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ORPASV Résumé de rapport

Project ID: 325953
Financé au titre de: FP7-JTI
Pays: France

Periodic Report Summary 2 - ORPASV (Electrohydraulic servovalve development, test and supply for Open Rotor Pitch Actuation System (Engine Demonstrator and Target Engine))

Project Context and Objectives:
The Topic addressed here is an essential part of the SAGE2 Demonstration project which aims at designing, manufacturing and testing a Counter-Rotating Open-Rotor Demonstrator, forerunner of future engines for the 2020’s with drastically reduced fuel consumption and emissions.

A part of the technological challenge of this architecture is the blade pitch control using electro hydraulic actuation, of which the electrohydraulic servovalves (EHSV or SV) are a key element.

The use of EHSV for electrohydraulic actuation is now state of the art in the aerospace industry, however the pitch control requirements extend beyond known applications by the high flow levels specified and the type of fluid with high viscosity and high viscosity variation with temperature.

Using state of the art EHSV would result in large envelope and weight products with oversizing aggravated by the need to provide the performance in all operating conditions.

ORPASV project can be split in three projects :

- Development of prototypes of EHSV (“demonstrator SV”) to equip Counter-Rotating Open-Rotor Demonstrator for engine testing
- Based on requirements of an Open Rotor target engine specification, development of prototype of EHSV (“target engine SV”) with optimized technologies. EHSV TRL targeted is 4
- Development of a test bench is necessary to test these specific EHSV products and reach the objectives of ORPASV project
Project Results:
Demonstrator SV activities (WP3 & WP6) :

The first period of the project allowed to validate the concept of SV compliant with Topic Manager specification and to perform the Preliminary Design Review (WP2) to prepare detailed design activities.

The main activities performed during this second period are :
- produce the definition files per preliminary design and interface adjustment inputs (WP3)
- perform and/or complete substantiation activities (WP3)
- establish detailed test program (acceptance test, development tests and qualification test procedures) (WP3)
- produce and/or update documentation for CDR per development plan (WP3)
- perform a make or buy analysis for the different servovalve components (WP6)
- manufacture by Zodiac Hydraulics or suppliers the components of servovalves (WP6)

The main results of the second period are :
- detailed drawings of servovalves (validated with Topic Manager during the Critical Design Review)
- associated justification files and documents (including compliance matrix with technical specification)
- 1D and 3D models of servovalve
- availability of specific toolings and tools to manufacture components and make assemblies
- availability of components necessary to produce first equipments (finishing process of housing still in progress at the end of this reporting period)
- manufacturing instruction process
- detailed test programs of SV
- availability of specific toolings for test making

Assembly, adjustment and acceptance activities of servovalves will begin once finishing process of housing will be set-up (in progress). First delivery of demonstrator SV to Topic Manager is scheduled Q2/2015 and final qualification Q4/2015.


Target engine SV activities (WP9 & WP10) :

During the first period of the project several “technological bricks” have been preliminary assessed in order to determine their applicability to the target engine SV requirements.

The second period of the project allowed to select suitable technological bricks, to identify optimized target engine SV architecture and to define associated preliminary design. To reach this stage, the main activities performed during this 2nd period of the project were :
- select new technologies to be introduced in demonstrator engine (WP9)
- conduct analysis and technology testing for low TRL technologies (WP9)
- present results to the Topic Manager to get concurrence to technology selection (WP9)
- combine results of previous tasks in innovative SV design concept (WP9)
- perform preliminary design and 3D modeling (WP9)
- perform design substantiation activities : 1D modeling, safety and reliability analysis, environmental condition analysis (WP9)
- establish risk mitigation test program for functional mock up SV (WP9)
- perform a make or buy analysis and pre-select suppliers for mock-up SV parts (WP9)
- establish detail design of functional mock up SV (WP9)
- produce PDR documentation per development plan (WP9)
- manufacture and assembly functional mock up SV (WP10), still in progress at the end of this second reporting period

Technology selection were based on criterias commonly set up between Topic Manager and Zodiac Hydraulics regarding servovalve and system impact :
- weight / size
- leakage level
- operating in extreme temperature
- life increase / reliability
- performance improvement
- environment compatibility

The main results of this period was to select the following technological bricks and integrate them in a preliminary design (validated with Topic Manager during the Preliminary Design Review). Selection was based on tests results and analysis at technological brick stage.
- 1st stage with piezo-electric actuator
- electronic 2nd stage position loop (using an LVDT sensor and deleting conventional mechanical feedback), this technological brick is not selected for engine system but only as a mean for test to develop servovalve.
- aluminium additive manufacturing of 1st stage housing
- steel additive manufacturing of the 2nd stage housing
- seals material suitable with the application (pressure / temperature / fluids)
- cadmium free brazing and lead free electrical soldering for environmental compliance
A functional mock-up was designed based from this preliminary design. Results of tests to be performed on this mock-up will be an important input to prepare detailed design activities. Manufacturing of this functional mock-up is still in progress at the end of this reporting period.

Detailed design of target engine SV is planned Q3/2015, final prototype end Q4/2015 and tests results (TRL4) Q2/2016.
In parallel of tests on final prototype, complementary works are planned all along the project, especially for technological bricks as additive manufacturing.


Test Bench activities (WP5) :

After a first period mainly dedicated to establish the detail design of test bench, the second period allowed to manufacture and accept the test bench.

Main activities performed during this 2nd period of the project :
- supply / manufacture the components of the bench
- integrate the test bench in Zodiac Hydraulics premises
- perform acceptation tests of the test bench with appropriate test unit
- produce documentation for test readiness review

The result of the second reporting period of the project was the building and the validation of test bench : entry in service was declared in January 2015.

Potential Impact:
ORPASV project will contribute in an essential way to the achievement of the Open Rotor engine concept progress, first by supplying the equipment needed for the demonstration of the Pitch Control System, and second by defining future generation servovalves able to fulfill this blade positioning function with improved performances, mass and robustness.
This project will pave the way for the future R&T activities aiming at designing the Target engine for an entry in service on the next generation of aircrafts.

Informations connexes


Julie Carduner, (Sales Engineer)
Tél.: +33237975180