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Flexible Test Rig of Aircraft Control Surfaces powered by EMAs

Periodic Reporting for period 2 - TR4EMACS (Flexible Test Rig of Aircraft Control Surfaces powered by EMAs)

Reporting period: 2018-06-01 to 2019-11-30

This proposal applies to a topic is intended to support the development of all electrical wing actuated and sourced Regional Turboprop Aircraft concept (FTB2 demonstrator). The topic targets four control surfaces, which are actuated by electro-mechanical actuators (EMAs).

The purpose of the flexible test rig to be designed, manufactured and powered on in this project is the validation of the EMAs and their corresponding actuation systems under realistic working conditions. It will:
• Validate both the control and the mechanical performance of each EMA actuation system under realistic working conditions.
• Validate the electrical consumption of each EMA actuation system.
• Validate the influence of EMAs actuation systems in the A/C electrical network representative rig.
• For the aileron actuation system, which includes both a HA and an EMA, to validate its influence in the A/C hydraulic network representative rig.
Consequently, this test rig is one of the cornerstones required to complete the on ground validation of control surface components and equipment.
Main objective of this project has been split into the following specific objectives:
1. Design a test rig architecture that serves to achieve the functionality and operational features required for the evaluation and validation of EMAs
2. Design, manufacture and assembly the mechanical components of the test benches that compose the test rig according to objective 1 and as requested in the Call text.
3. Design, implement and manufacture a test rig control system, according to objective 1, featuring a switching capability between stand-alone and integrated modes of operation, warning, alarms and protective functions to guarantee the integrity of the complete installation.
4. Design and program the control algorithms to command the antagonist HA for every test bench.
5. Power on all the test benches and generate their documentation. All test benches must be able to operate in stand-alone mode
1.- WP1 (Project Management)
Related to the management of the TR4EMACS project. Several tasks have been carried out in relation to this Work Package. Periodic meetings involving all the partners and the topic manager have been arranged to overview the advancements of the project. Various technical reviews have been organised (PDR, CDR, CISS, CIPS) for the Ailerons and Flap-Tabs Test benches with the attendance of all parties involved. Finally all the administrative and documentations tasks have been performed for this period.

Progress: 50%

2.- WP2 (EMA Ailerons Test Bench)
Rirstly, the Analysis of Requirements was carried out (T2.1). Then, the Structural Calculation of the Test Bench was performed (T2.2) and the Control Systems were defined (T2.3). Once the definition of the Test Bench was completed the Design for Manufacturing and the Selection of Industrial components was carried out (T2.4 and T2.5). The software specification for the control was defined (T2.6) and the Preliminary and Critical Reviews were hold (T2.7 and T2.8). Task T2.9 Manufacturing and T2.10 Software Development were completed and the Inspections at Supplier Site and at Purchaser Site were carried out (T2.11 T2.12 and T2.13). The Ailerons Test Bench was integrated in the customer facilities and it was Powered On as requested (T2.14).

Progress: 100%

3.- WP3 (EMA Spoiler Test Bench)
Not been started yet.


4.- WP4 (EMA Flap-Tab Test Bench)
Firstly, the Analysis of Requirements was carried out (T4.1). Then, the Structural Calculation of the Test Bench was performed (T4.2) and the Control Systems were defined (T4.3). Once the definition of the Test Bench was completed the Design for Manufacturing and the Selection of Industrial components was carried out (T4.4 and T4.5). The software specification for the control was defined (T4.6) and the Preliminary and Critical Reviews were hold (T4.7 and T4.8). Task T4.9 Manufacturing and T4.10 Software Development were completed and the Inspections at Supplier Site and at Purchaser Site were carried out (T4.11 T4.12 and T4.13). The Flap-Tabs Test Bench was integrated in the customer facilities and it was Powered On as requested (T4.14).

Progress: 100%

1.2.5 WP5 (EMA Winglet Tab Test Bench)
Not been started yet.

1.2.6 WP6 (Supports of Rigs Integration)
The integration of the Ailerons and the Flap-Tabs test benches is completed. The Mechanical, Hydraulic and Electrical integration was carried out without incidents.

Progress: 50%

1.2.7 WP7(Dissemination and Exploitation)
The initial plan for dissemination and exploitation of results was prepared. The actions foreseen in this plan have been carried out in parallel with the development of the test benches.

Progress: 40%

Regarding the milestones and deliverables that were set in the beginning of the project, the status can be found in corresponding sections.
The use of electrical systems in place of hydraulic systems are becoming the norm in all new aircrafts developments. The continuing need to reduce overall fuel burn on the aircraft leads to the use of more electrically powered systems. Thus, All-Electric Aircraft is a major target for the next generation of aircrafts to lower consumption of non-propulsive power reducing fuel burn.
TR4EMACS project contributes to produce a remarkable impact on the Competitiveness Position and Sustainable Development of the European Aeronautic Industry:
• Increase the competitiveness of the European aeronautical industry by developing new and advanced technologies.
• Meeting societal needs for environmentally friendly and safe validation processes.
• Develop and increase TRL of more efficient, compact and reliable systems.
• Contribution to reach EMA cost targets fixed by aircraft manufacturers by means of standardisation.
• Improve fuel consumption management.
• Compliance with European and World initiatives towards sustainable mobility and societal changes One of the impacts requested by the European Commission, is to reduce fuel consumption and hence CO2 emissions by 50% per passenger kilometre. This goal can only be achieved by a combination of several measures. TR4EMACS contributes to and strengthens the leading role of the EU to combat climate change.
• TRAEMACS will generate jobs and growth, in line with the objectives of the Clean Sky JTI.

The impact for the aero industry of the availability of on-ground testing equipment for the complete two wings is commented in what follows:
• EMA and control unit manufacturers: project result is a necessary tool for improving their products and evaluation/validation/certification of products, reducing costs and time to market.
• Tier-1 aircraft equipment manufacturer: the development of “more green” wings and “all electrical” wings requires better designs for control surfaces, whose performance is highly influenced by the actuation systems.
• Aircraft manufacturers: they will have the possibility of testing different scenarios and acquire knowledge and test/evaluate the opportunities/benefits associated to the introduction of EMAs.

In this project, liquid and gaseous effluents are not relevant as there are neither CO2 emissions nor any kind of bilge water generation. No solid wastes are produced and there is no use of raw materials and fuels.
This project will contribute to the reduction of pollutants and noise emissions, as this project is aligned to the objectives of Clean Sky 2 concerning environmental issues.
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