Work Package 1 was the definition of the Technology specification. The definition of the requirements and the later discussion about the specification lead to the start of the development phase.
The development of the new windshield design (Work package 2) comprised the upper windshield (base and fall-back solution), the lower cockpit windows, the assembly and the coating development (Anti-ice,-fog, IR). The planned designing activities were finished in the second reporting period and all the results from simulation and testing tasks have been included in reports necessary for Permit to fly. The windshield design was successfully fixed at the Milestone critical design review (CDR).
The simulation tasks (Work package 3) were carried out for several windshield design developments. This includes various frame and screw materials, windshield shapes, sizes, thicknesses, position and quantity of bolts, adhesive properties, thermal properties and impact requirements. A detailed substantiation report of the RACER windshield was finalized in the 3rd period, which is required for the permit to flight approval of the RACER demonstrator.
The testing activities (Work package 4) were concluded early 2019 with the bird-strike test of prototypes (windshield). A successful lower cockpit window bird-strike test already lead to the acceptance of the developed lower cockpit window design. The “permit to fly” demands numerous testing and documentations, which were performed within this work package. The testing included material testing, coating testing, adhesive testing and impact testing with artificial birds.
The work package 5 - Production started after the critical design review with the first production of sets of windshields and test articles for mock-up.
The lower cockpit windows and the windshield for the RACER demonstrator were manufactured at the end of the project and will be shipped to Airbus Helicopters in Marignane, France for the final assembly of the RACER.
The tasks of the project coordinator in Work package 6 – Project management included the communication towards the JU-Project Officer and the Topic manager. With this work package 6 the accurate submission of the deliverables was monitored within the consortium.
Overview of results:
- Design of windshield and lower cockpit windows validated
- Design of interface connection to canopy validated
- Assembly definition completed
- Test activities completed: Material testing; coating testing, climate tests, weathering tests, high-speed bird strike tests
- CAD drawings released
- Tooling production completed
- FEA Model validated with test results
- Supporting documentation for permit to flight approved
- Milestones successfully passed
- Prototypes manufactured
Publications and presentations of bird strike testing with a substitute bird contributed to any future standards for bird-strike testing and impact simulation.
Bird-strike tests were effective performed for the canopy partner of the RACER during WIMPER’s project duration and increased the acceptance of substitute birds for aeronautical impact tests.
FEA-simulation of polymeric materials generated knowledge for the university education, resulted in dissertations in this technology and lead to follow-up national SME-research projects.
The Coating technologies of functional coatings launched new businesses in other helicopters and fixed wing aircrafts.
The consortium demonstrated lightweight glazing solutions, which withstand bird strikes at high speeds. The resulting technology can be implemented in airframes where structural weight together with increased optical and mechanical performance is a relevant factor.
