Periodic Reporting for period 3 - HERWINGT (Hybrid Electric Regional Wing Integration Novel Green Technologies - HERWINGT)
Reporting period: 2024-01-01 to 2024-12-31
The aim of HERWINGT project is to design an innovative wing suitable for the future Hybrid-Electric Regional (HER) aircraft that will contribute to the overall target to reduce fuel burn, CO2 and other greenhouse gas emissions, by improving aerodynamic efficiency and reducing weight and will integrate hybrid-electric propulsion systems and other typical wing mounted systems.
The HERWINGT project will validate, down select, mature and demonstrate the concept, architecture, design and the key technologies that enable addressing an innovative wing design for a Hybrid Electric Regional aircraft (HER) with a maximum capacity of 100 seats and a range of 500 to 1000nm.
These challenges are translated into the following top-level objectives:
Objective 1: Deliver an innovative wing design for a hybrid-electrical regional aircraft (HERA)
Objective 2: Demonstrate a minimum fuel reduction of 15% attributable to wing improvements.
Objective 3: Demonstrate a structural weight reduction of at least 20% when compared to a 2022 SoA wing.
Objective 4: Analyze reduction potential in C02 and all other relevant GHG emissions.
Objective 5: Develop and demonstrate new technologies to increase aerodynamic performance.
Objective 6: Develop and demonstrate new technologies to increase structural performance and weight reduction.
Objective 7: Develop and demonstrate new technologies to increase aeroelastic performance.
Objective 8: Develop and demonstrate new technologies to achieve more integrated structural design.
Objective 9: Develop and demonstrate new technologies to improve Structural Health Monitoring (SHMS) and permit to increase design allowables.
Objective 10: Develop and demonstrate new technologies to improve wing systems efficiency.
Objective 11: Develop and demonstrate new technologies to improve wing systems integration with structure.
Objective 12: Develop and demonstrate new technologies to achieve more precise manufacturing/ assembly processes.
Objective 13: Develop and demonstrate new technologies to achieve greener manufacturing processes.
Objective 14: Deliver a roadmap towards wing full-scale demonstration at TRL 6 at aircraft level with a first flight not later than 2030.
Objective 15: Propose a qualification and certification plan linked to the proposed activities and suitable for Hybrid-Electric Regional (HER) aircraft.
Objective 16: Deliver digital twins and a life cycle assessment of the components, subsystems and full wing system compatible with the reference aircraft digital framework and requirements.
: Deliver digital twins and a life cycle assessment of the components, subsystems and full wing system compatible with the reference aircraft digital framework and requirements.
The HERWINGT project will validate, down select, mature and demonstrate the concept, architecture, design and the key technologies that enable addressing an innovative wing design for a Hybrid Electric Regional aircraft (HER) with a maximum capacity of 100 seats and a range of 500 to 1000nm.
These challenges are translated into the following top-level objectives:
Objective 1: Deliver an innovative wing design for a hybrid-electrical regional aircraft (HERA)
Objective 2: Demonstrate a minimum fuel reduction of 15% attributable to wing improvements.
Objective 3: Demonstrate a structural weight reduction of at least 20% when compared to a 2022 SoA wing.
Objective 4: Analyze reduction potential in C02 and all other relevant GHG emissions.
Objective 5: Develop and demonstrate new technologies to increase aerodynamic performance.
Objective 6: Develop and demonstrate new technologies to increase structural performance and weight reduction.
Objective 7: Develop and demonstrate new technologies to increase aeroelastic performance.
Objective 8: Develop and demonstrate new technologies to achieve more integrated structural design.
Objective 9: Develop and demonstrate new technologies to improve Structural Health Monitoring (SHMS) and permit to increase design allowables.
Objective 10: Develop and demonstrate new technologies to improve wing systems efficiency.
Objective 11: Develop and demonstrate new technologies to improve wing systems integration with structure.
Objective 12: Develop and demonstrate new technologies to achieve more precise manufacturing/ assembly processes.
Objective 13: Develop and demonstrate new technologies to achieve greener manufacturing processes.
Objective 14: Deliver a roadmap towards wing full-scale demonstration at TRL 6 at aircraft level with a first flight not later than 2030.
Objective 15: Propose a qualification and certification plan linked to the proposed activities and suitable for Hybrid-Electric Regional (HER) aircraft.
Objective 16: Deliver digital twins and a life cycle assessment of the components, subsystems and full wing system compatible with the reference aircraft digital framework and requirements.
: Deliver digital twins and a life cycle assessment of the components, subsystems and full wing system compatible with the reference aircraft digital framework and requirements.
Wing concepts and architecture:
Three wing concept configurations have been analysed and evaluated: Strut Braced high aspect ratio Wing (SBW), Cantilever high aspect ratio wing (CNT) and Distributed propulsion wing.
Aerodynamic design and aeroelastic optimization have been finished for cruise conditions. The geometry of the SBW has been optimized to improve low-speed stall performance for clean configuration. Besides, an aerodynamic optimization of the high-lift devices has been performed for take-off and landing configurations.
An amendment of the Grant Agreement has been prepared in order to align the activities to the new Ultra Efficient Regional Aircraft (UERA) use case.
Demonstrators:
The definition of the demonstrators that will be used for the testing and maturation of technologies is almost finished: Design principles were delivered and the majority of the Preliminary Design Reviews were performed by mid-2024 and Critical design reviews (CDR) were performed in the last weeks of 2024 e.g: CDR for the center wing box, the flap, thermoset and thermoplastic leading edges, induction ice protection system, Morphing Trailing Edge, Aileron and Droop Nose, etc.
The center wing box demonstrator has had to be reinforced in the interfaces with the load introduction actuators.
Nickel has been selected as the material for the foil of the induction ice protection system. It has been designed to be installed in the thermoset multi-functional leading edge. The specification for the test in the ice wind tunnel has been signed.
Characterization of the Sustainable Aviation Fuel (SAF) has been finished and compatibility with current aircraft fuel system has been assessed. The architecture of the test for the fuel quantity indicators has been delivered and SAF procurement has been closed with the delivery of the SAF samples to the test facilities.
The Finite Element Model Analysis for the Geometry of Omega-Stringers at Integrated Fuel Vent System demonstrator has concluded with very good results in terms of tightness, being improved by surface treatment. Connectors have been 3D printed.
Industrial means have been defined, and manufacturing and assembly processes have been detailed for the different demonstrators.
Tooling specifications are finished and, in some demonstrators, tooling and molds are already available and manufacturing trials have been launched.
Technology maturation:
The majority of technologies have passed Technical Readiness Level (TRL3) in 2024.
TRL4 has been prepared with the aim to pass the reviews in Q1 2025.
Results assessment:
In terms of Ecodesign, a draft version of the Life Cycle Assessment has been prepared in 2024 in advance to the final delivery committed for the end of 2025.
Impact Monitoring yearly report has been shared with the Project Officer
Structural Health Monitoring technology has been presented to EASA. The written feedback received from EASA has been used to populate the certification plan and the gaps identification documents.
Three wing concept configurations have been analysed and evaluated: Strut Braced high aspect ratio Wing (SBW), Cantilever high aspect ratio wing (CNT) and Distributed propulsion wing.
Aerodynamic design and aeroelastic optimization have been finished for cruise conditions. The geometry of the SBW has been optimized to improve low-speed stall performance for clean configuration. Besides, an aerodynamic optimization of the high-lift devices has been performed for take-off and landing configurations.
An amendment of the Grant Agreement has been prepared in order to align the activities to the new Ultra Efficient Regional Aircraft (UERA) use case.
Demonstrators:
The definition of the demonstrators that will be used for the testing and maturation of technologies is almost finished: Design principles were delivered and the majority of the Preliminary Design Reviews were performed by mid-2024 and Critical design reviews (CDR) were performed in the last weeks of 2024 e.g: CDR for the center wing box, the flap, thermoset and thermoplastic leading edges, induction ice protection system, Morphing Trailing Edge, Aileron and Droop Nose, etc.
The center wing box demonstrator has had to be reinforced in the interfaces with the load introduction actuators.
Nickel has been selected as the material for the foil of the induction ice protection system. It has been designed to be installed in the thermoset multi-functional leading edge. The specification for the test in the ice wind tunnel has been signed.
Characterization of the Sustainable Aviation Fuel (SAF) has been finished and compatibility with current aircraft fuel system has been assessed. The architecture of the test for the fuel quantity indicators has been delivered and SAF procurement has been closed with the delivery of the SAF samples to the test facilities.
The Finite Element Model Analysis for the Geometry of Omega-Stringers at Integrated Fuel Vent System demonstrator has concluded with very good results in terms of tightness, being improved by surface treatment. Connectors have been 3D printed.
Industrial means have been defined, and manufacturing and assembly processes have been detailed for the different demonstrators.
Tooling specifications are finished and, in some demonstrators, tooling and molds are already available and manufacturing trials have been launched.
Technology maturation:
The majority of technologies have passed Technical Readiness Level (TRL3) in 2024.
TRL4 has been prepared with the aim to pass the reviews in Q1 2025.
Results assessment:
In terms of Ecodesign, a draft version of the Life Cycle Assessment has been prepared in 2024 in advance to the final delivery committed for the end of 2025.
Impact Monitoring yearly report has been shared with the Project Officer
Structural Health Monitoring technology has been presented to EASA. The written feedback received from EASA has been used to populate the certification plan and the gaps identification documents.
HERWINGT’s challenge is to deliver a novel wing design for the future hybrid-electric regional aircraft (HER) that will contribute to the overall target to reduce fuel burn in at least 50% at aircraft level, CO2 and other GHG emissions.
For this, the novel wing will target a fuel reduction at integrated wing level of at least 15% and a structure weight reduction at full wing level of at least 20% and will fulfil the challenges of the wing integration with the novel hybrid-electric propulsion.
This is well beyond the state-of-the-art not only compared to existing wings operating in the market but also beyond many of the research demonstrators planned in EC and abroad.
For this, the novel wing will target a fuel reduction at integrated wing level of at least 15% and a structure weight reduction at full wing level of at least 20% and will fulfil the challenges of the wing integration with the novel hybrid-electric propulsion.
This is well beyond the state-of-the-art not only compared to existing wings operating in the market but also beyond many of the research demonstrators planned in EC and abroad.