European Small Aircraft OEM
Priority & Objectives for CS2
Presented By A. COZZOLINO
January, 23th 2013
Bruxelles,23th January 2013
SAT in the CS2
European Small Aircraft OEM partnership
Piaggio Aero - P180
Grob -G120 TP
Mielec – PZL M28
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).
Bruxelles,23th January 2013
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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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Small Aircraft OEM R&TD Priority (2020)
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%
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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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WP A.1 - More affordable and green composite structures for
small aircraft
 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)
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WP A.1 - Airframe Integrated Structure – Composite ground
demonstrator
 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.
Decrease of DOC & IOC BY 4%
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WP A.2 - More affordable and green metal structures for small
aircraft
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
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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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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
 Design
with ultra-light weight e.g. Inverter, E-Motor, E-Generator
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
Bruxelles, 23th January 2013
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.
Have been the Small Aircraft
priority taken into account?
Are the technology directly
employable in Small Aircraft?
Open Rotor
E-ECS
MTM
270 VDC Generator &
Energy Management
EMA
Are these technology
directly/easily scalable?
Low Power
deicing system
Are the architecture applicable
on small Aircraft dimensions?
 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.
Bruxelles,23th January 2013
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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
Bruxelles, 12th September 2012
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WP S1 – Efficient operation of small aircraft with affordable
health monitoring systems
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.
Operations
• Improve Dispatch ability
• Faster return to service
• Greater availability
• Avoid AOG
Costs
• Unscheduled Maintenance
• Scheduled Maintenance
• Spare Parts
• Warranty
• Support
• Fuel
Simplify
• Better Visibility
• Reduce logistics footprint
•Fleet management
Piaggio P180 Platform
Health monitoring System for small Aircraft will
contribute to operational cost reduction & to safety
improvement.
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Higher Standard of Safety
• Avoid and Mitigate failure
• Flight Operations
• Investigations
• Training
Reduction of the small aircraft Total
operative cost of 9% is expected (50%
reduction of total maintenance cost)
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WP S2 - More electric/electronic technologies for small
aircraft
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.
270 VDC Generation & Energy
Management System
EMA
Reduction of the small aircraft Total
Operative Cost of xx% is expected
E-ECS
Mielec M28 Platform
E- Brake
Low Power deicing system
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WP S3 – Fly-by-wire Architecture
Improving 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
Bruxelles,23th January 2013
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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.
+
System Integration Laboratory
Bruxelles,23th January 2013
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Mielec M28 Platform
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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)
multifunctional insulation
active noise control System
Slim dynamic seats
Cabin IFE
Evektor EV-55 Platform
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