optimised model delivered to the Partner 

10 1.9 Manufacturing of the optimised components 

11 1.10 Input06: Specifications for the optimised configuration wind-tunnel tests 

12 1.11 Wind tunnel test of the optimised configuration 

13 1.12 Data analysis and synthesis 

14 2 CFD computations 

15 2.1 Original configuration 

16 2.2 Optimised configuration 

17 2.3 Comparison with WT data and synthesis 


Planning and budget 

� Budget: 800 kEuros, 

2012 2013 2014 2015 

Sep Nov Jan Mar Mai Jul Sep Nov Jan Mar Mai Jul Sep Nov Jan Mar Mai Jul S 

� Expected start date : January 2013; Duration : 30 months 

� Evaluation: Detailed break-down for Tasks 1&2 recommended 

� Contractual aspects: Selected partner will be offered to enter the GRC 

consortium 


03/01 

03/01 

03/12 

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Design and Implementation of a Load 

Simulator Rig and Ground Test Bench 

Adaptation Kit for a HEMAS Test Rig 


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Design and Implementation of a Load Simulator Rig and Ground 

Test Bench Adaptation Kit for a HEMAS Test Rig (1/4) 

� Topic background and rationale: 

� Electromechanic actuation is slowly replacing the hydraulic actuation 

systems throughout the aviation industry. 

� To build a testing system composed by HEMAS for the simulation of main 

rotor loads. 

� Test the HEMAS system inside a simulated aircraft architecture. 

� Related GRC3 objective: To develop a complete Adaptation Kit in order to 

integrate the HEMAS equipment batch inside a simulated aircraft architecture . 


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� Design, manufacturing and acceptance on site of a complete Adaptation Kit in 

order to integrate the HEMAS equipment batch inside a simulated ground 

aircraft architecture (ETB). 

� Commissioning and initial operation of the Adaptation Kit on two different 

locations (Central Europe and Electrical Test Bench). 

� Support the rig operations to correct potential faults during the Clean Sky 

Program Development. 

© 2012 – CSJU/GRC-ITD Members � Summary task description: 


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� Electrical test bench and electromechanic actuation specifications. 

� Information exchange with conventional tools and planned technical 

meetings. 

� Skills and capabilities required from the applicant: 

� Experience in actuation test benches design, manufacture and installation is 

an asset. 

© 2012 – CSJU/GRC-ITD Members � Background material & Information exchange: 


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� 24 months (Jan. 2013 – Dec. 2014). 


� € 1.000.000 


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Sensoring and cockpit monitoring to 

reduce noise in manoeuvring flight 


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Development and Test of Novel Rotor Measurement Systems to 

Estimate Manoeuvring Noise During Rotorcraft Approaches and 

Departures (1/4) 

� Related GRC-5 objective: To develop innovative on-board systems 

allowing pilot to minimise noise annoyance during rotorcraft 

approaches and departures 


� Helicopter noise depends on rotor speed, thrust and angle of attack (AOA) 

� For in-flight noise monitoring, future systems will relay on crude estimates 

of these quantities, as they are hard to measure accurately 

� Inaccuracies are relevant in manoeuvring flight, when for instance rotor is 

flapping (change of AOA) to decelerate the vehicle and actual thrust is 

hundreds of kilograms different from weight or other estimates 

� Manoeuvring flight is typical during rotorcraft approaches and departures 

Need of innovative measurement systems to monitoring rotor 

state in-flight and accurately estimating rotorcraft radiated noise 


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Development and Test of Novel Rotor Measurement Systems to 

Estimate Manoeuvring Noise During Rotorcraft Approaches and 

Departures (2/4) 

� Review of current and future technologies for rotor force and blade angle 

measurement (D1) 

� Definition of requirements of a Pilot Acoustic Indicator display to monitor 

radiated noise (D2) 

� Preliminary Design Review of measurement system, reporting design and 

development activity (D3) 

� Validation against flight data of CFD tools to predict noise in manoeuvring 

flight (D4) 

� Design and Implementation of Pilot Acoustic Indicator (D5) 

� Critical Design Review of measurement system, reporting experimental 

activity (D6) 

� Application of unsteady noise prediction tool to study the effect of 

perturbations on low-noise procedures (D7) 

� Final demonstration of measurement system and pilot indicator (D8) 

© 2012 – CSJU/GRC-ITD Members � Summary task description: 


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GRC-05-006: Development and Test of Novel Rotor Measurement 

Systems to Estimate Manoeuvring Noise During Rotorcraft Approaches 

and Departures (3/4) 

� Suitable flight data for validation of tools and design of experiments 

� Vehicle system detailed design data, as required by the activity 

� Relevant material on rotor measurement systems 


� Unsteady rotor noise prediction 

� Design, development and test of measurement systems 

� Airborne display systems 

� Experimental lab for structural and fatigue tests on the measurement system 

� Capability to comply with CS 27/29, MIL -810/RTCA DO-160, RTCA DO-254 

© 2012 – CSJU/GRC-ITD Members � Background material & Information exchange: 


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GRC-05-006: Development and Test of Novel Rotor Measurement 

Systems to Estimate Manoeuvring Noise During Rotorcraft Approaches 

and Departures (4/4) 


� 24 months (Jan 2013 – Dec 2014) 


� € 1.500.000 


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Curved SBAS-guided IFR procedures for 

low noise rotorcraft operations 


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GRC-05-007: Curved SBAS-guided IFR procedures 

for low noise rotorcraft operations (1/5) 

� Related GRC-5 objective: To develop and test new rotorcraftspecific 

flight procedures to minimise noise impact in approaches 

and departures 


� Curved flight paths allow to avoid overfly of noise sensitive areas 

� For IFR procedures, curved flight paths shall be designed in compliance 

with RNP-AR ICAO specification 

� Current RNP-AR specification relies on barometric vertical guidance which 

is not suited for precise flight path optimisation in the vertical plane 

� SBAS (EGNOS in Europe) is the best guidance mean to optimise flight paths 

for noise reduction, both in the horizontal and vertical plane 

Need to define and assess new types of curved IFR procedures 

relying on SBAS guidance to minimise noise impact 

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� Summary task description: 

� Review and analysis of ICAO design criteria for curved segments (D1) 

� Assessment of SBAS guidance benefits for curved segments (D2) 

� Definition of design criteria for curved segments under SBAS guidance with or 

without transition to LPV in last part of final approach (D4, D3) 

� Adaptation of proposed design criteria to Point-in-Space procedures ((D5) 

� Comparison of benefits / constraints of the different solutions for curved IFR 

rotorcraft procedures (D6) 

� Safety study for a generic curved Point-in-Space (PinS) procedure (D7) 

� Detailed design and implementation of a PinS SBAS-guided curved helicopter 

approach to an heliport (D8) 

� Dissemination and organisation of a User Forum (D9) 


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� Background material & Information exchange: 

� ICAO PBN and related navigation specifications (RNPx, RNP-AR) 

� Information exchanges with GARDEN (currently running CleanSky project) 


� Full knowledge of ICAO air navigation regulations (PanOps, PBN manual, RNPx 

and RNP-AR specifications) and foreseen evolutions 

� Detailed analysis of ICAO procedure design criteria: 

� Understanding of existing criteria and ability to propose new ones 

� Satellite navigation, in particular SBAS 

� Detailed design, charting and safety analysis of IFR procedures, in particular 

RNP-AR procedures including curved segments 


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� 24 months (Dec. 2012 – Nov. 2014) 


� 580 000 € 


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Contact us 

For further information: 

info-call-2010-05@cleansky.eu 

www.cleansky.eu 


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BACK-UP SLIDES 


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GRC: Top Level WBS 


Innovative 

Rotor Blades 

Technology 

Evaluator 

GRC0: Management 

Technology Developments & Demonstrations 


Reduced Drag 

of Airframe & 

Dynamic 

Systems 

Engines / 

SAGE 5 


Integration of 

Innovative 

Electrical 

Systems 


Installation of a 

Diesel Engine 

on a Light 

Helicopter 

EcoDesign for 

Systems 

SGO / Energy 

Management 

GRC7: Preparation of T.E. 

for Rotorcraft 



Environment- 

Friendly Flight 

Paths 

Contribution from/to 

transversal ITDs 


EcoDesign 

Demonstrators 

(Rotorcraft ) 

EcoDesign for 

Airframe 

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GRC: Technological objectives 

1. Innovative Rotor Blades 

� Active and passive technologies to reduce rotor power consumption and acoustic signature 

2. Drag Reduction of Airframes and DynamicSystems 

� Passive and active flow controls for helicopter and tiltorotor components 

� Efficiency improvement (pressure losses) and noise emission reduction of engine intake 

3. Innovative Electrical Systems 

� Replacement of hydraulic systems on rotorcraft by electrically-powered systems 

� Reduction of carbon emissions and improved electrical power system efficiency. 

4. Diesel Engine 

� Integration of a Diesel engine on a light helicopter to reduce CO 2 emissions. 

5. Environment-Friendly Flight Paths 

� Noise abatement with optimized flight procedures in VFR & IFR including ATM constraints 

� Fuel consumption and pollutant emissions reduction through a mission profile optimization 

6. EcoDesign 

� Exploitation of eco-friendly technologies to specific rotorcraft components 

7. Technical Evaluator for Rotorcraft 

� Interface to Technology Evaluator for assessing actual impact of rotorcraft technologies 35 


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GRC-ITD Demonstration schedule 

GRC1 - Innovative Rotor Bades 

TRL Progress 

Active Rotor Blade 

Passive Rotor Blade 

GRC2 - Drag Reduction 

TRL Progress 

Drag Reduction 

(Hub & Fuselage) 

Engine Installation 

GRC3 - Inn. Electrical Systems 

TRL Progress 

HEMAS for FCS & utilities 

Helicopter Electrical Systems 

Electrical Tail Rotor 

GRC4 - Diesel Engine on a light H/C 

TRL Progress 

H/C design, test and validation 

GRC5 - Environment Friendly Flight Paths 

TRL Progress 

GRC6 - Eco-Design for Helicopters 

TRL Progress 

Engine Development 

2008 2009 2010 2011 2012 2013 

Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 

Giornata ACARE Italia – GRC Topics for CFP#12, 17 th May 2012 Torino 

Test & Evaluation 

PDR 2 CDR 

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5 6 

2014 2015 2016 

Technology Review 

Preliminary Design Detailed Design Ground Test 

2 

CoDR PDR 

3 

CDR 4 5 

Full-scale blade design 

Ground test: full scale rotor blade 

Design & manufacturing Whirl Tower test 

Technology Review 

Preliminary Design Detailed Design Final Tests 

2 CoDR 3 PDR 4 CDR 

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6 

Manufacturing Flight test (Hub) 

sub-assembly design & validation (WTT) 

WTT (fuselage) 

Numerical aerodynamics optimization Design & manufacturing Flight test 

H/C Requirements Equipments & Systems development /from SGO & ED) Ground Test 

3 

SR 

4 

5 

Test 

H/C pre-design, engine requirements Preliminary Design, detailed design, developmt. Ground Test 

2 3 SR 

CoDR PDR 

Def.phase: flight rules analysis, requirement & tools 

2 3 

Engine Design Development 

WTT 

Test 

Test 

6 

Whirl Tower test 

(Copper Bird on EDS) 

FlightTest 

CDR 5 6 

Test 

H/C adaptation design & development Test 

Tools development for in-flight 

environmental measures 

Procedure & Guidance Systems Development 

SR 

Design 

CoDR 

3 

PDR 

CDR 

Manufacturing Recycling 

Flight Test 

5 6 

GRC-ITD Environmental Goals 


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Clean Sky JU / Green RotorCraft ITD 

© 2012 by the CleanSky JU / Green Rotorcraft ITD (GRC) Members: AgustaWestland, Eurocopter, 

Liebherr-Aerospace, Hispano-Suiza, 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, SELEX Sistemi Integrati, 

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). 


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GRC - Clean Sky

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