Periodic Reporting for period 4 - STRONGRCRAFT (Safe, Technically Robust and Optical New Generation fuel system to be integrated on new RotorCRAFT)
Periodo di rendicontazione: 2021-11-01 al 2023-01-31
The objectives of the STRONGRCraft project are to develop, test and manufacture a highly performant, lightweight, cost effective and with limited environmental footprint fuel system for a high speed compound helicopter.
The fuel system comprise engine feeder, fuel transfer and ventilation systems.
The main achievement for the last period are the followings:
• The fuel systems design is finalized
• A first fuel system is closed to be delivered and will be installed for flight tests.
The weight reduction goal of the fuel system has been reached: 15% weight reduction
The weight reduction will permit to reduced environmental impact in terms of energy consumption.
Metallic material waste has been reduced according to the goal of 35%.
VOC emission during making of fuel tanks has been highly reduced by the replacement of the standard solvent by a new one with no VOC emission.
The fuel system comprise engine feeder, fuel transfer and ventilation systems.
The main achievement for the last period are the followings:
• The fuel systems design is finalized
• A first fuel system is closed to be delivered and will be installed for flight tests.
The weight reduction goal of the fuel system has been reached: 15% weight reduction
The weight reduction will permit to reduced environmental impact in terms of energy consumption.
Metallic material waste has been reduced according to the goal of 35%.
VOC emission during making of fuel tanks has been highly reduced by the replacement of the standard solvent by a new one with no VOC emission.
Main objectives of the project
Goal1 : weight reduction of the fuel system up to 15%
Reduction compared to existing (back-up) FS solutions, this corresponds to 38kg instead of 45kg.
Due to extension of the scope of the project, the overall weight of the Fuel System shall be below 130kg including fuel tanks and unusable fuel.
During the development, it was found out that due to higher attitudes requirements, the unusable fuel volume was much higher than expected (around 58kg instead of 13kg first)
Therefore the overall fuel system weight shall be included between 133kg and 178kg.
The aim is then to find solution to decrease this weight as much as possible.
To reduce weight , several design modification have been done:
-reduction of the thickness for aluminium intercoms
- nb of hoses
-
Goal2 : monitored and decreased use of hazardous substances regarding REACH regulation.
Reduction of surfaces to be treated with alodyne, whilst ensuring the same high level of protection against corrosion. More specifically, for each shipset, 40 parts (around 30% of the total number of “non-standard” parts) will be made of reinforced plastic polymers.
Due to the short timing no solution about alodyne substitution can be integrated.
The current list of non standard component who can avoid to use hazardous substances is 25%
Goal3: Environnemental impact (energy, waste, VOC)
Realistic overview of environmental impact of technologies (energy consumption, VOC emission and waste production). In particular, the targeted reduction in metallic material waste is estimated at 35%.
The average reduction in metallic material waste per part is still estimated at 35 %.
Goal4: Cost of potential product
An optimum between the level of performances of the high speed compound helicopter and the cost of the potential product, i.e. the maximum cost targeted for the product integrating innovative technologies improving the overall performances will not exceed the cost of the current FS (life cycle costs included).
Comparison between different suppliers and manufacturing processes are being performed to optimize the trade-off between innovative solutions and cost.
Goal1 : weight reduction of the fuel system up to 15%
Reduction compared to existing (back-up) FS solutions, this corresponds to 38kg instead of 45kg.
Due to extension of the scope of the project, the overall weight of the Fuel System shall be below 130kg including fuel tanks and unusable fuel.
During the development, it was found out that due to higher attitudes requirements, the unusable fuel volume was much higher than expected (around 58kg instead of 13kg first)
Therefore the overall fuel system weight shall be included between 133kg and 178kg.
The aim is then to find solution to decrease this weight as much as possible.
To reduce weight , several design modification have been done:
-reduction of the thickness for aluminium intercoms
- nb of hoses
-
Goal2 : monitored and decreased use of hazardous substances regarding REACH regulation.
Reduction of surfaces to be treated with alodyne, whilst ensuring the same high level of protection against corrosion. More specifically, for each shipset, 40 parts (around 30% of the total number of “non-standard” parts) will be made of reinforced plastic polymers.
Due to the short timing no solution about alodyne substitution can be integrated.
The current list of non standard component who can avoid to use hazardous substances is 25%
Goal3: Environnemental impact (energy, waste, VOC)
Realistic overview of environmental impact of technologies (energy consumption, VOC emission and waste production). In particular, the targeted reduction in metallic material waste is estimated at 35%.
The average reduction in metallic material waste per part is still estimated at 35 %.
Goal4: Cost of potential product
An optimum between the level of performances of the high speed compound helicopter and the cost of the potential product, i.e. the maximum cost targeted for the product integrating innovative technologies improving the overall performances will not exceed the cost of the current FS (life cycle costs included).
Comparison between different suppliers and manufacturing processes are being performed to optimize the trade-off between innovative solutions and cost.
Nb of Vent in reduction compare to std system.
Capacity of extreme altitude upgraded, 11 to 24: modifications applied on design.
integration of the balancing pump into a tanks instead of external location. Integration successfully done.
integration of plastic material for technical equipments.
integration of 3D printed parts for functionnal equipments. Integration done on secondo mona components (Pumps, pressure refueling system)
PDR closed with AHD
Analysis done for:
- Mecanical components
- crash
- electrical bonding
- volume
- vent
- fuel circulation
- weight & gravity center
CDR closed with AHD.
Drawings completed
- 3D drawings
- 2D drawings
- specifications for suppliers components
Demonstrator Production started:
- New coated Fabric successfuly produced. Lighter weight than standard coated fabric.
- 7 tanks successfully produced.
- Arcane implemented succesfuly instead of MEK solvent (no COV with arcane)
- All components (env 800 references ) procured.
Capacity of extreme altitude upgraded, 11 to 24: modifications applied on design.
integration of the balancing pump into a tanks instead of external location. Integration successfully done.
integration of plastic material for technical equipments.
integration of 3D printed parts for functionnal equipments. Integration done on secondo mona components (Pumps, pressure refueling system)
PDR closed with AHD
Analysis done for:
- Mecanical components
- crash
- electrical bonding
- volume
- vent
- fuel circulation
- weight & gravity center
CDR closed with AHD.
Drawings completed
- 3D drawings
- 2D drawings
- specifications for suppliers components
Demonstrator Production started:
- New coated Fabric successfuly produced. Lighter weight than standard coated fabric.
- 7 tanks successfully produced.
- Arcane implemented succesfuly instead of MEK solvent (no COV with arcane)
- All components (env 800 references ) procured.