Periodic Reporting for period 4 - GAM-2020-FRC (Fast Rotorcraft)
Periodo di rendicontazione: 2023-01-01 al 2024-04-30
The FRC IADP of CS2 consists of two separate demonstrators, the Next Generation Civil Tilt Rotor (NGCTR) and the RACER compound helicopter.
NGCTR TD final assembly has been completed with the installation of the main subsystems such as: instrumentation, harnesses, wing, morphing wing, ailerons, fuel system, hydraulics, tail fins, ruddervator, engines, nacelles, transmissions, electrical and avionic system, rotors and blades. Both wing and tail successfully performed the dynamic characterization and static test. Transmission test, avionic integration test and FCC system has been successfully completed. Acceptance Test Procedures for main subsystems has been completed. Workshops with Civil Airworthiness Authorities has been performed and preliminary Flight Clearance Justification documentation delivered.
Within 2024, with the availability of the ICDS, is foreseen the execution of the First Flight.
RACER
Increasing speed of helicopters raises a lot of interests for many missions: public transportation to connect cities or isolated locations, but also and more importantly for public emergency services such as Search and Rescue or Emergency Medical Service where higher speed would mean saving more lives. Nevertheless, high speed brings significant additional complexity to the architecture and to the dynamic system that affects the costs of ownership and availability of the helicopters.
In this context the ambition of the RACER project is to propose on one hand a competitive compound helicopter concept that would be the best compromise between capabilities (speed, range, agility) but also sustainability and cost, that will be major differentiators for future civil markets. And on the other hand, to propose a European sovereign solution: the CleanSky II project was the unique opportunity to work on European solutions for high-speed helicopters. Reaching the CSII objectives is definitely a must to maintain European industry competitiveness in this domain
NGCTR TD final assembly has been completed with the installation of the main subsystems such as: instrumentation, harnesses, wing, morphing wing, ailerons, fuel system, hydraulics, tail fins, ruddervator, engines, nacelles, transmissions, electrical and avionic system, rotors and blades. Both wing and tail successfully performed the dynamic characterization and static test. Transmission test, avionic integration test and FCC system has been successfully completed. Acceptance Test Procedures for main subsystems has been completed. Workshops with Civil Airworthiness Authorities has been performed and preliminary Flight Clearance Justification documentation delivered.
Within 2024, with the availability of the ICDS, is foreseen the execution of the First Flight.
RACER
Increasing speed of helicopters raises a lot of interests for many missions: public transportation to connect cities or isolated locations, but also and more importantly for public emergency services such as Search and Rescue or Emergency Medical Service where higher speed would mean saving more lives. Nevertheless, high speed brings significant additional complexity to the architecture and to the dynamic system that affects the costs of ownership and availability of the helicopters.
In this context the ambition of the RACER project is to propose on one hand a competitive compound helicopter concept that would be the best compromise between capabilities (speed, range, agility) but also sustainability and cost, that will be major differentiators for future civil markets. And on the other hand, to propose a European sovereign solution: the CleanSky II project was the unique opportunity to work on European solutions for high-speed helicopters. Reaching the CSII objectives is definitely a must to maintain European industry competitiveness in this domain
NGCTR (WP1):
Progress focused on TD Final Assembly and testing of the key systems.
Drawings release completed. Support to FAL to manage non-conformities given. Flight Clearance General Plan and Flight Clearance Justification (FCJ) Plans were updated in line with discussions with certification Authorities (ENAC/EASA). Flight test instrumentation for Ground Run (GR) and First Flight (FF) have been reviewed and agreed. Tiltrotor system design GR, FF activities and performance requirements have been cleared with necessary analysis and documentation. Aerodynamics database was updated using HIGHTRIP results. Similarly, rotor aeroelastic Model was updated using wind tunnel tests data from ATTILA project. Mass distribution for GR and FF was assessed and used to support GR and FF loads definition. Transmissions and Rotors system drawings were updated and released to support final assembly. Airframe structures analysis assessment competed for major components. Static and fatigue tests on the tail were completed. Wing, Nacelles and Tail Structural analysis completed and report released. Wing and Fins static test completed. Electrical and avionics systems: Interfaces Control Documents closed. Flight Test Plan released. V&V tests for internally developed software to be installed onboard were completed. FTP for onboard checks of equipment installation was released. FCS rig commissioning and system integration activities were completed leveraging on both prototypes and flight-representative units. CDR successfully completed. Qualification activities defined and completed. Airframe Systems drawings related to the auxiliary systems to the engine (fire detection system, drains, auxiliary ducts, etc.) were released with related test plans.
TD final assembly has been completed with the installation of the main subsystems such as: instrumentation, harnesses, wing, morphing wing, ailerons, fuel system, hydraulics, tail fins, ruddervator, engines, nacelles, transmissions, electrical and avionic system, rotors and blades. Both wing and tail successfully performed the dynamic characterization and static test. Transmission test, avionic integration test and FCC system has been successfully completed. Acceptance Test Procedures for main subsystems has been completed.
RACER (WP2):
During the last period all the efforts were committed to finish the assembly of the demonstrator.; finalization of prototype airframe, electrical harnesses, fuel system, flight command , hydraulics systems installation and the integration of the different networks and the upper deck installation: After receiving the Main Gear Box for flight the assembly of the RACER demonstrator has been completely finalized in February 2024 after having completed the final quality inspection. A huge part of the activity was also dedicated to flight clearance justification. The aircraft was transferred to the flight line in March 2024 for ground and flight test . The flight phase campaign started the 6th of April with the first ground run.The first flight took place on the 25th of April 2024: The RACER demonstrator performed around 8 hours of flight during 7 flights. The next steps of the test campaign are to prepare mission demonstrations (passengers transport, EMS, SAR, parapublic…) and to demonstrate the noise and CO2/Nox emissions savings.
ECO-DESIGN (WP3)
For NGCTR, results of LCA analysis for the 3 flagship demonstrators (wing, Nacelle, gearbox house-case) were collected towards final assessment and reporting. All proposed demonstrators have been accepted as best items in ECO-TA and complete technical report with LCI/LCA results.
For RACER, 3 Flagship Demonstrators were selected (Polycarbonate thermoformed cabin linings, MGB Jet pumps, MGB rear cover) . Life Cycle Inventories were performed on the production sites, and Life Cycle Assessments of the technologies were conducted by the ECO-TA. Improvement trends were shown, as well as the strong sensitivity of the environmental impacts of Additive Manufacturing technologies to a dedicated design definition.
TECHNOLOGY EVALUATOR (WP4)
Close collaboration between FRC and TE-TA led to the agreement on methodologies to assess the Conceptual vehicles toward the TE 2nd Assessment. For both FRC demonstrators, the impact was calculated in terms of CO2, NOx and noise.
For NGCTR, technical and performance assessment of the vehicle was delivered in cooperation with FASSTRIP2050 using data of NGCTR, AW139 and TEH-B as essential inputs for the preparation of the RotorCraft fleet forecast document. NGCTR noise hemispheres and AW139 were updated.
For RACER,a TESM model (Twin Engine Super Medium) representative of the conventional rotorcrafts flying with current technologies in the range 7 - 8t has been created in parallel to the RACER TE (Techno-Evaluator). Both models at rotorcraft level were used in order to compare the performances in terms of noise emissions and in terms of CO2 and NOx emissions. The results are reaching the saving reduction targets of -20% of the Cleansky 2 program in terms of Noise, CO2 and NOx while flying
Progress focused on TD Final Assembly and testing of the key systems.
Drawings release completed. Support to FAL to manage non-conformities given. Flight Clearance General Plan and Flight Clearance Justification (FCJ) Plans were updated in line with discussions with certification Authorities (ENAC/EASA). Flight test instrumentation for Ground Run (GR) and First Flight (FF) have been reviewed and agreed. Tiltrotor system design GR, FF activities and performance requirements have been cleared with necessary analysis and documentation. Aerodynamics database was updated using HIGHTRIP results. Similarly, rotor aeroelastic Model was updated using wind tunnel tests data from ATTILA project. Mass distribution for GR and FF was assessed and used to support GR and FF loads definition. Transmissions and Rotors system drawings were updated and released to support final assembly. Airframe structures analysis assessment competed for major components. Static and fatigue tests on the tail were completed. Wing, Nacelles and Tail Structural analysis completed and report released. Wing and Fins static test completed. Electrical and avionics systems: Interfaces Control Documents closed. Flight Test Plan released. V&V tests for internally developed software to be installed onboard were completed. FTP for onboard checks of equipment installation was released. FCS rig commissioning and system integration activities were completed leveraging on both prototypes and flight-representative units. CDR successfully completed. Qualification activities defined and completed. Airframe Systems drawings related to the auxiliary systems to the engine (fire detection system, drains, auxiliary ducts, etc.) were released with related test plans.
TD final assembly has been completed with the installation of the main subsystems such as: instrumentation, harnesses, wing, morphing wing, ailerons, fuel system, hydraulics, tail fins, ruddervator, engines, nacelles, transmissions, electrical and avionic system, rotors and blades. Both wing and tail successfully performed the dynamic characterization and static test. Transmission test, avionic integration test and FCC system has been successfully completed. Acceptance Test Procedures for main subsystems has been completed.
RACER (WP2):
During the last period all the efforts were committed to finish the assembly of the demonstrator.; finalization of prototype airframe, electrical harnesses, fuel system, flight command , hydraulics systems installation and the integration of the different networks and the upper deck installation: After receiving the Main Gear Box for flight the assembly of the RACER demonstrator has been completely finalized in February 2024 after having completed the final quality inspection. A huge part of the activity was also dedicated to flight clearance justification. The aircraft was transferred to the flight line in March 2024 for ground and flight test . The flight phase campaign started the 6th of April with the first ground run.The first flight took place on the 25th of April 2024: The RACER demonstrator performed around 8 hours of flight during 7 flights. The next steps of the test campaign are to prepare mission demonstrations (passengers transport, EMS, SAR, parapublic…) and to demonstrate the noise and CO2/Nox emissions savings.
ECO-DESIGN (WP3)
For NGCTR, results of LCA analysis for the 3 flagship demonstrators (wing, Nacelle, gearbox house-case) were collected towards final assessment and reporting. All proposed demonstrators have been accepted as best items in ECO-TA and complete technical report with LCI/LCA results.
For RACER, 3 Flagship Demonstrators were selected (Polycarbonate thermoformed cabin linings, MGB Jet pumps, MGB rear cover) . Life Cycle Inventories were performed on the production sites, and Life Cycle Assessments of the technologies were conducted by the ECO-TA. Improvement trends were shown, as well as the strong sensitivity of the environmental impacts of Additive Manufacturing technologies to a dedicated design definition.
TECHNOLOGY EVALUATOR (WP4)
Close collaboration between FRC and TE-TA led to the agreement on methodologies to assess the Conceptual vehicles toward the TE 2nd Assessment. For both FRC demonstrators, the impact was calculated in terms of CO2, NOx and noise.
For NGCTR, technical and performance assessment of the vehicle was delivered in cooperation with FASSTRIP2050 using data of NGCTR, AW139 and TEH-B as essential inputs for the preparation of the RotorCraft fleet forecast document. NGCTR noise hemispheres and AW139 were updated.
For RACER,a TESM model (Twin Engine Super Medium) representative of the conventional rotorcrafts flying with current technologies in the range 7 - 8t has been created in parallel to the RACER TE (Techno-Evaluator). Both models at rotorcraft level were used in order to compare the performances in terms of noise emissions and in terms of CO2 and NOx emissions. The results are reaching the saving reduction targets of -20% of the Cleansky 2 program in terms of Noise, CO2 and NOx while flying
The aim of the two platforms is to provide more speed, longer range, more productivity to fill the gap between conventional helicopters and other fixed-wing platforms. CS2 will demonstrate how these configurations will provide new and more effective services to citizens.