Eco-Design ITD Overview
V. Selmin, CSJU Project Officer
Clean Sky Info Day
Toulouse, 1rst February 2011
1
Clean Sky Info
InfoDay
Day,UK,
Day
on
Toulouse,
7th
London,
call 1rst
for
17th
proposals,
February
November
2011
11 October
2010
2010, Brussels
Clean Sky ITD Organisation and Eco-Design Setup
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Clean Sky Info Day, Toulouse, 1rst February 2011
Eco-Design ITD Participants and Global Share
116M€ Total Budget
ITD-Leaders
 Dassault Av.
 Fraunhofer
 Airbus
 Agusta Westland
 Alenia Aeronautica
 EADS-CASA
 Eurocopter
 Liebherr
 Safran
 Thales
Associate Partners
 EADS IW
 HAI
CASA
 IAI
 STORK-Cluster
 RUAG-Cluster
25% of Total Budget
Partners
Partner
participation
based on Call
for Proposals
„CfP“
IW
50% of Total Budget
25% of Total Budget
(Cluster)
Clean Sky Info Day, Toulouse, 1rst February 2011
(Cluster)
3
Eco-Design for Airframe & Systems
•
To design airframe for decreasing inputs, outputs and nuisances during a/c design
& production and withdrawal phases: for Airframe Application (EDA)
•
To design architectures of a/c systems, towards the more/all electrical a/c, with
the objective of reducing use of non-renewable and noxious fluids/ materials
during operations and maintenance: for Systems Application (EDS)
Inputs :
Raw materials
Water
Energy …
a/c Design &
Eco-Design
for systems
Production
Outputs,
nuisances :
Energy (warming)
Liquid effluents
Gaseous effluents
Solid waste …
Inputs :
Inputs :
Fuel
Lubricants
Energy …
Fuel
Water
Energy …
a/c
a/c Use &
Maintenance
Withdrawal
(Recycling)
Nuisances :
Nuisances :
Energy (warming)
CO2, NOx
Noise
Contrails
Crash waste …
Energy (warming)
Liquid effluents
Gaseous effluents
Solid waste …
Eco-Design for Airframe
Clean Sky Info Day, Toulouse, 1rst February 2011
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EDA Overview
Logic Flow
Clean Sky Technology Evaluator
WP 3.1
Evaluation Tool (Manufacture & withdrawal levels) / Modelling
WP 3.1.1
Current EcoStatement
WP 3.1.3
WP 3.1.2
Eco-Statement
Final EcoStatement
WP 3 Applications Studies
WP 1 Alternative
Solutions
Requirements
WP 3.2
Extrapolation to
Industrial Conditions /
Validation
WP 2 Technology
Development
WP 4 Lifecycle
Demo. Definition
Inputs from CE or
national projects
WP 5,6 Lifecycle
Demo.
• Equipped Airframe
• Equipment
Technology Areas
Area 1 : new
materials / new
architectures
Area 4 : end of
life management
Lifecycle demonstration through
Partial Demonstrators
Raw Materials
Elimination
Recycling
Eco-Design
for Airframe
Manufacturing
Green Repair
Product
Maintenance
Use
Area 3 : long life
structure
Clean Sky Info Day, Toulouse, 1rst February 2011
Area 2 : green
manufacturing
Global Demonstrator
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EDA Technical Areas
Area 1 : new
materials &
surfaces
Area 4 : end of life
management
Raw Materials
Elimination
Recycling
Eco-Design
for Airframe
Manufacturing
Green Repair
Area 3 : long life
structure
Product
Maintenance
Use
General objectives : Eco-Design and Green Manufacturing
Clean Sky Info Day, Toulouse, 1rst February 2011
Area 2 : green
manufacturing
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EDA Area 1: Materials
New materials – Requirements
 Structural function
Performances : weight saving
“Renewability” products
“Recyclability”
REACH (CMR…)
Materials production processes : energy,
cost, pollution
New materials – Requirements
 New functions
Anti icing
Low friction coating
Self healing, self cleaning
Electrical conductivity
…
Modelling
New emerging materials
 Composite
Resins and fibres made from
agriculture
nanotechnology, molecular design
Thermoplastics
Others
 Metallic
New light alloys
Surface treatment, protection
Clean Sky Info Day, Toulouse, 1rst February 2011
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EDA Area 2: Manufacturing
New processes – Requirements
 Industrial
Optimised Work Flow
Highly integrated processes
One shot process
Dry process
Low energy
Low emissions (noise)
Increased automation
Recycling of ancillaries
Materials – Requirements
 Current
Composite, metallic
 New
Green Composites, metallic
Low emissions (VOC, dust)
Low production waste and scrap
Recyclability
 Societal
AUTOCLAVE
Green Factory
Rigid Tooling
 Direct manufacturing
 Energy management
Injection
machine
resin injection
part to be filled
Vacuum
pump
autoclave pressure
 Virtual Reality
 Manufacturing waste management
Modelling
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Clean Sky Info Day, Toulouse, 1rst February 2011
EDA Area 3: Long Life Structure
Structural Diagnostic / Prognostic
Green Repair Solutions


Health Usage & Monitoring
 Real time monitoring
 Smart sensors
 Non Destructive Testing




Repair solutions for Thermoplastics
Rework technologies
Low energy techniques (Inductive devices,
IR- devices, oil heated devices, …)
Repair of severe damages
Testing and qualification of the repairs
Test Procedures
 Relevant vs in field experience
 Short testing cycle
 Ease of structure repair
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Clean Sky Info Day, Toulouse, 1rst February 2011
EDA Area 4: End of Life Management
Dismantling processes

Low energy
 Dry Processes
 Low effluents and waste
Materials end of life treatment for
reuse, elimination, storage
 Metallic
Separation, purification
Storage of end products
 Organic
Physical processing
Chemical processing
Biological processing
Energy
Storage of end products
 Equipment
Traceability all along the supply chain
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Clean Sky Info Day, Toulouse, 1rst February 2011
EDA Lifecycle Demonstration
Materials
Manufacturing
Production
Process
Validation article
TBD (significant
representative
equipped structure)
Use
Maintenance
Dismantling
Recycling
Partial tests
Clean Sky Info Day, Toulouse, 1rst February 2011
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EDA Logical Flow and Scheduling
2008
2009
Year 1
2010
Year 2
2011
Year 3
LCA tools
LCA current
techno.
2012
Year 4
2013
Year 5
Year 6
Year 7
LCA new
technologies
Selection of the technologies to be
developed (environmental impact, TRL, etc.)
Scoping
2015
LCA current
technologies
Simplified LCA Tool
and database
Advanced LCA Tool
and database
State of the Art
Specifications
Trade-off
2014
Technology
Evaluator
Technology Development
Selection of the technologies for
the lifecycle demonstration
Demonstrator
definition
Ground
Demonstration
Preparation
Ground
Demonstration
Clean Sky Info Day, Toulouse, 1rst February 2011
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EDS Overview
Clean Sky Technology Evaluator
WP 1 Common Architecture Studies (Generic Arch.)
Modelisation, simulations, validations
Requirements
WP 2
Bizjet Arch. Trade-off
Regional Arch. Trade-off
Rotorcraft Arch. Trade-off
Technologies
• ECS, anti / de-icing
• Actuators
• Electrical generators, Starters
• ...
Energy &
Thermal
Benches
definition
Eco-Design ITD
SGO ITD
GRA ITD
Rotorcraft ITD
WP 3, 4
Global Iron Bird
Energy : Iron Bird
Logic Flow
Thermal bench
Integration and models demonstration through
Electrical test bench
Clean Sky Info Day, Toulouse, 1rst February 2011
Thermal test bench
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EDS: System Architecture Evolution
Reference A/C 2000: on onboard energy from 3 types
CONDITIONNEMENT
Electrical
PROTECTION GIVRE
+
MOTEUR
APU
Hydraulic
BATTERIES
+
Pneumatic
GENERATEUR
DEMARREUR
DEMARREUR
PNEUMATIQUE
GENERATEUR
ELECTRIQUE
DISTRIBUTION
ELECTRIQUE
POMPE
HYDRAULIQUE
DISTRIBUTION
HYDRAULIQUE
AVIONIQUE
ACTIONNEURS
CDV
CALC FCS
VMS
ACTIONNEURS
SERVITUDES
Virtual A/C 2020: onboard energy based one type
CONDITIONNEMENT
PROTECTION GIVRE
Electrical
MOTEUR
GENERATEUR
DEMARREUR
ELECTRIQUE
PàC
DISTRIBUTION
ELECTRIQUE
AVIONIQUE
ACTIONNEURS
CDV
CALC FCS
VMS
ACTIONNEURS
SERVITUDES
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Clean Sky Info Day, Toulouse, 1rst February 2011
EDS Demonstration
Ground demonstration for the All Electric Small Aircraft
– Electrical: high power network
– Thermal: on board aircraft heat transfers
Electrical Ground Test
Hispano-Suiza (Colombes)
Thermal Test Bench
Fraunhofer (Holzkirchen)
Airframe Structure
S-Duct Area
Avionic Bay
W
Cabin
Hot Tubing
W
W
Vented Area
ECS
W
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Clean Sky Info Day, Toulouse, 1rst February 2011
Eco-Design ITD Master Plan
2010
Q1
Q2
Q3
2011
Q4
Q1
Q2
Q3
EDA
2012
Q4
Q1
Q2
PDR
Q3
2013
Q4
Q1
Q2
Q3
2014
Q4
CDR
Q1
Q2
Q3
2015
Q4
Q2
Q3
Ground Test
Technology
selection
Technology trade-off
Q1
Assessment,
Synthesis
Technology scoping
4
3
EDA Technology Development
5
4
6
EDS
PDR
CDR
Electrical Ground Test
General
architecture
selection
Common activities: generic arch., methods & tools
Assessment,
Synthesis
Thermal Ground Test
CS Technologies and a/c level design methodology development
4
CoDR
PDR
CDR
Technical meeting
Decision gate
Review meeting
Event
Demonstrator
Clean Sky Info Day, Toulouse, 1rst February 2011
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6
Bar of activity
TRL scale 0 1 2 3
45
6
7 168
Q4
Key Competencies requested from Partners
EDA
• Development of emerging green technologies related to the manufacturing and production,
as well as dismantling of the aircraft. Examples are:
 Chromium free dense and thin micro-arc coatings for corrosion protection of
light alloys
 Production technologies of Magnesium-Forming: lost wax, investment, gravitation
and sand casting
• Participation in the development of LCA (Lifecycle Assessment) tools for customisation
to the aeronautic industry.
• Participation to the demonstration activities.
EDS
• Development of methods and tools for thermal, electrical and energy transfer
modelling from the component level up to the aircraft level.
• Participation to the electrical and thermal on-ground demonstrations.
In order to cover the above topics, all components of the aeronautical world are
welcome from universities, research institutes, SMEs and large industries.
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Clean Sky Info Day, Toulouse, 1rst February 2011
Provisional list of Topics for Call 8
ITD - AREA - TOPIC
Identification
JTI-CS-ECO
JTI-CS-ECO-01
JTI-CS-2011-1-ECO-01-018
JTI-CS-2011-1-ECO-01-019
JTI-CS-2011-1-ECO-01-020
JTI-CS-2011-1-ECO-01-021
JTI-CS-2011-1-ECO-01-022
JTI-CS-2011-1-ECO-01-023
JTI-CS-2011-1-ECO-01-024
JTI-CS-2011-1-ECO-01-025
JTI-CS-ECO-02
JTI-CS-2011-1-ECO-02-008
JTI-CS-2011-1-ECO-02-009
JTI-CS-2011-1-ECO-02-010
JTI-CS-2011-1-ECO-02-011
Clean Sky - EcoDesign
Area-01 - EDA (Eco-Design for Airframe)
topics
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VALUE
MAX FUND
6.410.000
4.807.500
2.050.000
Environmental Data Models and Interface development
Borate-free cleaners used in anodizing processes
Chromate-free sealing of TSA
Industrialisation Set-Up of Thermoplastics «In situ » Consolidation Process
Development of flexible inductive thin sheet heating device for FRP repair applications
To develop recycling technologies of aeronautical composite materials through mechano-physical approaches
Simplified LCA Tool development
Production of yarns and fabrics based on recycled carbon fibres (CFs)
720.000
100.000
100.000
290.000
200.000
140.000
250.000
250.000
Area-02 - EDS (Eco-Design for Systems)
4.360.000
Electrical Model of Generic Architecture Electrical Power Distribution
Alternator with active power rectification and health monitoring
Development, Construction and Integration of Systems for Ground Thermal Test Bench
Heat pipe for critical applications
300.000
1.700.000
2.000.000
360.000
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Clean Sky Info Day, Toulouse, 1rst February 2011
© 2011 by the CleanSky Leading Partners: Airbus,
AgustaWestland, Alenia Aeronautica, Dassault Aviation, EADSCASA, Eurocopter, Fraunhofer Institute, Liebherr Aerospace,
Rolls-Royce, Saab AB, Safran Thales and the European
Commission.
Permission to copy, store electronically, or disseminate this
presentation is hereby granted freely provided the source is
recognized. No rights to modify the presentation are granted.
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Clean Sky Info Day, Toulouse, 1rst February 2011