Periodic Reporting for period 1 - SMART-FTI (Surface Module Approach for Rapid Testing in Flight Test Instrumentation)
Período documentado: 2020-06-01 hasta 2021-11-30
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.
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.
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.