Surface Module Approach for Rapid Testing in Flight Test Instrumentation

Projektinformationen

SMART-FTI

ID Finanzhilfevereinbarung: 886057

DOI

10.3030/886057

Projekt abgeschlossen

EK-Unterschriftsdatum 6 Mai 2020

Startdatum 1 Juni 2020

Enddatum 31 Mai 2023

Finanziert unter

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Gesamtkosten

€ 1 714 255,00

EU-Beitrag

€ 1 199 978,51

Koordiniert durch

VECTOFLOW GMBH
Germany

Periodic Reporting for period 2 - SMART-FTI (Surface Module Approach for Rapid Testing in Flight Test Instrumentation)

Berichtszeitraum: 2021-12-01 bis 2023-05-31

Zusammenfassung vom Kontext und den Gesamtzielen des Projekts

Every aircraft moving through the air needs to counter the aerodynamic drag. This requires fuel consumption. The target in every aircraft development should be to reduce aerodynamic drag, therefore fuel consumption and CO2-emissions. How is that achieved? During the development phase, simulations are performed to optimize the geometry and aerodynamics. However, these simulations are just mathematically approached models of the reality: based on assumptions and require simplifications of the real world. Therefore, measurements of aerodynamics during the flight with Flight Test Instrumentation (FTI) is required.
Flight Testing costs make up to 8% of total development costs for aircrafts. State of the art in flight testing are aerodynamic measurement probes distributed over the aircraft, which are connected via pneumatic tubing with a data acquisition system. This is a labor- and time- intensive approach, as the tubing needs to be laid and secured on the aircraft, possibly influencing the measured flow.
The Smart FTI consortium wants to revolutionize the approach: measurement systems are produced with additive manufacturing, which allows for weight optimization and design freedom for minimalized aerodynamic impact. Decentralized, small data acquisition systems are directly integrated into the FTI modules. Only a single Ethernet-Cable is exiting the modules and no extensive laying pneumatic tubing is required.
With this approach, the Smart FTI modules are attached on the aircraft in a fast and flexible way. The extended FTI assembly time is rendered a relic of the past and the created availability on a development aircraft can be used for further flight testing and data acquisition.
To show the viability of this approach, the newly developed “RACER”-prototype by Airbus Helicopters will be fitted with the new FTI to show the capability in-flight.

Arbeit, die ab Beginn des Projekts bis zum Ende des durch den Bericht erfassten Berichtszeitraums geleistet wurde, und die wichtigsten bis dahin erzielten Ergebnisse

Progress towards the project goal of an integrated FTI measurement solution has been made.
Together with the “RACER” OEM, regions of interests have been defined and interfaces to the helicopter have been identified. For the ROIs, FTI modules have been designed and reviewed within a preliminary design review. The designs are currently simulated to show their safety margins.
An innovative scanner with high accuracy has been developed. Key features are its capability for high accuracy pressure management and power over ethernet capabilities, allowing for installation with only one cable for data transmission and powering of the scanner. The design is laid out in a way, which allows a direct integration into an FTI module via an adapter piece, which is permanently fixed to the module.
On the manufacturing side, parameters for printing plastic and metallic modules are adapted for the complex geometries of the novel FTI modules. In addition, the design is adapted to the materials, which are novel to Vectoflow’s geometries.
A first prototype of a Plastic FTI Module has been printed successfully.

Fortschritte, die über den aktuellen Stand der Technik hinausgehen und voraussichtliche potenzielle Auswirkungen (einschließlich der bis dato erzielten sozioökonomischen Auswirkungen und weiter gefassten gesellschaftlichen Auswirkungen des Projekts)

An integrated solution of data acquisition and measurement probes can lead to more intensive flight testing. It is expected that with more experimental data on the aerodynamic flow a deeper understanding in aerodynamic effects can be generated. This will enable the possibilities for further aerodynamic optimization which will lead to an overall reduction in fuel consumption. This correlates to reduced CO2-emissions, which is critical with regards to a continuous growth of the aviation market.
Further, it can be expected that the emerging air taxi market will benefit greatly from enhanced flight-testing capabilities. This will lead to cost reduction in operations, therefore enabling access of a broader mass to air taxi transportation.

Rake Array for Velocity Measurement with integrated scanners

Concept Plastic Module for publication