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aerodays2015
Brusseles, Belgium, October 20 – 22, 2015
Pavel WOLF
Presentation of ESPOSA project
aerodays2015
Brusseles, Belgium, October 20 – 22, 2015
Pavel WOLF
Presentation of ESPOSA project
Project overview
• 41 partners (incl. 11 SMEs)
• 20 industrials, 11 research centres,
10 universities
• 15 countries :
CZ(7), PL(5), DE(5), ES(1), IT(5),
HU(1), RO(2), FIN(1), UK(1),
BE(3), NL(2), SVK(1),
UKRAINE(2), RU(1), TR (3)
Title : ESPOSA = Efficient Systems and Propulsion for Small Aircraft
level 2 project of 4th call of FP7, (ACP1-GA-2011-284859-ESPOSA)
Duration: 48+9M, start: Oct 2011 – end: June 2016
Website: www.esposa-project.eu
Coordinator : PBS Velká Biteš, a.s.
Administrator : VZLU
Consortium:
ENGINES
• turbo propeller and turbo shaft
gas turbine engines
• two power categories
(160250 kW and 300550 kW)
FLYING VEHICLES
• small turboprop aircraft, light helicopters
• transport utility aircraft, small commuter
aircraft (CS-23)
• unmanned aircraft systems for civil use
Future impact
Technical areas
RTD AREAS
New technologies and concepts for
key engine parts as compressor,
turbine, combustion chamber
and gear box.
New low costs manufacture
technologies for engine components
machining, casting and for coating.
Affordable solutions for electronic
engine control up to FADEC level,
tailored engine health monitoring
system for small aircraft operation…
Advanced and reliable simulation
tools and design methodologies for
mechanical, aerodynamic,
aeroacustic, thermal and aeroelastic
integration of engine into aircraft
structure…
RTD AREAS
New technologies and concepts for
key engine parts as compressor,
turbine, combustion chamber
and gear box.
New low costs manufacture
technologies for engine components
machining, casting and for coating.
Affordable solutions for electronic
engine control up to FADEC level,
tailored engine health monitoring
system for small aircraft operation…
Advanced and reliable simulation
tools and design methodologies for
mechanical, aerodynamic,
aeroacustic, thermal and aeroelastic
integration of engine into aircraft
structure…
PROJECT
OBJECTIVES
Modern gas turbine engine
affordability.
Reduction of DOCs by 10-
15%.
Pilot workload
PROJECT
OBJECTIVES
Modern gas turbine engine
affordability.
Reduction of DOCs by 10-
15%.
Pilot workload
PROJECT
AREAS
Optimal engine components.
Lean manufacture.
Modern engine systems.
Engine/aircraft integration.
PROJECT
AREAS
Optimal engine components.
Lean manufacture.
Modern engine systems.
Engine/aircraft integration.
C O
M P
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E S
S
C O
M P
E T
I T
I V
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S
• Project activities will include extensive
validation on the test rigs (validation on
component level)
• The most promising technologies (value/cost
benefit) will be selected and integrated into
higher functional complexes and further
evaluated on the engine test beds (validation
on engine level)
Demonstration activities
• The functionality of certain project outcomes will also be demonstrated and
validated in flight conditions to reach higher TRL level (validation on aircraft
level)
Objectives / Engines
The target for “BE2” engine
(measured in DOC) :
• Reduction of depreciation costs - by
1,5 3%
• Reduction of fuel consumption
(fuel costs) – by 2,55%
• Reduction of maintenance and MRO
related costs – by 6%
The target for “BE1” engine :
• About 60% price reduction compare to
the gas turbine engine currently available
• Lower maintenance costs (TBO
prolongation) compare to piston engines.
• EECU (engine control system)
• Create new engine segment
Reduction of
maintenance cost
by 40%
Reduction of fuel
consumption (fuel
costs) – by 1015%
Reduction of
depreciation costs
by 15 20%
Reduction of engine
waight and mass
Reduction DOC
by 10 -14 %
SP1 start technical activities with definition of high
level requirements (airframers - req. on propulsion
unit, engine producers - req. on engine
components / systems)
SP2 and SP3 work comprises performance
improvements of key engine components, their
improved manufacture in terms of costs and
quality.
SP4 is dedicated to novel modern electronic
engine control based on COTS, pioneering the
engine health monitoring for small engines and
providing advanced more electric solutions for fuel
control systems.
SP5 summarizes particular achievement of
SP2,3,4 in functional complex and provides the
space for their validation on engine test benches
SP6 addresses problematic design areas
connected with turboprop/shaft engine installation
into airframe structure, including the use of
composite materials. The work will be conducted
taking into account specifics of different aircraft
configurations.
SP7 validates not only installation technologies
developed in SP6 but also selected engine in
operational conditions
SP1 Requirements on Propulsion Units
Performances
SP2 Optimal Engine
Components
SP3 Lean
Manufacture Technologies
SP4 Reliable “COTS” Based Systems
for Small Engine
SP0 Consortium and Project Management
Engine
Technologies
SP5 - Engine and Systems Integration and Validation
SP6 - Advanced Design Methods for Engine/Airframe Integration
SP7 - Validation of Engine/Airframe Integration and In-Flight Demonstration
SP8 - Assessment of Small GTE Potential for Air Transport
ENGINE PRODUCERS‘
ROADMAP
AIRFRAMERS‘
ROADMAP
Overall assessment of project outputs and
perspectives for future small GTE propulsion
Validation of
design tools &
methods in real
conditions
New technical concepts for engine
components & engine systems / Innovative
manufacture
Inputs & Engine
Requirements
Validation of new engine systems in real
conditions
Components & systems integration
and validation on test rigs (on engines)
Definition and
acquisition of
parameters for
BE1, BE2 engine
installations
New design tools &
methodologies for
engine/airframe
integration
Project work flow
SP1 - Technical activities with definition of high level requirements of air framers requirements on propulsion unit, engine producers requirements on engine components and systems)
• Review of existing power units for small size aircraft – technological and economical challenges
• Forecast of technological and economical challenges for small size aircraft engine based on requirements for future small air transport system
• Specification of Baseline Engine BE1/2 and components for both units
• Enhanced BE1 and BE2 engine matematical modeling
SP1 Requirements on Propulsion
units performances
Periodic Review Meeting – 5-6 November 2014, Vienna
•PBS – BE1 engine data - outputs from altitude baro chamber in CIAM
•TUD – development of mathematical modeling calculation for BE1
•NLR – development of mathematical modeling calculation for BE2
Input
Output
API
e.g. BE2 model
Enhanced BE1/2 engine model
Work comprises performance improvements of key
engine components, their improved manufacture in terms
of costs and quality.
• In ESPOSA project are implemented
two types of Engines BE2 and BE1
SP2 Optimal Engine Components
BE1 –TP / TS 100 (PBS)
• Optimal small compressor
• Advanced low-cost small turbine
• Efficient NGV – cooled blades
• Efficient combustion concept proposal for a new combustion chamber (JETIS, RQL)
• Efficient combustion nozles concept
• Advanced dynamic modelling of high speed turbomachinery on the gearbox
• Advanced automatic control system for small GTE
• BE1 platform
EB2 – AI450 S2 (IVCHENKO)
• Preparation of potential technologies for use in next-generation engine
• Optimal Small Compressor
• Advanced Cooled Small Turbine
• Streamlining the production function and the combustion chamber and nozzles
• Cooling diffuser blade wheels
• Optimization of transmission
• Analysis of the dynamic conduct of the engine
BE2 platform
• High pressure ratio and high efficiency small centrifugal compressor according to its optimal weight, thermal and strength criteria is almost done
• Flow temperature and stresses fields acquisition for strength and clearance values evaluation in centrifugal compressor;
• Outlet system optimization in order to reach an impeller-outlet system matching is done;
• Developing an system of measurement gaps in centrifugal compressor is still in process
WP21 Optimal small compressor
• Advanced Small Cooled High Pressure Turbine aerodynamic investigations
• Advanced Small Cooled High Pressure Turbine Optimization
• Low Pressure Turbine optimization
• Investigation and design of a high efficiency inter-turbine duct (optimization)
• Advanced turbine CFD throughflow calculations with optimized components-
HPT, LPT, inter-turbine diffuser
• Simple cooling for vanes of small turbine (BE1)
• Turbine blades linear cascade experimental study
• Experimental Aerodynamic investigations of Advanced small turbine
• Experimental Research of Advanced small turbine Cooling system
• Turbine radial clearance measurement system in process
WP 2.2 - Advanced Cooled Small
Turbine
• BE1 injector - design of final RQL fuel nozzles with acceptable
parameters - done
• BE1 JETIS FANN sectors experimental verification – in process
• BE1 RQL FANN planar sector experimental verification - done
• BE1 RQL/JETIS LES simulation - done
• BE1 FANN JETIS combustion chamber delivered to WP5.1- in process
• BE1 FANN RQL combustion chamber delivered to WP5.1 – in process
WP 2.3 - Efficient combustion
concept BE1
• Research of original fuel injector with swirlers – done
• Optimized combustor numerical research finished – done
• Designed ecological parameters weren‘t achieved – swirler
optimization designed – done
• Test rig modification for installation of Advanced combustor - done
WP 2.3 - Efficient combustion
concept BE1
• Gearbox enhancement guidelines definition - done
• Gearbox dynamic loads and inputs - done
• Gearbox key components production – again in production (finalization of 2pc
pinion without modification and 2 sets of modified wheels A10, A20, A30, A40)
• Gearbox components measurement
• Gearbox assembly and Gearbox pre-test operations
• Gearbox testing and post processing
WP 2.4 - Optimum Gearbox
Concept
• Design of different low-cost machining strategies for BE1-impeller -
followed by evaluation using reference process A - done
• Design of low-cost machining strategy for BE2-compressor-stage -
followed by evaluation using reference process B – done
• Development of mathematical software for tool design - done
• Testing of BE2/BE1-compressor-stage on internal engine test bench in
SP5 - in process
WP 3.1 - Low-cost machining for
compressors
913 915
612
676
555596
405 420
293
639690
471
Machining t ime [min] Preparat ion t ime [min] Cut t ing tool costs [€]
Summary of ent ire process chain
Areference-Process C1-Process DPBS-Process DComot i-Process
-26 %
- 55%
- 30 %-39 %
- 54 % - 25 %
-2 %
- 52 % - 23 %
Main objectives: • Development of design of castings – ceramic shells
• Development of casting technology
• Casting of turbine wheels, Casting of guide wheels
• Testing of mechanical properties of materials
Task planned: • Ceramic shells development for casting of Hf containes alloys.
• Casting of turbine wheels from MAR-M 247 for BE1 demonstrator.
• Preparation of specimens from MAR-M 247 and CM247LC for material testing
• Testing of material properties (tensile, creep, LCF, HCF).
• Introduction of result from turbine wheels in to the guide wheels.
WP 3.2 - Precise and low-cost
casting technologies for turbine
wheels
Development of new TBC configurations
for turbine vanes and combustion chamber. Development of wear resistant
coatings for bearings mountain seats on engine shaft and compressor rotor blades
roots. Testing of lab-scale components under standard conditions for the aerospace
sector.
• Specifications on coating requirements
• TBCs for turbine nozzle guide vanes
• TBCs for flame tube elements of the combustion chamber
• Wear resistance coatings for bearings mountain seats
(engine shaft)
• Anti-fritting coatings for compressor rotor blade roots.
• Characterization / validation procedures for
coatings in BE2
• Specification on testing of proposed material
systems for combustor
WP 3.3- Development of
progressive coating solutions
• Development of low cost manufacturing technologies for gear wheels: contour induction hardening as an alternative to gas carburizing, superfinishing, manufacturing of CURVIC couplings. Validation of the new technology through a component test campaign (pitting / scuffing/ bending)
Main objective of the task:
• To evaluate the applicability of CIH, actually used for splines and/ or bearing seats, as an alternative to carburizing for case hardening of accessory gear.
• To identify a suitable steel for CIH
• To validate this technology through a component test campaign
Advantages of CIH
• Green Process: Contour hardening allows
removing the galvanic operation of copper
plating and de-plating.
• Copper plating-related costs
• Process-related costs
• Increase of productivity
WP3.4 - Low-cost gearbox
manufacturing and test
SP4-Contributions to new design
Reliable “COTS” Based Systems for Small Engine
New technologies for EEC/FADEC using COTS‐based HW/SW
control components, MEMS technology for energy harvesting and
scavenging, wireless sensors, reusable HW/SW components and
embedded reliable real time operation systems (RTOS), MBD
development, obsolescence management of electronic component
New technologies and components for smart health monitoring
system (HUMS “light”) based on wireless sensor network (WSN)
• Advanced automatic control system for
small engines
• Smart Health Monitoring Systém
• Affordable more electric solution for fuel and propeller control
systems
BE1/BE2/EEC I/EEC II – modular
concept
Vibration
Module EMM
Module
EEC-II
Channel
B
EEC-II
Channel
A
BLDC
Channel
A - B
BE2 BE1
WP4.1 - EEC I for BE1
BLDC
CH A / B
BLDC
CH A / B
Senzors
BLDC
CH A / B
Senzors
BLDC
CH A / B
WP4.1 - EEC II for BE2
BE1/BE2/EEC I/EEC II – MBD
synergi
Configuration of GSP for BE2 BE2 model in Matlab/Simulink
BE1 model in Matlab/Simulink
Configuration of GSP for BE1
WP.4.3 Fuel and Propeller Control
WP 5.1 - Validation of BE1 on Test Rig
- Validation of new components (compressor, turbine, combustor, control
system) and its development tests
- Acknowledgement of BE1 parameters and overall functionality
WP 5.2 - Validation of BE2 on Test Rig
- Validation of new components (compressor, HP and LP turbine, combustor,
control system) and its development tests
- Definition of BE2 parameters and updated mathematical model
WP 5.3 - Validation of BE2 in Altitude Test Chamber
- Verification of BE2 mathematical model through bench tests
- Main and operational characteristics of the BE2 engines will be verified in a
wide range of external conditions
SP5 Engine and System
Validation and Integration
BE1 PBS
Test components and
test rig technical
requirements review
Test plans for engine
and components
validation
Test rig specification and
design
Test rig preparation:
-special equipment
- test engines
- software
Test rig preparation
process
SP
3
SP
2
SP
4
WP 5.1 - Validation of BE1 and
BE2 on Test Rig
BE2 Ivchenko - Progres
WP 5.2 WP 5.3
Test components and
test rig technical
requirements review
Test plans for engine
and components
validation
Test rig specification and
design
Test rig preparation:
-special equipment
- test engines
- software
Test rig preparation
process
SP
3
SP
2
SP
4
WP 5.1 - Validation of BE1 and
BE2 on Test Rig
• Mapping of power unit installation requirements
• Application of innovative analysis technologies for engine integration
• Application of innovative technologies for power unit mechanical
integration in W7.1, WP7.2
WP OBJECTIVES/OUTPUTS
• Mapping of power unit installation requirements for selected aircraft
configurations and engines (ACC TR1, ACC PU2, ACC TR2, ACC HE1
and ACC HE2)
• DMU level 0 – first design of engine installation and inputs for
modification
• Creation of optimization of engine integration methodology in WP6.2, 6.3,
6.4 and WP6.5
• Application and verification of optimization methodology
• Creation of PDR (DMU L1) for ACC TR1, PU2, TR2, HE1 and HE2
All activites are done
WP6.1 - Innovative methods of
design solution and integration
of the engine to the airframe
DMU Level 0
DMU L1
DMU Level 0
WP6.1 - Twin TP engine
integration in tractor modification
(TR2) Aircraft: Twin TR – EV 55 (EVECTOR) CZ, DMU - L1 - done
Benefits •Reduced weight (15% less)
•Reduced production cost (45% less standard production)
•Possibility of outer shape optimization
•Minimization of engine maintenance time
DMU Level 0
WP6.1 – Sing.TP engine
integration in tractor modification
(TR1)
• Reduced weight
• Accessibility of engine
• Mount and accessibility of accessories
• Technology
• Minimization of development time and cost
Benefits • Minimization of air inlet drag
• Optimization of article separation
• Minimization of development time and cost (reducing of mistake during installation with influence to
preparing redesign of engine installation and production
tools and requirements for development tests)
Aircraft: TR – I31T (ILOT) PL, DMU - L1 - done
DMU Level 0
WP6.1 - Twin TP engine
integration in pusher
modification (PU2) Aircraft: ORKA (M&M) PL, DMU L1 – done
• Reduced weight
• Accessibility of engine
• Mount and accessibility of accessories
Benefits • Minimization of air inlet drag
• Optimization of particle separation
• Minimization of development time and cost (reduction of mistake during installation with influence to
preparing redesign of engine installation and production
tools and requirements for development tests)
DMU Level 0
WP6.1 - TS engine integration in
light helicopter (HE1)
• Reduced weight
• Accessibility of engine
• Mount and accessibility of accessories
Benefits • Minimization of air inlet drag
• Optimization of IFB
• Minimization of development time and cost (reduction of mistake during installation with influence to
preparing redesign of engine installation and production
tools and requirements for development tests)
B250, WINNER Helico (Belgie), DMU L1 – done
DMU Level 0
WP6.1 - TS engine integration in
ultra light helicopter (HE2)
Benefits • Minimization of air inlet drag
• Optimization of IFB
• Minimization of development time and cost (reduction of mistake during installation with influence to
preparing redesign of engine installation and production
tools and requirements for development tests)
T- line, IRI (Italy), DMU L0, L1 done
WP6.2 Reliable design
technology for aerodynamic
engine/airframe integration
• Effect of non uniform inflow on propeller performances
• Aerodynamic design methodology of nacelle external shape
• Innovative technologies and aerodynamic design methodology for air
inlet and internal nacelle duct
• Aero-Acoustic and aerodynamic assessment and methodologies
Method and tool for the unsteady aerodynamics of propeller - models and SW
tool for aeroelastic interference considering fatigue effects (INCAS)
WP 6.3 - Tools for engine and
nacelle integration "Whirl Flutter"
• Detailed structural model
• Modeling of the propeller dynamics
using MSC rotor dynamics
• Obtaining the global load spectrum
• Select critical location for Principal
Structural Elements
• Calculate nominal stress levels for PSEs
and local stress levels at critical
locations
• Calculate fatigue life and Margin of
Safety
For TR1 Aircraft:
• Oil Cooler Analysis (on ground and in air)
• Nacelle Thermal Analysis (cruise operation, engine
shutdown, climb operation)
• Nacelle Thermal Stress Evaluation (cruise operation)
• Exhaust Jet Analysis (on ground, cruise and climb
conditions)
For PU2 Aircraft:
• Oil Cooler Analysis (on ground and in air)
• Nacelle Thermal Analysis (cruise operation, engine
shutdown, climb operation)
• Nacelle Thermal Stress Evaluation (cruise operation)
• Exhaust Jet Analysis (on ground, cruise and climb
conditions)
For TR2 Aircraft:
• Oil Cooler Analysis (on ground and in air)
• Nacelle Thermal Analysis (cruise operation, engine
shutdown, climb operation)
• Nacelle Thermal Stress Evaluation (cruise operation)
• Exhaust Jet Analysis (on ground, cruise and climb
conditions)
For HE1 Helicopter:
• Oil Cooler Analysis
WP6.4 Reliable simulation tools
for engine thermal integration
WP6.5 New design and
manufacturing approaches for
"hot" composite nacelles
• Most suitable composite materials and processes
• Process windows and material properties.
• Design engineering approach
• Understanding “benefits”
• Validated new technology
• Provide technology to WP7.1
• All activities are focused to I31T (ILOT) and P180 (PIAGGIO)
• Objectives
WP6.1
T6.5.1 T6.5.2
T6.5.3
T6.5.4
SP7
A
B
C
WP6.4
2nd nacelle: • Adapted bagging • Adapted location resin reservoirs • Generally results
WP6.5 New design and
manufacturing approaches for
"hot" composite nacelles
WP7.1 Validation of integration design methodologies Validation of complex design methodology for engine integration within various
airframes Engine/airframe installation for different kind of aircraft – knowledge.
WP7.2 Qualification Activities for Flight Testing The engine ground tests and qualifications of the engine for flight Main operational characteristics of the BE1 engine verified and
aircrafts (I-23, ORKA, Rotorcraft Winner, Rotorcraft IRI) prepared for flight demonstration.
WP7.3 Overall Demonstration in In- flight Conditions Demonstration of the results developed engine technologies in in-flight conditions
and validation of complex design tools and methodologies for BE1 engine integration within various airframes.
Results of flight tests for airplanes: I-23, ORKA & rotorcrafts with new powerplant and validation flight performance of the BE1 engines for four aircraft platforms
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SP7 Validation of Engine
/Airframe Integration
and In-Flight Demonstration
Institute of Aviation ILOT - TR-1 Margański & Mysłowski PU-2
WINNER HELICO HE-1 IRI HE-2
Innovative Aircraft Demonstrator
Platforms of ESPOSA
WP7.2 Qualification Activities for Flight Testing
• The engine ground tests and qualifications of the engine for flight
BE1 life testing according to the typical flight profile for EM-11C Orka airplane
• Finished second 500 hour period – target for ESPOSA project (1000 hours)
achieved
Measurement in altitude test chamber
Measurement on the ground test bench
• Test verification of MTV-25 propeller for I-31T airplane
• test with the same propeller
• lower vibration, lower noise,engine faster acceleration
WP 7.2 Qualification Activities for
Flight Testing
Water ingestion test
• realized within the EM-11C Orka approval process
• test cycle defined to fulfill CS-E 790, CS-23.901 – worst case: 4% of water
• engine operation during the test was stable without surge indication
WP 7.2 Qualification Activities for
Flight Testing
Czechowice – Dziedzice, Poland 22 Oct 2014 – first engine run
13 February 2015 – first flight
WP7.1 PU-2 Progress
Czechowice – Dziedzice First engine run on 4 March
2015
10 June 2015 – first flight
WP7.1 TR-1 Progress
Sorinnes –Chassis
WP7.1 HE-1 Progress
WP7.1 HE-2 Progress
Summary of ESPOSA project
The project ESPOSA should encourage both aircraft
and engine producers in using new solutions for their
aircrafts and gas turbine engines by demonstrating their
feasibility and by proving their advantages.
Thank you for your attention !
The project ESPOSA should encourage both aircraft
and engine producers in using new solutions for their
aircrafts and gas turbine engines by demonstrating their
feasibility and by proving their advantages.
Thank you for your attention !