Periodic Reporting for period 5 - VALEMA (VALidation tests of ElectroMechanical Actuators and its dedicated control units at TRL 6 level)
Berichtszeitraum: 2021-05-01 bis 2022-07-31
The VALEMA Project, within the Clean Sky 2 programme, follows two main objectives.
• To manufacture and assemble optimized and reliable innovative Electro-Mechanical Actuators (EMAs), and their dedicated Electronic Control Units (ECUs) for Aileron/Spoiler (A/S) flight control surfaces actuation and for winglet/flap-tab surfaces actuation that were previously designed and developed in EMA4FLIGHT according to the GA Nº 738042 (Development of Electromechanical Actuators and Electronic Control Units for Flight Control Systems). These Motor, ballscrew and mechanical parts/ECU subsystems will be, in the future, boarded onto FTB2 Regional Aircraft IADP for their in-flight validation.
• To perform certification activities regarding both the HW and SW of the ECUs in order to obtain a permit to fly in the FTB2 demonstrator of the Regional Aircraft.
The development of electromechanical actuation systems for aircrafts will help to achieve the objectives set by ACARE for the aeronautics industry as they will reduce the weight of the aircrafts enabling a consumption reduction. The designed sub-systems are improved by electric motor and ballscrew innovative architecture, advanced control strategies and smart safety, diagnostic and maintenance functions.
To summarize the manufacturing objective, 10 Flap-tab ECU units have been delivered to the Topic Manager (TM), as well as 3 EMA units for the Aileron System, 7 EMA units for the Spoiler System, 11 SHA units for the Aileron System, 6x Roll Feel Units, motors and ballscrew for subsequent supply and integration into the Airbus DS Regional Ground Demonstrator.
The A/S ECU hardware development failed and did not achieve the expected results within the time and efforts needed to support FTB#2 step 2. So, A/S ECU HW and SW integration has not been finished. The knowledge acquired in HW and SW certification according to DO-254 and DO-178C for primary control surfaces actuation is planned to be exploited in other related projects with similarities.
• To manufacture and assemble optimized and reliable innovative Electro-Mechanical Actuators (EMAs), and their dedicated Electronic Control Units (ECUs) for Aileron/Spoiler (A/S) flight control surfaces actuation and for winglet/flap-tab surfaces actuation that were previously designed and developed in EMA4FLIGHT according to the GA Nº 738042 (Development of Electromechanical Actuators and Electronic Control Units for Flight Control Systems). These Motor, ballscrew and mechanical parts/ECU subsystems will be, in the future, boarded onto FTB2 Regional Aircraft IADP for their in-flight validation.
• To perform certification activities regarding both the HW and SW of the ECUs in order to obtain a permit to fly in the FTB2 demonstrator of the Regional Aircraft.
The development of electromechanical actuation systems for aircrafts will help to achieve the objectives set by ACARE for the aeronautics industry as they will reduce the weight of the aircrafts enabling a consumption reduction. The designed sub-systems are improved by electric motor and ballscrew innovative architecture, advanced control strategies and smart safety, diagnostic and maintenance functions.
To summarize the manufacturing objective, 10 Flap-tab ECU units have been delivered to the Topic Manager (TM), as well as 3 EMA units for the Aileron System, 7 EMA units for the Spoiler System, 11 SHA units for the Aileron System, 6x Roll Feel Units, motors and ballscrew for subsequent supply and integration into the Airbus DS Regional Ground Demonstrator.
The A/S ECU hardware development failed and did not achieve the expected results within the time and efforts needed to support FTB#2 step 2. So, A/S ECU HW and SW integration has not been finished. The knowledge acquired in HW and SW certification according to DO-254 and DO-178C for primary control surfaces actuation is planned to be exploited in other related projects with similarities.
The work performed until the end of the Project is summarizes herein:
• Manufacturing: The plans and requirements have taken into account the system requirements and the manufacturing routes have been analysed in order to optimize the manufacturing time, the raw material used and the environmental impact. The motor, ballscrews and Flap-Tab ECU have been manufactured and delivered to the TM for later supply and integration on Airbus DS Regional Ground Demonstrator.
• HW certification: The PHAC generated within the EMA4FLIGHT project has been reviewed and updated and the records required for the certification is being collected. The PHAC has been formally approved by the Certification Liaison.
The development plans for the aileron/spoiler ECU HW generated within EMA4FLIGHT have been reviewed and updated.
The test benches for the acceptance tests have been adapted.
• SW certification: the development plans and standards generated within the EMA4FLIGHT project have been reviewed and updated. These plans and standards have been formally approved by the Certification Liaison.
The documentation and evidences for software requirements and preliminary design have also been generated and approved by the Certification Liaison. These elements have been updated and internally approved for the critical design review.
Additionally, several tasks for testing and formal verification of the source code have been performed.
A/S ECU hardware development has failed and will not achieve the expected results within the time and efforts needed to support FTB#2 step 2. So, A/S ECU HW and SW integration has not been finished. TM proposed to develop an alternative A/S ECU, as mitigating action included in TM GAM, after having been agreed by JU and Airbus DS to support FTB#2 step 2.
Dissemination & communication activities performed from the beginning of the project are:
• UMBRA paper about electrical motor designed for EMA4flight and VALEMA projects. Conference IECON 2019, Lisbon, Portugal, October 14-17, 2019
• GMV has generated 3 articles in internal magazine, GMV NEWS: Apr 2017, Dec 2017 and Nov 2019.
• Article in TECNALIA web page. April 3,2020
• GMV has prepared an article for AerospacheTechReview.com. “Critical SW Application at High Speeds Featuring a Digital Signal Processor (DSP)”, December 2021
• TECNALIA participation in R3ASC’18. May 30- June 1,2018, Toulouse. TECNALIA presented one Poster
• GMV has included a mention to the VALEMA project in its 2020 yearly report.
• SKYLIFE has created a web page
• GMV website
The achieved results are expected to be mature enough for implementation by TM in a flight demonstrator via its own development programme.
For the flap tab ECU, the expected exploitable result will be probably a new HW revision of the ECU with minor or major changes function of the results of the ground and flight tests being conducted by the TM and the CS2JU Member (Airbus DS). Shall this exploitation opportunity occur, a dedicated agreement in written shall be signed between both parties.
Limited possibilities to exploit results for A/S ECU HW or SW once the ECU will not be produced. Anyhow GMV and TECNALIA plan to use SW and HW, respectively, with similarities to the ones developed here in other related projects.
The experience acquired in VALEMA reinforces and consolidates RAMEM's knowledge in mechanical manufacturing and improves RAMEM's positioning to win future contracts for the manufacture of this type of components.
GMV has improved its skills in HW and SW certification for critical systems (DAL-A). GMV will use the experience gained in critical hardware and software certification in future aeronautics programmes.
• Manufacturing: The plans and requirements have taken into account the system requirements and the manufacturing routes have been analysed in order to optimize the manufacturing time, the raw material used and the environmental impact. The motor, ballscrews and Flap-Tab ECU have been manufactured and delivered to the TM for later supply and integration on Airbus DS Regional Ground Demonstrator.
• HW certification: The PHAC generated within the EMA4FLIGHT project has been reviewed and updated and the records required for the certification is being collected. The PHAC has been formally approved by the Certification Liaison.
The development plans for the aileron/spoiler ECU HW generated within EMA4FLIGHT have been reviewed and updated.
The test benches for the acceptance tests have been adapted.
• SW certification: the development plans and standards generated within the EMA4FLIGHT project have been reviewed and updated. These plans and standards have been formally approved by the Certification Liaison.
The documentation and evidences for software requirements and preliminary design have also been generated and approved by the Certification Liaison. These elements have been updated and internally approved for the critical design review.
Additionally, several tasks for testing and formal verification of the source code have been performed.
A/S ECU hardware development has failed and will not achieve the expected results within the time and efforts needed to support FTB#2 step 2. So, A/S ECU HW and SW integration has not been finished. TM proposed to develop an alternative A/S ECU, as mitigating action included in TM GAM, after having been agreed by JU and Airbus DS to support FTB#2 step 2.
Dissemination & communication activities performed from the beginning of the project are:
• UMBRA paper about electrical motor designed for EMA4flight and VALEMA projects. Conference IECON 2019, Lisbon, Portugal, October 14-17, 2019
• GMV has generated 3 articles in internal magazine, GMV NEWS: Apr 2017, Dec 2017 and Nov 2019.
• Article in TECNALIA web page. April 3,2020
• GMV has prepared an article for AerospacheTechReview.com. “Critical SW Application at High Speeds Featuring a Digital Signal Processor (DSP)”, December 2021
• TECNALIA participation in R3ASC’18. May 30- June 1,2018, Toulouse. TECNALIA presented one Poster
• GMV has included a mention to the VALEMA project in its 2020 yearly report.
• SKYLIFE has created a web page
• GMV website
The achieved results are expected to be mature enough for implementation by TM in a flight demonstrator via its own development programme.
For the flap tab ECU, the expected exploitable result will be probably a new HW revision of the ECU with minor or major changes function of the results of the ground and flight tests being conducted by the TM and the CS2JU Member (Airbus DS). Shall this exploitation opportunity occur, a dedicated agreement in written shall be signed between both parties.
Limited possibilities to exploit results for A/S ECU HW or SW once the ECU will not be produced. Anyhow GMV and TECNALIA plan to use SW and HW, respectively, with similarities to the ones developed here in other related projects.
The experience acquired in VALEMA reinforces and consolidates RAMEM's knowledge in mechanical manufacturing and improves RAMEM's positioning to win future contracts for the manufacture of this type of components.
GMV has improved its skills in HW and SW certification for critical systems (DAL-A). GMV will use the experience gained in critical hardware and software certification in future aeronautics programmes.
The new actuation systems will help the reduction of emissions of the aircrafts due to the reduction on the overall weight of the aircraft, therefore, contributing to reach the goals set by ACARE for the aeronautic industry in 2050. The developed ECU, motor and ballscrews for aileron spoiler subsystems and the flap tab ECU will contribute to weight savings and therefore, to a greener aviation.
New actuation systems or generated knowledge in advanced control strategies and smart safety, diagnostic and maintenance functions enable an increase of the competitiveness of all companies of the VALEMA consortium and the TM in the Electric Aircraft sector.
For the flap tab ECU, the expected exploitable result will be probably a new HW revision of the ECU with minor or major changes function of the results of the ground and flight tests being conducted by the TM and the CS2JU Member (Airbus DS).
Global impact at platform level, as estimated by the platform integrator (Airbus DS) for the Demonstrator D4-ET1: 43% CO2 and 70% NOx reduction; 45% noise reduction during take off; improvement of reliability and life cycle cost; increased health monitoring. The Demonstrator D4-ET1 is responsibility of the Topic Manager and includes parts manufactured and delivered in VALEMA.
New actuation systems or generated knowledge in advanced control strategies and smart safety, diagnostic and maintenance functions enable an increase of the competitiveness of all companies of the VALEMA consortium and the TM in the Electric Aircraft sector.
For the flap tab ECU, the expected exploitable result will be probably a new HW revision of the ECU with minor or major changes function of the results of the ground and flight tests being conducted by the TM and the CS2JU Member (Airbus DS).
Global impact at platform level, as estimated by the platform integrator (Airbus DS) for the Demonstrator D4-ET1: 43% CO2 and 70% NOx reduction; 45% noise reduction during take off; improvement of reliability and life cycle cost; increased health monitoring. The Demonstrator D4-ET1 is responsibility of the Topic Manager and includes parts manufactured and delivered in VALEMA.