Achievements Timeline

Clean Sky's projects are helping to dramatically slash the air industry's CO2, other gases and noise footprints by developing new engine architectures, improved wing aerodynamics, lighter composite structures, smarter trajectories, and more electrical on-board energy.

While some technologies can be assessed during their development phase at component or system level, many key technologies will need to be validated via dedicated test programmes, involving large-scale ground or in-flight demonstration installations: this is the major goal of Clean Sky. These demonstrators integrate several technologies at a major system level or at aircraft level, enabling them to be tested in a relevant operating environment.

To date, more than 30 main demonstrators of different sizes, some of which are in a technical sequence, are being developed at a very high technological maturity level. In the following section the most significant and representative demonstrators from each ITD are presented with the highlights of their content.

The timeline below shows some examples of cutting-edge technologies leading to those results.

Achievements

Achieved Planned

 

ALECSys
-

ALECSys (Advanced Low Emissions Combustion System) Demonstrator – Rolls-Royce plc

 

Objectives:

  • Optimisation of a new lean-burn and low-emissions combustion system

Main features:

  • The lean-burn system improves the pre-mixing of fuel and air prior to ignition – delivering a more complete combustion of the fuel and, as a result, lower NOx and particulate emissions, both of which are increasingly important to airline customers in terms of operating economics and environmental performance

Expected benefits:

  • Reduction in emissions for future engines.  Technology from the system features in both the Advance3 and the UltraFan® demonstrator programmes

Main outcome:

  • The ALECSys Demonstrator successfully ran for the first time on a testbed in Derby, UK
  • The engine is now at the Glacier test facility (Thompson, Manitoba, Canada) for the planned cold weather testing
     
Wind tunnel
-

Wind tunnel test with active flow control on a real aircraft geometry equipped with a classical and an Ultra High Bypass Ratio (UHBR) nacelle successfully completed in the Kryogenic Cologne Wind Tunnel (KKK) - Large Passenger Aircraft IADP [Platform 1]

 

Main features

  • Wind tunnel test on a real aircraft configuration applying active flow control technology at the wing/pylon region. To ensure high Re numbers the configuration was tested under cryogenic conditions in the Cologne wind tunnel
  • The test was done in the frame of a CfP project (AFLOWTEST) led by the NLR and TU -Delft   

Main outcomes

  • First wind tunnel results of active flow control applied on a real aircraft configuration with high Reynolds numbers
  • Suporting the preparation of the planned flight test featuring active flow control technology at the pylon wing area

Main expected benefits

  • Applying flow control technology will reduce the lift loss induced by the closed coupled installation of the UHBR engine to the wing
     
UltraFan
-

UltraFan® key aircraft integration design features and roadmap towards for flight test demonstration settled (LPA WP1.5.2 & WP1.6.4 - Large Passenger Aircraft IADP [Platform 1]

 

Main features / challenges

  • Overall Aircraft Design: Engine-Wing Close Coupling, physical integration (new structural concept), novel pylon technology
  • Low drag & weight nacelle: Short inlet, translating cascades 
  • Engine distortion: Pylon mounts, engine stiffness
  • Enhanced Acoustic Treatment: Stricter requirements with less area for treatment
  • More Integrated Heat Management Systems: Managing higher engine heat loads without compromising power plant system integration

Main outcomes

  • Flying Test Bed vehicle selection made in collaboration with Airbus
  • Key enabling technology development underway
    • Low Speed Fan Rig testing
    • Power Gear Box (PGB) attitude and power rig running, full demonstrator power achieved
  • Power gear Box Manufacturing Joint Venture established
    • ATT, Aerospace Transmission Technologies GmbH
    • Rig parts delivered to support rig testing, future factory planning underway
    • First PGB vehicle strip
  • Piloting new ways of working
    • PM Award won by PGB team – APM awards
    • Leeds university Socio-Technical study
    • Embedding automation packages
    • Model based systems engineering 

Main expected benefits

  • Parallel development and preparation of UltraFan® aircraft integration and flight test preparation and research engine development will ensure high maturity of engine technology and achieving substantial fuel burn and noise reduction of the integrated engine
     
Printed Electrics Aircraft Cabin Sidewall
-

Printed Electrics Aircraft Cabin Sidewall demonstrator - Large Passenger Aircraft IADP [Platform 2]

 

Main features / challenges

  • Design and develop a modular, integrated aircraft sidewall  that combines insulation , structural and electrical functions
  • Create a printed electrics framework to enable easy and customizable integration of electrical functionality

Main outcomes

  • Technology and design concept review (“TRL 2”) passed in summer 2017
  • Quarterly sprint reviews from Q3 2017
  • First functional, full size demonstrator completed

Main expected benefits

  • Increase of manufacturing flexibility
  • Reduction of weight compared to classical “State of the Art” solutions
  • Reduction of recurrent production cost
     
Advanced Geared Engine
-

Advanced Geared Engine Configuration (HPC & LPT Technology Demonstration) - Engines ITD

 

Objectives

  • Integral efficiency enhancement of the next generation of a geared engine’s compression system: The goal is to precisely fine-tune the interaction of the low-pressure compressor, inter compressor duct (ICD) and high-pressure compressor to identify and leverage new potential for even more fuel-thrifty engines

Main features

  • The ICD is the transition channel between the low- and high-pressure compressors. An important step towards its improvement is the systematic mapping of the flow conditions in short, steep transition channels. To this aim, an entirely new wind-tunnel test rig was built at DLR Institute of Propulsion Technology in Cologne, MTU’s Center of Competence (CoC) for propulsion systems in cooperation with GKN
  • The ICD rig measures the channel flow in an unprecedented depth of detail: 500 pressure tapping points, probe measurements at three traversing plains, the use of laser technology and turbulence probes allow detailed insights in the flow mechanisms

Main outcome 

  • The new technologies could already go into the next generation of geared turbofan engines

Expected benefits

  • Different ICD configurations are being tested over the course of the year 2018. Based on the ICD rig test results obtained, a two-shaft test rig will be designed and built. Both the low- and high-pressure compressor will be tested together as one entity
  • The tests will provide a much better understanding of the flow conditions in the ICD. These results will allow to come up with particularly compact designs to further reduce the length, and hence the weight of future engines
Aircraft Monitoring Chain
-

Primary development of the Aircraft Monitoring Chain & Ground Support System (AMCGSS) [Part of REACTOR project] - Large Passenger Aircraft IADP [Platform 3]

 

Main features

  • Simultaneous monitoring of multiple aircraft, means to file a flight plan, enhancing the flight crew situational, aircraft performance calculations and communication with various entities (e.g. ATC)
  • HMI design achieved with pilot input and in collaboration with Coventry University

Main outcomes

  • The AMCGSS is now fully functional as a stand-alone technology with all high-level requirements met.

Main expected benefits

  • Provides support to the onboard crew operation under specific situations (e.g. degraded systems, high workload, and emergency situations). Intended to be operated with other cockpit based technologies focused on pilot workload reduction
     
Hybrid Laminar Flow Control
-

Hybrid Laminar Flow Control (HLFC) Horizontal Tail Plane passed review to enter detailed design – Large Passenger Aircraft IADP [Platform 1] (Airbus, Aernnova and DLR)

 

Objectives:

  • Design and manufacture an innovative composite design of the HLFC HTP leading edge
  • To develop a new manufacturing solution based on automatable Composite Liquid Resin Impregnation technologies with out-of-autoclave curing, hybridized with titanium micro-perforated sheets
  • Support to data acquisition during long-term flight testing to mature the design of the HLFC leading edge
  • Best exploitation of the restricted aero-design space to allow a performance improved HLFC HTP 

Main outcomes:

  • Technology Readiness Level 3 (TRL3) review successfully passed
  • Matured the design of the HLFC leading edge section, incl. Systems selection and integration
  • Developed Laser drilling characteristics with pressure loss measurements 
  • Manufacturing of trials for the 1 shot process, and manufacturing of inner skin with Liquid Resin Infusion
  • Tests for High Velocity Impact, Fatigue, material characterisation, etc.

Expected benefits:

  • Overall aircraft drag benefit / fuel burn savings
  • Lower ecological footprint of the manufacturing process for composite structures
Advance3 Demonstrator
-

Advance3 Demonstrator – Rolls-Royce plc

 

Objectives:

  • The demonstrator will test a new engine core that will deliver maximum fuel burn efficiency and low emissions

Main features:

  • The Advance3 core features a new Core Design with a two stage high pressure turbine and a single-stage intermediate pressure turbine; incorporating a range of cutting-edge technologies - 3D printing/ALM and lean burn combustion

Expected benefits:

  • The new core forms a key part of the Rolls-Royce Advance and UltraFan® engine designs, both of which are central to our future engine strategy and technology programme

Main outcome:

  • The Advance3 demonstrator engine successfully ran for the first time on a Derby, UK testbed – performing as expected during the initial test
  • The engine will continue testing in Derby, with future tests gathering data on the performance of the engine across more than 2,800 parameters
CROR
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SAGE 2 CROR Ground test demonstrator, Istres - Safran, Snecma

Objectives & benefits:

  • The Contra Rotating Open Rotor (based on a geared unducted architecture) is an aircraft engine offering a 30% fuel burn reduction compared to the the year 2000 turbofan reference engine, allowing a significant decrease of the CO2 emissions

Main features:

  • The Open Rotor configuration aims at meeting several technological challenges such as a new propulsion mode, an innovative aerodynamic configuration and unprecedented manufacturing processes

Read more...

BLADE First Flight [SFWA]
-

BLADE First Flight [SFWA]

 

Objectives: 

  • The project is assessing the feasibility of introducing natural laminar flow technology for commercial aviation

Main features:

  • Flight Test Aircraft modification (A340-300 MSN001)
  • Advanced laminar wing aerodynamic design
  • Advanced Flight test instrumentation to measure laminar flow during flight test
  • Two alternative integrated structural concepts for a laminar wing
  • High quality, low tolerance manufacturing and repair techniques
  • Shielding Krueger high lift anti contamination device

Expected benefits:

  • Fuel burn saving on short/mid-range aircraft compared to an equivalent aircraft with a conventional wings

Main outcomes:

  • Flight Test Installation validated during first flight
  • No issue on Aircraft systems and structures
  • Laminarity observed since first flight
  • Flight test campaigns ongoing from 2017 to 2019
     
Noise Shielding Tail Plane
-

Noise Shielding Tail Plane – Airframe ITD

 

Objectives:

  • Model representative of the U-tail of the LSBJ (scale 1) with a dedicated test set up
  • Positioning of the model in the area of the engine of a Falcon and ground test for evaluation of the noise shielding performance
A330
-

Successful flight tests of MEMS based GPAHRS on A330 – Large Passenger Aircraft IADP [Platform 3]

 

Main features:

  • Installation onboard a Flight Tests Airbus A330 of a prototype GPAHRS developed by Honeywell
  • Connection to the aircraft GPS receivers and to flight tests installation
  • Performance of 65 Flight hours with dynamic manoeuvres

Main outcomes:

  • The comparison with the aircraft navigation sensors has demonstrated a performance equivalent to current navigation systems

Main expected benefits:

  • Will provide additional navigation information source to enhance navigation systems reliability and availability, to reduce flight operations disruptions and support permanent autopilot capability
     
SFWA
-

SFWA Low Speed BizJet (LSBJ) - Dassault, DNW

 

Objectives:

  • Scale model representative of the LSBJ conceptual bizjet aircraft with U-tail (based on a Falcon configuration)
  • Aerodynamic characterisation tests in DNW WT to be followed by acoustics tests on the same model with dedicated test set-up
GRC
-

GRC Electric Tail Demonstration - AgustaWestland

Main features:

  • Electrification of the tail rotor drive function
  • The ‘Electric Tail Demonstrator’, based on concepts explored by the ELETAD project, incorporates the high power/weight ratio laboratory motor design into a high integrity aircraft system capable of installation and dynamic evaluation on an aircraft tail demonstration rig

Main outcomes:

  • The Electric Tail Demonstrator system is currently TRL3, with the key motor parts from ELETAD that are at TRL 4
  • The ground demonstration will dynamically evaluate the system representing flight mission profiles, reaching TRL 5

Expected benefits:

  • Assessment of innovative helicopter tail Rotor architectures
GRA
-

GRA Cockpit demonstrator Airbus Defence & Space

Main features:

  • A second cockpit ground demonstrator has been prepared, and has achieved a major step towards the internal target of 10% weight saving

Main outcomes:

  • Different frame materials are under investigation to identify the best material for acoustic, fatigue and crash behaviour
SFWA
-

SFWA High-speed business jet Demonstrator

Objectives:

  • To validate the aero efficiency and aero loads of innovative control surfaces (smart flap). Global and partial force measurements will be used, combined with detailed pressure distribution. Another test campaign will have an inlet rake

Main features:

  • Handling qualities of innovative HTP (Horizontal Tail Plane), canard, flaperon, continuous settings slats
  • Air intake unsteady distortion measurements
  • Model manufacture technique : SLM (Selective Laser Melting (additive manufacturing technique))

Expected benefits:

  • Fuel burn saving and noise reduction on long haul operations compared to current fleet
SFWA
-

SFWA Low-sweep business jet Demonstrator

Objectives:

  • Noise shielding measurement, acoustic and fatigue characterisation and thermal characterisation for U-Tail configuration

Main features:

  • Far field microphones installed on the ground for installation effect measurements
  • Metallic and composite panels installed on the U-Tail for thermal and acoustic fatigue measurements

Expected benefits:

  • Noise reduction on short range flights compared to current fleet
sgo
-

SGO Multi Criteria Departure Procedure - Airbus, Thales

Expected benefits:

  • Adaptive-increased Glide Slope (A-IGS) and Multi Step Cruise (MSC) functions are developed to optimise aircraft trajectories with respect to environmental criteria and flight operation efficiency. Tests will be performed in AIRLAB Thales simulator

Objectives:

  • Define green trajectories (departure, cruise and final approach)
  • Demonstrate the environmental friendliness of the functions in a representative operational environment
  • Follow up the technical maturity of the technologies and system architectures

Main features:

  • Cockpit with real software products (real code on native platform) and simulated equipmen
GRC Passive Optimized Blade - Airbus Helicopters
-

GRC Passive Optimized Blade - Airbus Helicopters

Main feature:

5-bladed passive rotor optimised in terms of acoustics, performance, comfort and cost.

Achieved benefits:

  • Unprecedentedly low external noise signature
  • Excellent comfort even without any vibration isolation means
  • Higher speed and significant increase of payload

Award:

The AH-D GRC1 rotor design has been awarded with the renowned American Helicopter Society’s (AHS) Grover E. Bell Award for an outstanding research and experimentation contribution to the field of vertical flight development.

SFWA
-

End of wing assembly of (BLADE) Breakthrough Laminar Aircraft Demonstrator in Europe

Objective:

  • To demonstrate in flight that the Natural Laminar Flow (NLF) wing produced at ‘industrial scales’ will confer significant performance, with low maintenance and operational costs

Main features:

  • Test Aircraft modifications (A340-300) and manufacturing
  • Advanced passive laminar wing aerodynamic design
  • Two alternative integrated structural concepts for a laminar wing
  • High quality, low tolerance manufacturing and repair techniques
  • Anti-contamination surface coating
  • Shielding Krueger high lift device

Expected benefits:

  • Fuel burn saving on short/mid-range aircraft compared to an equivalent aircraft with a conventional wing
GRAF
-

GRA Fuselage demonstrator One Piece Barrel - Alenia Aermacchi

Main features:

The fuselage demonstrator has 2 components :

  • The fabrication of the fuselage barrel as a Composite ‘one piece barrel’
  • The testing of this barrel for fatigue and static behaviour

Main benefits:

  • New fuselage concept architecture
SGOA
-

SGO A320 e-FTD (electric Flying Test Demonstrator) - Airbus

Main features and outcomes:

  • The A320 will be configured for flight testing in two test campaigns of More Electric Aircraft architecture, integrating the following items:
  • Liebherr 50kW e-ECS, verifying the interaction & control laws between compressors & scoop air intake & A/C, and the electrical functionality and associated DC system/power electronics. Also part of this effort is the scoop air intake performance
  • The Electrical Power Centre is based on HVDC and several sensors
  • The Primary Ice Detection System (PFIDS), whose goal is to automatically activate the Ice Protection System when the A/C encounters icing conditions (from -40°C to +10°C), is currently at TRL 5 as a component, after Verification of the Detection performance in Icing Wind Tunnel (IWT)
SAGEL
-

SAGE Lean burn Demonstrator - Rolls Royce

Objectives & features:

The Lean Burn Programme objective is to deliver a verified generic Lean Burn System against a set of validated requirements complying with regulatory and company demands for emissions and safety, and with acceptable reliability at minimum life cycle cost and weight. • The test programme is based on Trent 1000 donor engines (ALECSYS) for engine ground testing

  • Emissions capability at representative future cycles has been demonstrated in a dedicated core engine experiment on the EFE (Environmentally Friendly Engine) vehicle
  • The programme is also envisaging a full scale flight test campaign on a B747 flying test bed
  • The programme is scheduled to achieve TRL 5/MCRL 4 by mid-2016
SFWA
-

SFWA Low-sweep business jet Demonstrator Dassault

Objectives:

  • Noise shielding measurement, acoustic and fatigue characterisation and thermal characterisation for U-Tail configuration

Main features:

  • Far field microphones installed on the ground for installation effect measurements
  • Metallic and composite panels installed on the U-Tail for thermal and acoustic fatigue measurements

Expected benefits:

  • Noise reduction on short range flights compared to current fleet
GRC AW
-

GRC AW139 VFR procedures, Pilot evaluation and flight trials - AgustaWestland

Main objectives:

  • Gain confidence in the acoustic benefits of steep departure and approach procedures with respect to conventional ones, based on correlation with AW139 prototype flight acoustic measurements on-board and on-ground
  • Involvement of partner project MANOEUVRES, to improve the acoustic prediction capability for manoeuvring unsteady conditions, and to propose the concept of a Pilot Acoustic Indicator, able to provide on-board noise predictions allowing the adaption of the flight path

Main outcomes:

  • After completing pilot handling, guidance and workload validation of the VFR environment friendly paths, using an engineering simulator AWARE, demonstration in flight of the noise abatement for this project in Q2 2016
agf
-

GRC Active Gurney Flap - AgustaWestland

Next-generation helicopters will consider adaptive and innovative components within their rotor blades in order to obtain performance benefits.

AgustaWestland and its partners are developing and testing an Active Gurney Flap system through a series of progressive tests consisting of:

  • Model Rotor test (controlled environment test)
  • 2D Static Test, University Twente (initial fully sized blade data)
  • 2D Dynamic Test (at CIRA IWT1) (blade representative testing, controlled environment)
  • Whirl Tower (full scale rotor; full systems capability test ahead of flight)
  • Flight test on an AW139 helicopter TRL 6

Expected benefits:

  • Demonstration of advanced Rotor Blade concept
GRAA
-

GRA All-Electric Aircraft demonstrator - Alenia, ATR, Partners

Objectives:

  • The ATR 72 FTB (flying test bed) A/C will be modified at the end of the structural test campaign for the AEA Technologies in flight demonstration

Main features:

  • EPGS: Electrical Power
  • Installation of 270 HVDC Generation distribution including Electrical Power Center (EPC) and Simulated Resistive Electrical Load (SREL)
  • E-ECS (Electric Environmental Control System) (35 kW), with a dedicated control rack
  • EMAs : Installation of two electrical actuators (one for FCS, one for LG (each mounted on a dedicated test bench, both located in Cabin) An FTI/Flight Test Station (FTES) will also be installed in the cabin.

Expected benefits:

  • Implementation of more electric aircraft architecture
SFWA
-

SFWA Wing assembly for the BLADE demonstrator - AERNNOVA

Main features:

  • As the evolution of the concept to a flyable demonstration, after the successful ground based demonstrator, two semi wings (8m span each) were designed and manufactured with the involvement of SAAB and GKN UK for two different solutions (fully integrated composite, standard wing design), both of them complying with the stringent requirements of tolerance, stability, and accuracy of the shape of the wing to keep the laminarity in all flight regimes

Main outcomes:

  • After this assembly the wings will be delivered to Airbus for integration in the A340 flying test bed. Wind tunnel tests have been conducted to assess the handling qualities of this modified configuration
GRCd
-

GRC Demonstration of Diesel powered light helicopter - Airbus Helicopters, Marignane

Objectives:

  • A flying demonstrator based on an EC120 serial helicopter and fitted with a newly designed High Compression Engine (HCE, a reciprocating engine using Kerosene) has been developed by Airbus Helicopters in the frame of GRC 4
  • For this research project, Airbus Helicopters teamed up with TEOS Powertrain Engineering, France (leader of the Consortium), and AustroEngine GmbH, Austria (partners of the project HIPE 440 selected in 2011)

Main features & benefits:

  • In the power class related to EC120 engines (300 to 400kW), the main advantages of HCEs compared to turboshaft engines are the lower specific fuel consumption, lower CO2 emissions, and higher performance in hot/high conditions thanks to the superchargers. Target Mass-to-power ratio < 0.8 kg/kW
sage gt
-

SAGE Geared Turbofan - MTU

Main objectives:

  • Advanced Geared Turbofan Demonstrator, with MTU and Partners’ contribution with innovative technologies concerning materials and manufacturing processes
  • Engine components concerned:
    • New highly efficient high-pressure compressor
    • Lightweight, high speed low-pressure turbine
    • Advanced lightweight and efficient turbine structures
    • Lightweight and reliable fan drive gear system
    • New systems for a more electric engine
sage tecj
-

SAGE TECH 800 - TURBOMECA

Objectives:

  • Core turboshaft engine demonstrators in the power range 1,000- 2,000 SHP

Main features:

  • High efficiency compressor, combustion chamber, high-pressure, and low-pressure turbine

Main outcomes:

  • Turbomeca developed the technologies with support of several partners
  • Full scale and life cycle validation achieved
GRA ATR
-

GRA ATR first flight, Crown Panel - Alenia, ATR, Fraunhofer

Objectives & Main outcomes:

  • Innovative sensorized EPOXY CFRP fuselage “crown” panel
  • Integrated Technology Demonstrator of Alenia (research, development, design, manufacturing and optical fibres sensor instrumentation), ATR (installation and operation; test aircraft), and Fraunhofer (panel piezo-electric sensor instrumentation) 
  • Aim of flight test campaign was to support the development of innovative EPOXY CFRP panel with embedded layer to provide additional acoustic damping, as well as two different technologies for Structural Health Monitoring (SHM)

Expected benefits:

  • They concern weight, internal noise, assembly costs and structural health monitoring
sgo e
-

SGO Electrical Power Distribution Centre - Zodiac Aero Electric

Main features:

  • An innovative Electrical Power Distribution Center (EPDC) adapted to “More Electrical Aircraft” architecture and sized for a single aisle airliner has been developed
  • The EPDC is the vital link between the electrical power sources of the aircraft and the electrical power users

Main outcomes:

  • The EPDC was integrated in the PROVEN test rig
GRC D
-

GRC Demonstration of Helicopter Low Noise Procedures - Airbus Helicopters

Objectives:

  • The low-noise IFR (Instrument Flight Rules) approach procedures were flown using accurate lateral and vertical guidance provided by EGNOS (European Geostationary Navigation Overlay Service), the European Satellite-Based Augmentation System (SBAS), and in the presence of airplane traffic, which proved the suitability of these helicopter-specific procedures to achieve Simultaneous Non Interfering (SNI) aircraft and rotorcraft IFR operations at a medium-size commercial airport

Main features & benefits:

  • The procedures are based on the noise optimised flight paths successfully validated in 2013 with an H155 and have demonstrated noise footprint reductions of up to 50%
  • Detailed design and integration of the procedures in Toulouse airspace was performed by partner project GARDEN (coordinated by Egis Avia)
SfWA v
-

SFWA Vibration control demonstrator - Dassault, ONERA

Objectives:

  • Development of innovative design for aircraft next generation to benefit from advanced technologies to alleviate loads and vibrations and reduce structural weight

Main features:

  • Development and demonstration of the technologies developed in this domain on a ground vibration test

Main outcomes:

  • It demonstrated the capability to implement an efficient closedloop vibration control with a significant vibration level reduction and validated the vibration control law design methodology
SGO p
-

SGO Primary Ice Detection System (PFIDS) - Zodiac Aerospace

Main features:

  • 3 weeks of testing conducted, covering Design verification: Thermal tests, conditions in App C, App O FZDZ and App D Ice Crystals & Mixed phase

Main outcomes:

  • Preparation for flight tests by Safety of Flight (D0160 + Hail + Lightning)
sfwa fluid
-

SFWA Fluidic control surfaces - Fokker Elmo

Objectives:

  • Enhancement of control surfaces performances via active flow control at leading edge and at flap/spoiler region and to support load control function

Main features:

  • Development of an Integrated Active Component Demonstrator (IACD) for maturation of low TRL technologies such as flap with fluidic actuation and verification of physical integration in an Iron Bird

Expected benefits:

  • Better low speed/high lift performances (lower size, weight of high lift components, simplified layout of movables)

Main outcomes:

  • For the fluidic actuator, CFD and experiment proves that the pulsed actuator works in full blowing (by CFD, up to 9% lift gain)
  • Electromagnetic Compatibility (EMC) measurements have been carried out on the cable harnesses and tests for thermal verification have been set up
  • The test rig is fully operational for further investigations
ECO D
-

ECO DESIGN Thermal Test Bench - Fraunhofer IBP

Main features:

  • The TTB plays a key role in the simulation and testing of new systems with regard to thermal behavior, allowing a wide range of thermal measurements to be conducted on a genuine aircraft fuselage split into the three main sections of cockpit, cabin, and empennage
  • The test facility also includes the Aircraft Calorimeter (ACC) that simulates extreme conditions such as rapid decompression and thermal shock, i.e. extremely rapid changes in temperature
  • The main benefit offered by the TTB is the reduction of real-life test flights, while simultaneously protecting the environment
SGO s
-

SGO Skin heat exchanger (LSHX) A320 ATRA Flying Test Bed - Airbus, DLR and Liebherr

Main features:

  • As part of the development for advanced cooling systems, a Skin heat exchanger (LSHX) has been installed on the DLR A320 ATRA for two test campaigns (September to December 2014)
  • The LSHX performances have been assessed for different conditions, analysing the aerodynamic data (boundary layer, heat transfer coefficient), allowing the validation and improvement of numerical models
SAGE 3
-

SAGE 3 (ALPS) first flight - Rolls-Royce

Objectives:

  • Rolls-Royce’s goals to deliver a 20% fuel efficiency improvement, compared to the first generation of Trent engines for the Advance and UltraFan™ engines (for a timeframe of 2020 and 2025), are pursued through the Advanced Low Pressure System (ALPS), part of the SAGE 3 ITD. One of the most striking advances has been the testing of the composite fan that will be incorporated into both engine designs

Main outcome:

  • The CTi (Carbon Titanium) fan blade and associated composite engine casings deliver a weight saving of around 1,500 lb on a twin engine aircraft. Composite panels containing electrical harnesses and pipework fit around the fancase, reducing weight and simplifying maintenance
     
  • Testing in 2014 consisted of first test bed runs in Derby, UK, to crosswind testing at the Rolls-Royce facility at the John C. Stennis Space Centre, Mississippi, and most recently full flight tests on a Rolls-Royce Boeing 747 flying test bed at Tucson, Arizona, where one of the four RB211 engines was replaced with a Trent 1000 “donor” engine with CTi blades
     
  • A total of six flights took place over eleven days in October 2014
SFWA
-

SFWA Laminar Wing GTD (Ground Based Demonstrator) - Airbus

Objective:

  • Design, manufacture and test a full scale element of a SRA (Short Range Aircraft) NLF (Natural Laminar Flow) wing leading edge including all relevant systems

Main features:

  • The GBD (Ground Based Demonstrator) is a 4.5m long by 1m wide section of flight-representative wing leading edge attached to a partial wing box assembly. The leading edge accommodates a Krueger flap in two sections, allowing two different design philosophies to be investigated

Main outcomes:

  • Ground Based Demonstrator (full scale leading edge) fully functional
  • Formal integration of electro-thermal anti-ice system, moveable Krueger flaps, electrical bonding network, and lightening protection
  • Successful bird strike tests
  • Numerous manufacturing & assembly lessons learnt (esp. accessibility)
SGO
-

SGO Multi Criteria Departure Procedure (MCDP) function - Airbus, Thales

Objectives:

  • MCDP function is developed to optimise aircraft trajectories with respect to environmental criteria and flight operation efficiency
  • Define green trajectories (departure, cruise, and final approach)
  • Demonstrate the environmental friendliness of the functions in a representative operational environment

Main outcomes:

  • The technical maturity of the technologies and system architectures
ECO
-

ECO DESIGN Electrical Test Bench – [COPPER Bird] - Labinal Power System

Main features:

  • The COPPER BIRD® was created in 2002 to meet the needs of more electrical aircraft, in the context of the POA (Power Optimised Aircraft) European project to characterise an innovative electrical architecture and define a new integration methodology for Electrical Aircraft Equipment
  • With Clean Sky the Labinal Power System’s test rig has reached further capabilities, complying with airframers’ new requirements, and providing a state of the art Electrical Test Bench for small aircraft and helicopters, towards the More Electric Aircraft architectures
  • COPPER - Characterization and Optimization of Power Plant Equipment Rig
GRC
-

GRC Demonstration of Diesel powered light helicopter - Airbus Helicopters, Marignane

Objectives:

  • A flying demonstrator based on an EC120 serial helicopter and fitted with a newly designed High Compression Engine (HCE, a reciprocating engine using Kerosene) has been developed by Airbus Helicopters in the frame of GRC 4
  • For this research project, Airbus Helicopters teamed up with TEOS Powertrain Engineering, France (leader of the Consortium), and AustroEngine GmbH, Austria (partners of the project HIPE 440 selected in 2011)

Main features & benefits:

  • In the power class related to EC120 engines (300 to 400kW), the main advantages of HCEs compared to turboshaft engines are the lower specific fuel consumption, lower CO2 emissions, and higher performance in hot/high conditions thanks to the superchargers. Target Mass-to-power ratio < 0.8 kg/kW
SAGE5
-

SAGE 5 First rotation of TECH800 - TURBOMECA

Objectives:

  • Core turboshaft engine demonstrators in the power range 1,000- 2,000 SHP

Main features:

  • High efficiency compressor, combustion chamber, high-pressure, and low-pressure turbine

Main outcomes:

  • Turbomeca developed the technologies with support of several partners
  • Full scale and life cycle validation achieved
SAGE
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SAGE Contra-Rotating Open Rotor (CROR) demo engine flying test bed– test in DNW windtunnel - Airbus

Objective:

  • To demonstrate viability of full scale innovative engine concept in operational condition

Main features:

  • New propeller design (high performance, low noise)
  • Engine – pylon – aircraft integration concept
  • New CROR – engine integration technology
  • Advanced CROR aero-acoustic design

Expected benefits:

  • Fuel burn saving on short/mid range aircraft compared to current fleet
SFWA
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SFWA Advanced Lip Extended Acoustic Panel (ALEAP) - Airbus

Main outcome:

  • The technology to reduce the fan noise of large turbofan engine was validated in operational conditions at original scale in a flight test campaign in 2010

Expected benefits:

  • After the successful validation in flight, the technology to manufacture the key parts relevant for this technology shall be reviewed and matured to reach TRL 6 (activities to be carried out outside of SFWA)

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