Periodic Reporting for period 4 - NGCTR DIGIFuel (Distribution and Gauging Interconnected Fuel System for the Next Generation Civil Tilt Rotor)
Okres sprawozdawczy: 2021-06-01 do 2023-01-31
The objectives of this project are scientific/technological and industrial regarding competitiveness. DIGIFuel aims at achieving the following objectives:
- studying, designing, developing, manufacturing, testing and qualifying a flight-cleared fuel distribution and gauging system for the demonstrator
- identifying and experimenting an innovative fuel system architecture
- maximizing the reliability of the engine feed function
- pioneering the use of intelligent transfer pumps and innovative level sensors and introducing CANBUS communication among major components of the system
- removing the risk of explosion by introducing a gauging system based on fiber-optics
- validating the functionality of the fuel system
and reaching a mature definition of the Fuel System and its components, which might stand out as a benchmark for future aircrafts.
Thanks to its expected technical outcomes, fostered within such relatively long industrial collaboration on research topics between the partners and the airframer, DIGIFuel can also target the following:
- a set of new equipments, featuring innovative technologies and validated by operational data in the field of aeronautical Fuel Systems, will be mature for the implementation on the Tilt-Rotor platform, as well as on other conventional types of aircrafts
- the partnership between SM and PoliMi will be strengthened with mutual benefits on further collaborations in the development of innovative solutions for aerospace applications even beyond the scope of NGCTR
- SM will make a step forward and gain solid expertise on the integration of novel fuel system components and technologies onto peculiar airframes such as the NGCTR, which will make Europe competitive towards the rest of aerospace industry
- at the same time LHD will get first-hand touch of the promising potentialities of such novelties and be the first to enjoy their benefits
- the joint cooperation in the context of Clean Sky 2 will establish an example of durable, open and fruitful collaboration within Europe, thus shaping and reinforcing a worldwide industrial excellence in the integration of systems and aircrafts
- studying, designing, developing, manufacturing, testing and qualifying a flight-cleared fuel distribution and gauging system for the demonstrator
- identifying and experimenting an innovative fuel system architecture
- maximizing the reliability of the engine feed function
- pioneering the use of intelligent transfer pumps and innovative level sensors and introducing CANBUS communication among major components of the system
- removing the risk of explosion by introducing a gauging system based on fiber-optics
- validating the functionality of the fuel system
and reaching a mature definition of the Fuel System and its components, which might stand out as a benchmark for future aircrafts.
Thanks to its expected technical outcomes, fostered within such relatively long industrial collaboration on research topics between the partners and the airframer, DIGIFuel can also target the following:
- a set of new equipments, featuring innovative technologies and validated by operational data in the field of aeronautical Fuel Systems, will be mature for the implementation on the Tilt-Rotor platform, as well as on other conventional types of aircrafts
- the partnership between SM and PoliMi will be strengthened with mutual benefits on further collaborations in the development of innovative solutions for aerospace applications even beyond the scope of NGCTR
- SM will make a step forward and gain solid expertise on the integration of novel fuel system components and technologies onto peculiar airframes such as the NGCTR, which will make Europe competitive towards the rest of aerospace industry
- at the same time LHD will get first-hand touch of the promising potentialities of such novelties and be the first to enjoy their benefits
- the joint cooperation in the context of Clean Sky 2 will establish an example of durable, open and fruitful collaboration within Europe, thus shaping and reinforcing a worldwide industrial excellence in the integration of systems and aircrafts
As regards WP1, periodic reviews have been performed between DIGIFuel and LHD as well as Joint Meetings with partners working on the project.
During the Covid-19 spread, meetings have been continuously held in remote only.
The Trade-Off studies (WP2) resulting from joining work between SM and LHD have led to the release of the technical documentation:
- definition of the fuel system final layout and parts list
- fuel pump smart controls studies
- fuel gauging and sensing technology studies
- a preliminary system safety analysis
A preliminary design of Technology Demonstrator gauging and distribution sub-system with optical fiber started during the 1st reporting period.
The preliminary design studies resulting from the joining work between SM and LHD have led to the release of:
- preliminary equipment interface and performance definition
- study and definition of equipment validation campaign and lab testing
- preliminary innovative equipment performance calculation and reporting
- reliability analyses
- preliminary safety and hazard analysis
- preliminary simulation data and SW plans
Activities leading to completion of WP4 allowed opening of the meeting on 12/2019.
Preparation of CDR closure was performed via web meetings, up to formal closure of the CDR meeting. This task was accomplished on 06/2020.
Some modification of the fuel system architecture, as defined in WP3, had to be introduced as a result of the development activities performed by the consortia and by LHD. It was decided to introduce CANBUS communication also for fuel gauging probes, avoiding introduction of fiber optics.
Second half of 2020 and first half of 2021 had to be entirely devoted to completion of Task 4.1. Following achievements are recalled:
- evaluation of equipment installation with LHD. Activities culminated in 12/2020
- analysis of performance points of the fuel system. Several aspects had been analyzed, up to equipment performance full definition in 11/2020
- definition of pipeline routing and 3D model in 12/2020
- definition of CANBUS interface and protocol finalized in 05/2021
In WP5 all production data have been issued, discussed and updated relevant to installation drawings of equipment.
For the equipment also General Assembly Drawing, as well as subassy and component drawings have been generated. Part List have been filed and updated in SM PLM system.
Additionally, for any of the equipment (innovative or supporting), dedicated Acceptance Test Procedures and other system documents have been issued and submitted to topic leader for comment/acceptance.
Equipment prototypes have been assemble, mechanically, electronically and SW integrated and tested.
As part of the forecasted activities of WP6, Qualification by Analysis and Similarity for each equipment was foreseen for initial installation on NGCTR demonstrator, followed by an actual test campaign (defined via a Qualification Program Plan) to support experimental flight trials. SM has prepared a Qualification Program Plan dedicated to NGCTR, that will be executed in parallel to installation of innovative and supporting equipment on Technical Demonstrator (foreseen period: April-June 2023).
Communication and dissemination has been performed by SM (by displaying JU/CS2 Logo and Project Titles and illustrating the project to attendees) during Air Shows, as well as by PoliMi through preparation of scientific document (dissertation thesis).
A Master’s Degree Thesis work has been prepared at SM, during 2022, by Riccardo Barbera, an Aeronautical Engineering Student of the Palermo University.
SM has additionally attended the event Clean Aviation, at Volandia Park and Museum, on 22 October 2022. SM has provided a presentation about its case history in the framework of Clean Sky 2.
During the Covid-19 spread, meetings have been continuously held in remote only.
The Trade-Off studies (WP2) resulting from joining work between SM and LHD have led to the release of the technical documentation:
- definition of the fuel system final layout and parts list
- fuel pump smart controls studies
- fuel gauging and sensing technology studies
- a preliminary system safety analysis
A preliminary design of Technology Demonstrator gauging and distribution sub-system with optical fiber started during the 1st reporting period.
The preliminary design studies resulting from the joining work between SM and LHD have led to the release of:
- preliminary equipment interface and performance definition
- study and definition of equipment validation campaign and lab testing
- preliminary innovative equipment performance calculation and reporting
- reliability analyses
- preliminary safety and hazard analysis
- preliminary simulation data and SW plans
Activities leading to completion of WP4 allowed opening of the meeting on 12/2019.
Preparation of CDR closure was performed via web meetings, up to formal closure of the CDR meeting. This task was accomplished on 06/2020.
Some modification of the fuel system architecture, as defined in WP3, had to be introduced as a result of the development activities performed by the consortia and by LHD. It was decided to introduce CANBUS communication also for fuel gauging probes, avoiding introduction of fiber optics.
Second half of 2020 and first half of 2021 had to be entirely devoted to completion of Task 4.1. Following achievements are recalled:
- evaluation of equipment installation with LHD. Activities culminated in 12/2020
- analysis of performance points of the fuel system. Several aspects had been analyzed, up to equipment performance full definition in 11/2020
- definition of pipeline routing and 3D model in 12/2020
- definition of CANBUS interface and protocol finalized in 05/2021
In WP5 all production data have been issued, discussed and updated relevant to installation drawings of equipment.
For the equipment also General Assembly Drawing, as well as subassy and component drawings have been generated. Part List have been filed and updated in SM PLM system.
Additionally, for any of the equipment (innovative or supporting), dedicated Acceptance Test Procedures and other system documents have been issued and submitted to topic leader for comment/acceptance.
Equipment prototypes have been assemble, mechanically, electronically and SW integrated and tested.
As part of the forecasted activities of WP6, Qualification by Analysis and Similarity for each equipment was foreseen for initial installation on NGCTR demonstrator, followed by an actual test campaign (defined via a Qualification Program Plan) to support experimental flight trials. SM has prepared a Qualification Program Plan dedicated to NGCTR, that will be executed in parallel to installation of innovative and supporting equipment on Technical Demonstrator (foreseen period: April-June 2023).
Communication and dissemination has been performed by SM (by displaying JU/CS2 Logo and Project Titles and illustrating the project to attendees) during Air Shows, as well as by PoliMi through preparation of scientific document (dissertation thesis).
A Master’s Degree Thesis work has been prepared at SM, during 2022, by Riccardo Barbera, an Aeronautical Engineering Student of the Palermo University.
SM has additionally attended the event Clean Aviation, at Volandia Park and Museum, on 22 October 2022. SM has provided a presentation about its case history in the framework of Clean Sky 2.
NGCTR DIGIFuel has been carried out following the standard path of aeronautical system development programmes.
It is worth to recall that the main target of the whole project consists in the supply of qualified, flyable fuel system, including supporting equipment, and not just isolate development units.
The engineering design life cycle of the fuel system to be developed will undergo documented, comprehensive, systematic examinations of the design to evaluate the adequacy of the design requirements, to evaluate the capability of the design to meet these requirements, and to identify problems.
SM will thus develop a subset of innovative components (among which programmable fuel pumps and fuel level sensors with CANBUS communication, eventually preferred to fibre optics application) that, together with existing state-of-the-art components, in an uncommon system architecture featuring a pre-filtered supply tank for each engine, will enable LHD to reach the TRL6 level.
If, on the one side, the programmable fuel pumps integrated in the NGCTR avionic system will allow an efficient CoG Management as well as a flexible fuel distribution capability, on the other side the level sensors will grant the novelty of CANBUS communication, while ensuring a safer installation.
It should be made clear that the technical effort of this project focuses on the development of an innovative system configuration itself, and on reaching the demonstration of the advantages that the innovative features introduced in the dedicated components yield to it.
It is worth to recall that the main target of the whole project consists in the supply of qualified, flyable fuel system, including supporting equipment, and not just isolate development units.
The engineering design life cycle of the fuel system to be developed will undergo documented, comprehensive, systematic examinations of the design to evaluate the adequacy of the design requirements, to evaluate the capability of the design to meet these requirements, and to identify problems.
SM will thus develop a subset of innovative components (among which programmable fuel pumps and fuel level sensors with CANBUS communication, eventually preferred to fibre optics application) that, together with existing state-of-the-art components, in an uncommon system architecture featuring a pre-filtered supply tank for each engine, will enable LHD to reach the TRL6 level.
If, on the one side, the programmable fuel pumps integrated in the NGCTR avionic system will allow an efficient CoG Management as well as a flexible fuel distribution capability, on the other side the level sensors will grant the novelty of CANBUS communication, while ensuring a safer installation.
It should be made clear that the technical effort of this project focuses on the development of an innovative system configuration itself, and on reaching the demonstration of the advantages that the innovative features introduced in the dedicated components yield to it.