Periodic Reporting for period 2 - ICEPASS (innovative ICE Protection And Shielding System for HLFC Demonstrator)
Periodo di rendicontazione: 2022-01-01 al 2023-07-31
The IcePass project is an innovation action that began in July 2020. SONACA was the topic manager of the action. At the moment of this report, the project has come to the end of its total duration (37 months).
In the framework of the LPA program, IcePass project aimed at covering two systems for the Leading Edge of the HLFC (High Lift Flow Control) wing Ground Base Demonstrator (GBD). In particular, it dealt with the developing and manufacturing of electrical harnesses for power feed and monitoring lines of the Ice Protection System (IPS) and for he Shielding/Krueger actuation system as well as of the actuation system to deploy and retract the latter.
IcePass brought innovation to the activity by means of the introduction 3D printing for the manufacturing of brackets and supports, an innovative way to carry electricity, the so-called raceways, and the introduction of slip rings as connectors between electric lines located on movable parts. Moreover, IcePass project has shown evidence that the electric actuation of a high-lift device is feasible without impact on performance. The project designed, manufactured and installed a full electric actuation system that was able to deploy and retract the Krueger Flap of the HLFC-WIN demonstrator in total fulfillment of its requirements. The implementation of these innovative contributions is a key issue whose demonstration on the GBD helps alleviate the lack of space in the HLFC leading edge. Likewise, it paves the way to reduce industrialization risks in the introduction of the HLFC solutions in a new generation of greener and electrical aircrafts.
In the framework of the LPA program, IcePass project aimed at covering two systems for the Leading Edge of the HLFC (High Lift Flow Control) wing Ground Base Demonstrator (GBD). In particular, it dealt with the developing and manufacturing of electrical harnesses for power feed and monitoring lines of the Ice Protection System (IPS) and for he Shielding/Krueger actuation system as well as of the actuation system to deploy and retract the latter.
IcePass brought innovation to the activity by means of the introduction 3D printing for the manufacturing of brackets and supports, an innovative way to carry electricity, the so-called raceways, and the introduction of slip rings as connectors between electric lines located on movable parts. Moreover, IcePass project has shown evidence that the electric actuation of a high-lift device is feasible without impact on performance. The project designed, manufactured and installed a full electric actuation system that was able to deploy and retract the Krueger Flap of the HLFC-WIN demonstrator in total fulfillment of its requirements. The implementation of these innovative contributions is a key issue whose demonstration on the GBD helps alleviate the lack of space in the HLFC leading edge. Likewise, it paves the way to reduce industrialization risks in the introduction of the HLFC solutions in a new generation of greener and electrical aircrafts.
IcePass project reached substantial progresses during the second reporting period. The most relevant of them are:
ICEPASS SYSTEM REQUIREMENTS
A Compliance Document was agreed with SONACA. The document served as foundation of the detailed design approved at CDR, which was manufactured and installed in the GBD afterwards.
POWER AND MONITORING ELECTRIC LINESI
ICD routing dependencies were confirmed and frozen in the corresponding HLFC33000 and HLFC38000 ICD drawings.
The architecture of the power and monitoring lines for GBD was detailed designed.
During the CDR, SONACA stated that the design was mature enough for GBD and therefore, the CDR was considered passed.
Raceway tracks and covers as well as other supporting elements were 3D printed by Adática. All raceway lines were pre-assembled at Adática’s facilities prior to installation in GBD.
SHIELDING/KRUEGER ACTUATION SYSTEM
The Shielding/Krueger actuation system for GBD was detailed designed. The design was finally based on a rotation electrical motor plugged to a right-angle gearbox for moving every kinematic station of the Krueger flap.
During the CDR, SONACA stated that the design presented was mature enough for GBD and therefore, the CDR was considered passed.
A Test Bench for the internal testing of the Shielding/Krueger actuation system was designed, manufactured and installed in Adática’s facilities.
The Shielding/Krueger actuation system was installed and extensively tested in the aforementioned test bench.
The control software of the Shielding/Krueger actuation system was developed and tested together in the internal Test Bench prior to deployment at GBD.
GBD INSTALLATION AND TESTING
Power and monitoring electric lines were installed in the GBD by a dedicated team.
Likewise, the three sets of motor and gearbox, together with the control hardware and all the other mechanical elements involved in the assembly were installed in the GBD, properly connected and electrically powered through the previously installed power lines.
IPS monitoring lines were connected accordingly to dummy thermocouples and LED lights at the fixed leading edge and Krueger flap respectively.
Once the installation of the IcePass contribution to the GBD was completed, a number of checks and tests were carried out in situ in order to evidence compliance with the requirements agreed with SONACA in the Compliance Document.
Adática left the GBD with all IcePass elements properly installed, checked and ready for testing according to the HLFC testing program in the months to follow.
ICEPASS SYSTEM REQUIREMENTS
A Compliance Document was agreed with SONACA. The document served as foundation of the detailed design approved at CDR, which was manufactured and installed in the GBD afterwards.
POWER AND MONITORING ELECTRIC LINESI
ICD routing dependencies were confirmed and frozen in the corresponding HLFC33000 and HLFC38000 ICD drawings.
The architecture of the power and monitoring lines for GBD was detailed designed.
During the CDR, SONACA stated that the design was mature enough for GBD and therefore, the CDR was considered passed.
Raceway tracks and covers as well as other supporting elements were 3D printed by Adática. All raceway lines were pre-assembled at Adática’s facilities prior to installation in GBD.
SHIELDING/KRUEGER ACTUATION SYSTEM
The Shielding/Krueger actuation system for GBD was detailed designed. The design was finally based on a rotation electrical motor plugged to a right-angle gearbox for moving every kinematic station of the Krueger flap.
During the CDR, SONACA stated that the design presented was mature enough for GBD and therefore, the CDR was considered passed.
A Test Bench for the internal testing of the Shielding/Krueger actuation system was designed, manufactured and installed in Adática’s facilities.
The Shielding/Krueger actuation system was installed and extensively tested in the aforementioned test bench.
The control software of the Shielding/Krueger actuation system was developed and tested together in the internal Test Bench prior to deployment at GBD.
GBD INSTALLATION AND TESTING
Power and monitoring electric lines were installed in the GBD by a dedicated team.
Likewise, the three sets of motor and gearbox, together with the control hardware and all the other mechanical elements involved in the assembly were installed in the GBD, properly connected and electrically powered through the previously installed power lines.
IPS monitoring lines were connected accordingly to dummy thermocouples and LED lights at the fixed leading edge and Krueger flap respectively.
Once the installation of the IcePass contribution to the GBD was completed, a number of checks and tests were carried out in situ in order to evidence compliance with the requirements agreed with SONACA in the Compliance Document.
Adática left the GBD with all IcePass elements properly installed, checked and ready for testing according to the HLFC testing program in the months to follow.
IcePass project introduces an innovative way to carry electricity. Traditional electric harnesses groups a limited number of cables together. In the leading edge, the space is very limited and the routing design tend to present complex solutions. The innovative concept implemented consists of arranging the harness not in a cylindrical way but by putting all the cables in a flat pattern disposition. With this flat configuration, all the cables are installed inside a tailor made electric raceway. It acts as integrated support structure suppressing the need of other installations. The raceway is replaceable by means of screws enabling the mount / dismount operations easily. The manufacturing technology selected for the raceway is additive manufacturing, which enables to manufacture complex shapes and tailor made applications.
IcePass also introduces an innovative way of connecting harnesses in movable parts. The solution usually adopted is to give extra length to the wires enabling the parts to move without the interference of the cable. This solution is not ideal because the harness is free to move in an uncontrolled way. IcePass implements, along with the raceways, the use of electrical slip ring connectors in the movable parts. They enable to turn freely one side of the connector from the other enabling smarter solutions suppressing the extra length of the harnesses and releasing the harness from possible torsion stresses. This solution improved significantly the performance of the shielding system power and monitoring feed lines.
At last, IcePass project has shown evidence that the electric actuation of a high-lift device is feasible without impact on performance. The project designed, manufactured and installed a full electric actuation system that was able to deploy and retract the Krueger Flap of the HLFC-WIN demonstrator in total fulfillment of its requirements.
The implementation of all these innovative contributions is a key issue whose demonstration on the GBD helped alleviate the lack of space in the HLFC leading edge. Likewise, it paves the way to reduce industrialization risks in the introduction of the HLFC solutions in a new generation of greener and electrical aircrafts.
The impacts at the end of the project are:
COMPETITIVENESS:
+ Better peerformace of the aircraft by a reduction of weight in the electrification of the IPS and Shielding systems and by a reduction of the space required for overall electrification lines compared to traditional ones.
+ Cost reduction related to manufacturing of harnesses and to the time for assembly, inspection or substitution of harnesses.
ENVIRONMENTAL: less fuel consumption and CO2 emissions due to a positive contribution to the drag reduction of the HLFC wing demonstration, due to the employ of additive manufacturing, which reduce material wastes and due to the contribution of IcePass to make possible the electrification of aircrafts
SOCIAL: Creation of qualified jobs free of gender bias, which have a direct correlation to improvement of living standards
INNOVATIION: Development of and European Industrive in Additivie Manufacturing
IcePass also introduces an innovative way of connecting harnesses in movable parts. The solution usually adopted is to give extra length to the wires enabling the parts to move without the interference of the cable. This solution is not ideal because the harness is free to move in an uncontrolled way. IcePass implements, along with the raceways, the use of electrical slip ring connectors in the movable parts. They enable to turn freely one side of the connector from the other enabling smarter solutions suppressing the extra length of the harnesses and releasing the harness from possible torsion stresses. This solution improved significantly the performance of the shielding system power and monitoring feed lines.
At last, IcePass project has shown evidence that the electric actuation of a high-lift device is feasible without impact on performance. The project designed, manufactured and installed a full electric actuation system that was able to deploy and retract the Krueger Flap of the HLFC-WIN demonstrator in total fulfillment of its requirements.
The implementation of all these innovative contributions is a key issue whose demonstration on the GBD helped alleviate the lack of space in the HLFC leading edge. Likewise, it paves the way to reduce industrialization risks in the introduction of the HLFC solutions in a new generation of greener and electrical aircrafts.
The impacts at the end of the project are:
COMPETITIVENESS:
+ Better peerformace of the aircraft by a reduction of weight in the electrification of the IPS and Shielding systems and by a reduction of the space required for overall electrification lines compared to traditional ones.
+ Cost reduction related to manufacturing of harnesses and to the time for assembly, inspection or substitution of harnesses.
ENVIRONMENTAL: less fuel consumption and CO2 emissions due to a positive contribution to the drag reduction of the HLFC wing demonstration, due to the employ of additive manufacturing, which reduce material wastes and due to the contribution of IcePass to make possible the electrification of aircrafts
SOCIAL: Creation of qualified jobs free of gender bias, which have a direct correlation to improvement of living standards
INNOVATIION: Development of and European Industrive in Additivie Manufacturing