engineering, tolerance analysis and Determinant Assembly Approach of wing bo
WP 1.1, 1.2 Indicative Funding Topic Value (in k€) 750 k€
Duration of the action (in months) 48 months Indicative Start Date16
Q1 2017
Identification Title JTI-CS2-2016-CFP03-FRC-
01-02
Development and demonstration of a high power density homokinetic drive joint for civil rotor applications
Short description (3 lines)
The objective is to deliver flight cleared homokinetic drive units for civil tiltrotor proprotors. Representative test items will be used for structural and environmental testing and the flight cleared components will be integrated in the tiltrotor rotor system.
CfP03 Call Text 94 1.
Background
The aim of the Fast Rotorcraft (FRC) project is to use technologies developed through the Clean Sky Programme to demonstrate a tiltrotor configuration that combines the vertical lift capability of the conventional helicopter with the speed capability of a fixed wing aircraft in a sustainable way.
The outcome of this project is substantiation of a flight cleared homokinetic drive unit integrated into a proprotor system. This will form part of an advanced rotorcraft configuration with high cruise speed, low fuel consumption and gas emission, low community noise impact, and high productivity for operators. A large scale flightworthy demonstrator embodying the new European tiltrotor architecture will be designed, integrated and flight tested.
Figure 2: Rotor system at neutral position (0 deg blade flap) For illustration purposes only, design subject to change
Figure 3: Rotor System with 11 deg blade flap For illustration purposes only, design subject to change
CfP03 Call Text 95 2.
Scope of work
This Call is for Partners to perform design, manufacture, test and associated project management activities to produce a flightworthy homokinetic drive unit as part of the FRC demonstrator configuration.
The compact drive unit will transmit power across a range of torque and RPM values, while allowing the misalignment between the driving rotor mast and the driven hub plane. The homokinetic joint will need to accommodate the range of proprotor flapping motion and any transient torque from flight manoeuvres.
The required tasks with associated Deliverables and Milestones are presented in the following tables:
Tasks
Ref. No. Title - Description Due Date
T0 Project Management T0-T0+48
T1 Design and Development of a homokinetic drive unit. T0-T0+12 T2 Manufacture of specimens for characterisation testing T0+12-T0+18
T3 Characterisation testing T0+18-T0+24
T4
Updating of the homokinetic drive unit design according to characterisation test results and evolution of the overall rotor design
T0+24 -T0+30 T5 Manufacture of prototype for structural testing T0+30 -T0+36
T6 Structural endurance testing T0+36 -T0+42
T7 Manufacture of flight hardware T0+42 -T0+46
T8 Support to obtaining Flight Clearance T0+42 -T0+48
Further details related to specific activities are given below: Task T0:
Accounts for ongoing project management of the programme. Task T1:
The Topic Manager will provide information on the material and geometry of the interface with the hub. The design requirements to be fulfilled by Task 1 are as follows:
Reference Max continuous power: 5000 shp
Transient power capability: 10000 shp
Working RPM:
CfP03 Call Text 96 Space envelope:
External Diameter < ~350mm
Internal Diameter to accommodate mast ~170 mm
Figure 4: Notional space envelope for homokinetic device
* Designs that include a homokinetic device integrated with the hub will be considered. Maximum motion range:
±11° Flapping
Figure 5: Illustration of max flapping angle
Damage tolerant design that complies with civil certification requirements. Minimum weight to fulfil functional requirements
Task T2:
Representative specimens, (at least two (2)) for characterisation testing will be manufactured to be tested at a location agreed between the Partner and the Topic Manager.
Task T3:
Where applicable, characterisation testing on coupons and structural elements will be conducted to validate strain performance of the chosen materials under the expected operating range of temperature and humidity.
The results from characterisation testing will be assessed by the Topic Manager in the context of the Plate driven
from mast
Hub
Notional space for homokinetic drive unit*
CfP03 Call Text 97 development of the overall rotor system design.
Task 4:
Task 4 is to account for a second iteration loop that refines the design of the homokinetic drive according to the evolution of the rotor system. This task includes assessment of the impact of any refinement in loads. On the basis of this assessment, any refinement to the design will require analysis and where applicable, testing of representative samples to substantiate any differences. Task T5:
At least two (2) off prototype homokinetic drive units will be manufactured for structural testing at a location agreed between the Partner and the Topic Manager.
Task 6:
Structural testing of the representative specimens will be conducted to validate predicted fatigue behaviour. Results of the test will be used to manage inspections and removal of the assembly. Where applicable, limit and ultimate load static testing will also be required to substantiate the structural performance of the assembly.
Task 7:
Manufacture of at least two (2) off homokinetic drive units for the flying demonstrator aircraft. Task 8:
The partner will support achievement of flight clearance through reporting test and analysis results that substantiate the homokinetic device.
General Remarks:
Integration into the overall rotor design will be an ongoing activity to ensure acceptable dynamic performance of the drive unit and that geometric and kinematic clearance between rotor system components are maintained.
Development of the homokinetic unit will be conducted in close co-operation with the Topic Manager.
All correspondence and technical proposals shall be written in English. Where the originals of any documents submitted are in a language other than English, a translation will be provided.
CfP03 Call Text 98 3.
Major deliverables/ Milestones and schedule (estimate)
Deliverables
Ref. No. Title - Description Type Due Date
D1 Concept Document/Report T0+8
D2 Detailed Drawings Document/Report T0+12
D3 Availability of specimens for Characterisation Testing Hardware T0+18 D4 Assessment of strain characteristics Document/Report T0+24 D5 Availability of prototype for endurance testing Hardware T0+36
D6 Endurance Test Report Document/Report
/Presentation T0+42
D7 Availability of flight hardware Hardware T0+46
D8 DDP for Flight Clearance Document/Report T0+48
Milestones (when appropriate)
Ref. No. Title - Description Type Due Date
M1 PDR Design Review T0+8
M2 CDR (TRL of at least 5 for each system, technology and manufacturing process proposed)
Design Review T0+12 M3 Availability of test specimens for characterisation testing Hardware
Availability
T0+18
M4 Characterisation test report Document T0+24
M5 Availability of prototype for endurance testing Hardware Availability
T0+36
M6 Structural Test Report Document T0+42
M7 Delivery of flight hardware for installation into Rotor Assy Hardware Availability
T0+46 M8 Flight Clearance (TRL-7 for each system, technology and
manufacturing process)
Flight Readiness Review
T0+48
NOTE: Deliverables and Milestones listed in the above tables are intended to be part of the technical data exchange between the selected CfP candidate and the Topic Manager (AW), while the contractual milestones and deliverables, and related terms of agreements, between the selected CfP candidate and the JU will be detailed and mutually agreed during the Negotiation Kick-off meeting phase.
4.
Special skills, Capabilities, Certification expected from the Applicant(s)
The Topic Manager is responsible in front of the airworthiness agency and it is therefore mandatory that the Topic Manager will be supported by the Partner with respect to all qualification related
CfP03 Call Text 99 activities in relation the homokinetic joint and the constituent materials. Therefore the Partner has to provide all documentation necessary to achieve “Permit to Fly”, including:
Material data which are required to achieve a “Permit to Fly”.
Using material, processes, tools, calculation tools etc. which are commonly accepted in the aeronautic industry and by certification authorities.
Approach to calculation methods and the tools used will be agreed between the Partner and Topic Manager to ensure harmonisation of calculation processes/tools.
Interaction with the Topic Manager at each stage of development. Access to production and test facilities.
It is expected, that by T0+12, at least TRL 4 is achieved for each system/technology proposed. If this is not achieved on time, the Partner has to initiate a mitigation plan how to reach the
target of TRL 7 at the end of the programme.
The Partner has to perform the updates of documentation in case of in-sufficient documentation for authorities.
Special Skills
- Competence in management of complex projects of research and manufacturing technologies. - Experience in design and manufacture of constant velocity joints.
- Design, analysis and configuration management tools of the aeronautical industry (i.e. CATIA v5 release 21, Abaqus, VPM)
-Analytical vs Experimental correlation capability
- Experience with TRL Reviews or equivalent technology readiness assessment techniques in research and manufacturing projects for aeronautical or automotive industry
- It is desirable to have proven experience in collaborating with reference aeronautical companies with industrial air vehicle developments with “in – flight” components experience.
- Capacity to support documentation and means of compliance to achieve experimental prototype “Permit to Fly” with Airworthiness Authorities (i.e. EASA, FAA and any others which may apply). - Capacity to specify material and structural tests along the design and manufacturing phases of aeronautical components, including: material screening, and instrumentation.
- Capacity to perform structural and functional tests of aeronautical components: test preparation and analysis of results
- Capacity to repair “in-shop” components due to manufacturing deviations.
- Capacity of performing Life Cycle Analysis (LCA) and Life Cycle Cost Analysis (LCCA) of materials and structures.
- Capacity of evaluating design solutions and results along the project with respect to Ecodesign rules and requirements.
CfP03 Call Text 100 - Product Organization Approvals (POA) is desirable
- Quality System international standards (i.e. EN 9100:2009/ ISO 9001:2008/ ISO 14001:2004)
- Qualification as Material and Ground Testing Laboratory of reference aeronautical companies (i.e. ISO 17025 and Nadcap).
- Advanced Non Destructive Inspection (NDI) and components inspection to support new processes in the frame of an experimental Permit to Fly objective.
Material and Processes
In order to reach the main goals of the project two major aspects have to be considered for materials and processes, namely: maturity and safety.
Because of the ambitious plan to develop a flying prototype in a short time frame, the manufacturing technology of the partner must be on a high maturity level (TRL4) at the start of the project in order to be able to safely reach the required technology readiness for the flying demonstrator.
To secure this condition, the Partner will have to demonstrate the technology readiness of proposed materials and process and manufacturing technology with a TRL review, to be held together with the Topic Manager.
The TRL review must be held within one year after beginning of the project and must confirm a maturity of TRL5 or at least TRL4 if a solid action plan to reach TRL5 within the scope of one further year and finally meet the TRL target for the demonstrator, validated and accepted by the Topic Manager. Since the schedule of the project and the budgetary framework do not allow for larger unanticipated changes in the middle of the project, it is required that at the start of activities the partner demonstrates capability to develop and manufacture the required items with a baseline technology which will be a back-up solution if the new technology to be introduced proves to be too challenging.
This back-up plan, which shall secure the meeting of the project goals shall also be agreed between AW and the Partner within six months after start of the activities and approved by the JU.
Furthermore the management and planning activities in this Call shall support the safe inclusion of the developed technology into the complete flying Next GenCTR Demonstrator.
CfP03 Call Text 101
II.
Next generation smart active inceptors for a civil tiltrotor
Type of action (RIA or IA) IA
Programme Area (ref. to SPD) FRC Joint Technical Programme (JTP) Ref. (ref.
to Work Package)
WP 1.1, 1.6