ED Presentation Take off Vienna June 1st 2010 V3 & Flow Control New Aircraft Configurations Low...

Clean Sky

The Joint Technology Initiative

For Aeronautics & Air Transport

Clean Sky

The Joint Technology Initiative

For Aeronautics & Air Transport

Eco-Design ITD

Technical Overview

Dr. Florian Mayer(Fraunhofer)

Clean Sky – Eco-Design ITD“Take off”, June 1st, 2010, Vienna

This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval

Clean Sky – Eco-Design ITD – Technical overview2

Reduced fuel

consumption (CO2 &

NOx reduction)

External noise

reduction

"Ecolonomic"

life cycle

� Engines

� Loads & Flow Control

� New Aircraft Configurations

� Low weight

� Aircraft Energy Management� Mission & Trajectory Management

� Engines� Mission & Trajectory Management

� Configurations

� Rotorcraft Noise Reduction

� Aircraft Life Cycle

� Engines

� Loads & Flow Control

� New Aircraft Configurations

� Low weight

� Aircraft Energy Management� Mission & Trajectory Management

� Engines

� Mission & Trajectory Management

� Configurations

� Rotorcraft Noise Reduction

� Aircraft Life Cycle

Eco-Design – Objectives Eco-Design – Objectives



� Eco-Design will focus on green design and production,

withdrawal, and recycling of aircraft, by optimal use of raw

materials and energies thus improving the environmental impact

of the whole products life cycle and accelerating compliance with

the REACH directive.

� Eco-Design is focused on designing equipped airframe for

decreasing inputs (raw materials, energy, water, etc.), outputs

and nuisances (energy / warming, liquid effluents, gaseous

effluents, solid waste, etc.) and on eliminating non-renewable

and noxious fluids and materials (i.e. removal of hydraulics � all

electric aircraft) during operations and maintenance, without

reducing aircrafts' levels of safety, quality and performance.




�To design systems for reducing use of non-renewable and nocive fluids /

materials during operations and maintenance: for Systems Application (EDS)for Systems Application (EDS)

�To design airframe for decreasing inputs, outputs and nuisances during a/c

design & production and withdrawal phases: for Airframe Application (EDA)for Airframe Application (EDA)

EcoEco--Design for AirframeDesign for Airframe

EcoEco--DesignDesign

For systemsFor systems

Inputs :

Raw materials

Water

Energy …

Outputs,

nuisances :Energy (warming)

Liquid effluents

Gaseous effluents

Solid waste …

a/c Design &

Production

Inputs :

Fuel

Lubricants

Energy …

Nuisances :Energy (warming)

CO2, NOx

Noise

Contrails

Crash waste …

a/c Use &

Inputs :

Fuel

Water

Energy …

Nuisances :

Energy (warming)

Liquid effluents

Gaseous effluents

Solid waste …

a/c

Withdrawal(Recycling)


Maintenance



2 ED ITD Leaders

IWIW

CASACASA

8 ITD Leaders

5 Associates

(Cluster) (Cluster)

Eco-Design – MembersEco-Design – Members



� A total of 43 beneficiaries (with affiliates and clusters’ members)

� 10 Research organisations

� 2 SME

� From 8 Countries (France, Germany, Israel, Italy, Netherland, Spain, Switzerland, UK)

Eco-Design – BeneficiariesEco-Design – Beneficiaries

� Current Budget

� Total Eco-Design: 116 M€

� Eco-Design for Airframe: 79 M€

� Eco-Design for Systems (small A/C): 37 M€

� 25% thereof for other Partners through CfPs



� Design airframe for decreasing inputs, outputs andnuisances during A/C design & production and withdrawal phases

� Deliver eco-design recommendations to the vehicletypes considered within Clean Sky

� Evaluate new promising technologies and then to identify and maturate the ecologically sound design solutions

� Introduce eco-design tools in the current aircraft designprocess

Eco-Design – EDA ObjectivesEco-Design – EDA Objectives



TECHNOLOGY AREAS

Manufacturing

Product

Use

Maintenance

Green Repair

EliminationRecycling

Eco-Design

for Airframe

Raw Materials

Area 3 : long life structure

Area 4 : end of life management

Area 2 : green manufacturing

Area 1 : new materials / new

architectures

Manufacturing

Product

Use

Maintenance

Green Repair

EliminationRecycling

Eco-Design

for Airframe

Raw Materials

Area 3 : long life structure

Area 4 : end of life management

Area 2 : green manufacturing

Area 1 : new materials / new

architectures

Lifecycle demonstration throughGlobal demonstrator Partial demonstrators

Eco-Design – EDA General IssuesEco-Design – EDA General Issues



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

� …

New emerging materials

�Composite

� Resins and fibres made from agriculture

� nanotechnology, molecular design

� Thermoplastics

� Others

�Metallic

� New light alloys

� Surface treatment, protection

Modeling

Eco-Design – EDA Area 1: MaterialsEco-Design – EDA Area 1: Materials



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

� Societal

Materials – Requirements

�Current

�Composite, metallic

�New

�Green Composites, metallic

�Low emissions (VOC, dust)

�Low production waste and scrap

�Recyclability

Green Factory

�Direct manufacturing

�Energy management

�Virtual Reality

�Manufacturing waste management Modeling

Rigid Tooling

AUTOCLAVE

Vacuum

pumpInjection

machine

resin injection

part to be filled

autoclave pressure

Eco-Design – EDA Area 2: ManufacturingEco-Design – EDA Area 2: Manufacturing



Test Procedures

�Relevant Vs in field experience

�Short testing cycle

�Ease of structure repair

Structural Diagnostic / Prognostic

� Health Usage & Monitoring

� Real time monitoring

� Smart sensors

� Non Destructive Testing

Green Repair Solutions

� 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

Eco-Design – EDA Area 3: Long Life StructureEco-Design – EDA Area 3: Long Life Structure



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

Dismantling processes

� Low energy

� Dry Processes

� Low effluents and waste

Eco-Design – EDA Area 4: End of Life managementEco-Design – EDA Area 4: End of Life management



Materials

Manufacturing

Materials

Manufacturing

Validation article

TBD (significant representative equipped structure)

Production

Process

Production

Process

DismantlingDismantling

RecyclingRecycling

Modelling + manufacturing + testingUse

Maintenance

Use

Maintenance

Partial testsPartial tests

Eco-Design – EDA Overall Life Cycle DemonstrationEco-Design – EDA Overall Life Cycle Demonstration



Level

Recycling

concept

Separa-

bility

Recycla-

bility

Eco

Design

Guideline

Modular

structure

Types and

numbers

of joints

Tolerability

in recycling

Repair, life

span, con-

sumption

Access-

ability

Dismant-

ling depth

and time

Types and

numbers of

material

Auxilliary

agents,

processing

Separa-

bility

Time for

dis-

mantling

Materials

choice and

tolerability

Toxicity,

generation,

processing

Structure Joining

technol.

Materials Eco-Profile

materials

products

modules

sys-

tem

Eco-Design – EDA Comprehensive Eco-Friendly Materials and Manufacturing ApproachEco-Design – EDA Comprehensive Eco-Friendly Materials and Manufacturing Approach



To demonstrate the feasibility and highlight the “ecolonomic” benefits

at aircraft level of “oil-less power-by-wire” for small cabin aircraft.

� Removal of hydraulics:

less environmental impact in terms of aircraft maintenance

and disposal.

� All-electrical system:

Current: different media (electric, hydraulic, pneumatic)

Future: electricity as the only media

� Innovative energy management:

new energy management, intelligent load shedding, power

regeneration on actuators, sharing of Electrical Control Unit over

actuators, etc.

� greener power efficiency and fuel consumption,

reduced CO2 and NOx emissions

Eco-Design – EDS ObjectivesEco-Design – EDS Objectives



� Validate an a/c design methodology and tools for

optimisation of Integrated Vehicle Systems Architecture

� Demonstrate feasibility and ecolonomic benefits of the

all electric a/c concept

� Evaluation / maturation of electrical & thermal

technologies

� Prepare the ecolonomic design through drastic reduction of ground and flight tests thanks to the

virtual a/c concept

Eco-Design – EDS ObjectivesEco-Design – EDS Objectives



LOGIC FLOW

Integration and models demonstration throughElectrical test bench Thermal test bench

ECSVented Area

Cabin

Hot Tubing

S-Duct Area

W

W

W

W

Avio

nic

Ba

y

Airframe Structure

ECSVented Area

Cabin

Hot Tubing

S-Duct Area

W

W

W

W

Avio

nic

Ba

y

Airframe Structure

Electrical bench

GENERIC ARCHITECTURE STUDIES

Thermal bench

Integration Demonstrators

Clean Sky Technology Evaluator

TECHNOLOGY DEVELOPMENT

A/C APPLICATION

Electrical bench

GENERIC ARCHITECTURE STUDIES

Thermal bench

Integration Demonstrators

Clean Sky Technology Evaluator

TECHNOLOGY DEVELOPMENT

A/C APPLICATION

Eco-Design – EDS OverviewEco-Design – EDS Overview



� Demonstrate an optimisation of high power electrical

network operation

� Demonstrate optimised air circulation patterns

� Demonstrate passive temperature control (radiation,

conduction)

� Demonstrate active temperature control (heat pipe, ...)

� Demonstrate advanced materials in aircraft structures

� Demonstrate accurate modeling of the thermal

environment, including the effects of active thermal control technologies

� Validate the methodology and associated modeling for

the thermal side

Eco-Design – EDS – Demonstration: Electrical & Thermal TechnologiesEco-Design – EDS – Demonstration: Electrical & Thermal Technologies



ECSVented Area

Cabin

Hot Tubing

S-Duct Area

W

W

W

W

Avio

nic

Ba

y

• Hot pressurised air for engine bleed

Airframe Structure

ECSVented Area

Cabin

Hot Tubing

S-Duct Area

W

W

W

W

Avio

nic

Ba

y

• Hot pressurised air for engine bleed

Airframe Structure

Eco-Design – EDS – Demonstration: Thermal BenchEco-Design – EDS – Demonstration: Thermal Bench

Fraunhofer Flight Test Facility FTF,Holzkirchen



� www.cleansky.eu

� http://cordis.europa.eu/home_de.html

Eco-Design – OverviewEco-Design – Overview



Eco-Design – CfP Topics – Call #3 2010 April-JulyEco-Design – CfP Topics – Call #3 2010 April-July

Identification topics VALUE MAX FUND

JTI-CS-ECO 4 740.000 555.000

JTI-CS-ECO-01 740.000

JTI-CS-2010-3-ECO-01-004 70.000JTI-CS-2010-3-ECO-01-005 250.000JTI-CS-2010-3-ECO-01-006 220.000JTI-CS-2010-3-ECO-01-007 200.000

JTI-CS-ECO-02

ITD - AREA - TOPIC

Clean Sky - EcoDesign

Area-01 - EDA (Eco-Design for Airframe)

Area-02 - EDS (Eco-Design for Systems)

Development and implementation of Magnesium sheets in A/C

Integration development of a wireless strain monitoring system with a simulation toolEnhanced local heating device capable of high and homogeneous temperature for the repair of large composite damagesAccelerated fatigue testing methodology for fiber reinforced laminates for aircraft structures

Next Call (#4) will be opened in July

ED Presentation Take off Vienna June 1st 2010 V3 & Flow Control New Aircraft Configurations Low...

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