Periodic Reporting for period 4 - FASE-LAG (FAil-Safe Electro-mechanical actuation for LAnding Gear)
Reporting period: 2021-12-01 to 2022-06-30
In the past years, several industrial programmes have initiated the concept of a More Electric Aircraft in order to reach objectives of reduced environmental emissions and noise. In fact, there is a consensus in the aerospace community that more electrically powered systems will lead to weight saving, reliability improvement and life-cycle cost reduction. Therefore, the use of electromechanical actuation (EMA) can be a solution to help the development of a cleaner aviation because, with respect to traditional hydraulic actuation, it is:
• Less complex because of the absence of a hydraulic system
• Better suited to long term storage since there is no leak potential
• More energy efficient compared with hydraulic systems
• Easier to install and maintain (no filtration, no bleeding, better testability with potential for more efficient maintenance planning)
• Less complex to control from a power-distribution and power-management perspective (power is
transmitted without mass transfer).
Nevertheless, some critical issues of this technology need to be addressed. Based on this scenario, the FASE-LAG project is specifically focused on overcoming these issues and improving technology performance, reliability and safety using new technologies and architecture.
Main technical objectives are as follows:
1. The development of electromechanical actuation system (EMAS) for landing gear application characterized by reduced spatial envelope and weight, improved reliability and increased safety level (having redundant architecture for emergency extension).
2. Testing the EMAS for landing gear actuation system in a test rig to verify the achievement of the targeted TRL.
At the end of project, the FASE-LAG consortium developed innovative actuation system for MLG and NLG exploiting a fault-tolerant / jamming-tolerant architecture suitable for safety-critical aerospace applications. Software and Electronic control unit able to control the dual electromechanical actuator were also developed. Finally, the actuation system was tested on a test rig.
The results reached in the FASE-LAG project allow to use this new and revolutionary actuator’s architecture in the next MEA generation both for Landing Gears applications both for primary slight surface control on A/C of mayor aerospace players.
• Less complex because of the absence of a hydraulic system
• Better suited to long term storage since there is no leak potential
• More energy efficient compared with hydraulic systems
• Easier to install and maintain (no filtration, no bleeding, better testability with potential for more efficient maintenance planning)
• Less complex to control from a power-distribution and power-management perspective (power is
transmitted without mass transfer).
Nevertheless, some critical issues of this technology need to be addressed. Based on this scenario, the FASE-LAG project is specifically focused on overcoming these issues and improving technology performance, reliability and safety using new technologies and architecture.
Main technical objectives are as follows:
1. The development of electromechanical actuation system (EMAS) for landing gear application characterized by reduced spatial envelope and weight, improved reliability and increased safety level (having redundant architecture for emergency extension).
2. Testing the EMAS for landing gear actuation system in a test rig to verify the achievement of the targeted TRL.
At the end of project, the FASE-LAG consortium developed innovative actuation system for MLG and NLG exploiting a fault-tolerant / jamming-tolerant architecture suitable for safety-critical aerospace applications. Software and Electronic control unit able to control the dual electromechanical actuator were also developed. Finally, the actuation system was tested on a test rig.
The results reached in the FASE-LAG project allow to use this new and revolutionary actuator’s architecture in the next MEA generation both for Landing Gears applications both for primary slight surface control on A/C of mayor aerospace players.
The project is divided into 5 work packages (WP). WP1 is related with project management and dissemination of results. Other work packages are related to technical research activities.
The WP2 was focused on the definition of system requirements and definition of the architectures of the Nose and Main Landing gear electromechanical actuators, related control unit and software. The WP3 started in the first reporting period but was completed in the fourth and final one. These activities are devoted to the detailed design of the actuation system. The WP4 and WP5 started in the second reporting period during the design phase of the actuator. Such WPs were related respectively to the prototype manufacturing and testing to achieve the targeted TRL.
In term of technical progress, the following main achievements must be highlighted for each WP.
- Evaluation of new technologies and architecture in the design of the actuation system (WP2)
- Definition of the actuation requirements and architecture (WP2)
- Progress in the detailed design towards PDR phase (WP3)
- Definition of the test rig architecture and requirements (WP4)
- Progress in the detailed design towards CDR phase (WP3)
- Design and manufacturing of the test rig (WP4)
- Engineering test for evaluation and validation of the motor synchronization techniques (WP4)
- Manufacturing of EMA, ECU and cables (WP4)
- SW development and design (WP3 and WP4)
- Test of ECU boards (WP5)
- Integration activities between EMA, ECU and Software (WP4)
- Testing activities on the complete actuation system (WP5)
- TRL assessment (WP5)
The WP2 was focused on the definition of system requirements and definition of the architectures of the Nose and Main Landing gear electromechanical actuators, related control unit and software. The WP3 started in the first reporting period but was completed in the fourth and final one. These activities are devoted to the detailed design of the actuation system. The WP4 and WP5 started in the second reporting period during the design phase of the actuator. Such WPs were related respectively to the prototype manufacturing and testing to achieve the targeted TRL.
In term of technical progress, the following main achievements must be highlighted for each WP.
- Evaluation of new technologies and architecture in the design of the actuation system (WP2)
- Definition of the actuation requirements and architecture (WP2)
- Progress in the detailed design towards PDR phase (WP3)
- Definition of the test rig architecture and requirements (WP4)
- Progress in the detailed design towards CDR phase (WP3)
- Design and manufacturing of the test rig (WP4)
- Engineering test for evaluation and validation of the motor synchronization techniques (WP4)
- Manufacturing of EMA, ECU and cables (WP4)
- SW development and design (WP3 and WP4)
- Test of ECU boards (WP5)
- Integration activities between EMA, ECU and Software (WP4)
- Testing activities on the complete actuation system (WP5)
- TRL assessment (WP5)
The aim of FASE-LAG research activities is to advance the state-of-the-art in electrical actuation. Significant technological breakthroughs in the scope of the project are expected to be:
• Development of compact, highly reliable, minimum-maintenance electromechanical actuation systems for landing gear application, having fault-tolerant architecture to allow for emergency extension;
• Decrease of maintenance operations and maintenance costs due to built-in testability;
• The higher reliability design will lead to operation with increased Time Between Overhaul and less unscheduled maintenance, thus with less delay and more reliable scheduling enabling seamless mobility for passengers;
• Improvement of Small A/C energy consumption and, therefore, compliance with the European and world initiatives towards a sustainable mobility and societal changes
These technological results will contribute to foster the competitiveness of European aviation through cost efficiency and innovation. They will:
• Contribute to the development of a new generation of small aircraft with better handling qualities, reduced fuel consumption and lower operating and life-cycle costs
• Provide a contribution in establishing market leadership for the European aviation stakeholders in electric actuation for critical aircraft systems
• Introduce a new fault tolerant architecture in order to increase safety
• Reduce costs associated with maintenance and non-operational aircraft status.
• Development of compact, highly reliable, minimum-maintenance electromechanical actuation systems for landing gear application, having fault-tolerant architecture to allow for emergency extension;
• Decrease of maintenance operations and maintenance costs due to built-in testability;
• The higher reliability design will lead to operation with increased Time Between Overhaul and less unscheduled maintenance, thus with less delay and more reliable scheduling enabling seamless mobility for passengers;
• Improvement of Small A/C energy consumption and, therefore, compliance with the European and world initiatives towards a sustainable mobility and societal changes
These technological results will contribute to foster the competitiveness of European aviation through cost efficiency and innovation. They will:
• Contribute to the development of a new generation of small aircraft with better handling qualities, reduced fuel consumption and lower operating and life-cycle costs
• Provide a contribution in establishing market leadership for the European aviation stakeholders in electric actuation for critical aircraft systems
• Introduce a new fault tolerant architecture in order to increase safety
• Reduce costs associated with maintenance and non-operational aircraft status.