Clean Sky. The Joint Technology Initiative For Aeronautics & Air Transport. Eco-Design ITD. Clean Sky Eco-Design ITD Take off, June 1 st, 2010, Vienna

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1 Clean Sky The Joint Technology Initiative For Aeronautics & Air Transport Dr. Florian Mayer (Fraunhofer) Clean Sky Eco-Design ITD Take off, June 1 st, 2010, Vienna Eco-Design ITD Technical Overview

2 Eco-Design Objectives Reduced fuel consumption (CO 2 & NOx reduction) External noise reduction "Ecolonomic" life cycle Engines Loads & Flow Flow Control Control New Aircraft Configurations Low weight Aircraft Energy Management Mission & Trajectory Management Aircraft Energy Management Mission & Trajectory Management Engines Mission & Trajectory Management Configurations Rotorcraft Noise Noise Reduction Aircraft Life Cycle Aircraft Life Cycle 2

3 Eco-Design Objectives Eco-Design will focus on green design and production, withdrawal, and recycling of aircraft, by optimal use of raw materials and energies thus improving the environmental impact of the whole products life cycle and accelerating compliance with the REACH directive. Eco-Design is focused on designing equipped airframe for decreasing inputs (raw materials, energy, water, etc.), outputs and nuisances (energy / warming, liquid effluents, gaseous effluents, solid waste, etc.) and on eliminating non-renewable and noxious fluids and materials (i.e. removal of hydraulics all electric aircraft) during operations and maintenance, without reducing aircrafts' levels of safety, quality and performance. 3

4 Eco-Design Objectives To design airframe for decreasing inputs, outputs and nuisances during a/c design & production and withdrawal phases: for Airframe Application (EDA) To design systems for reducing use of non-renewable and nocive fluids / materials during operations and maintenance: for Systems Application (EDS) Inputs : Inputs : Inputs : Raw materials Water Energy Fuel Lubricants Energy Fuel Water Energy Eco-Design For systems a/c Design & Production a/c Use & Maintenance a/c Withdrawal (Recycling) Outputs, nuisances : Energy (warming) Liquid effluents Gaseous effluents Solid waste Nuisances : Energy (warming) CO2, NOx Noise Contrails Crash waste Nuisances : Energy (warming) Liquid effluents Gaseous effluents Solid waste Eco-Design for Airframe 4

5 Eco-Design Members 2 ED ITD Leaders 8 ITD Leaders CASA 5 Associates IW (Cluster) (Cluster) 5

6 Eco-Design Beneficiaries A total of 43 beneficiaries (with affiliates and clusters members) 10 Research organisations 2 SME From 8 Countries (France, Germany, Israel, Italy, Netherland, Spain, Switzerland, UK) Current Budget Total Eco-Design: 116 M Eco-Design for Airframe: 79 M Eco-Design for Systems (small A/C): 37 M 25% thereof for other Partners through CfPs 6

7 Eco-Design EDA Objectives Design airframe for decreasing inputs, outputs and nuisances during A/C design & production and withdrawal phases Deliver eco-design recommendations to the vehicle types considered within Clean Sky Evaluate new promising technologies and then to identify and maturate the ecologically sound design solutions Introduce eco-design tools in the current aircraft design process 7

8 Eco-Design EDA General Issues TECHNOLOGY AREAS Area 4 : end of life management Area 1 : new materials / new architectures Elimination Recycling Green Repair Eco-Design for Airframe Raw Materials Manufacturing Maintenance Area 3 : long life structure Use Product Lifecycle demonstration through Global demonstrator Partial demonstrators Area 2 : green manufacturing 8

9 Eco-Design EDA Area 1: Materials New materials Requirements Structural function Performances : weight saving Renewability products Recyclability REACH (CMR ) Materials production processes : energy, cost, pollution New materials Requirements New functions Anti icing Low friction coating Self healing, self cleaning Electrical conductivity Modeling New emerging materials Composite Resins and fibres made from agriculture nanotechnology, molecular design Thermoplastics Others Metallic New light alloys Surface treatment, protection 9

10 Eco-Design EDA Area 2: Manufacturing New processes Requirements Industrial Optimised Work Flow Highly integrated processes One shot process Dry process Low energy Low emissions (noise) Increased automation Recycling of ancillaries Societal Materials Requirements Current Composite, metallic New Green Composites, metallic Low emissions (VOC, dust) Low production waste and scrap Recyclability AUTOCLAVE Green Factory Direct manufacturing Energy management Virtual Reality Manufacturing waste management Injection machine Rigid Tooling resin injection part to be filled autoclave pressure Modeling Vacuum pump 10

11 Eco-Design EDA Area 3: Long Life Structure Structural Diagnostic / Prognostic Health Usage & Monitoring Real time monitoring Smart sensors Non Destructive Testing Green Repair Solutions Repair solutions for Thermoplastics Rework technologies Low energy techniques (Inductive devices, IR- devices, oil heated devices, ) Repair of severe damages Testing and qualification of the repairs Test Procedures Relevant Vs in field experience Short testing cycle Ease of structure repair 11

12 Eco-Design EDA Area 4: End of Life management Dismantling processes Low energy Dry Processes Low effluents and waste Materials end of life treatment for reuse, elimination, storage Metallic Separation, purification Storage of end products Organic Physical processing Chemical processing Biological processing Energy Storage of end products Equipment Traceability all along the supply chain 12

13 Eco-Design EDA Overall Life Cycle Demonstration Materials Manufacturing Production Process Use Use Maintenance Modelling + manufacturing + testing Validation article TBD (significant representative equipped structure) Dismantling Recycling Partial Partial tests tests 13

14 Eco-Design EDA Comprehensive Eco-Friendly Materials and Manufacturing Approach system Recycling concept Separability Recyclability Eco Design Guideline products Modular structure Types and numbers of joints Tolerability in recycling Repair, life span, consumption modules Accessability Dismantling depth and time Types and numbers of material Auxilliary agents, processing materials Separability Time for dismantling Materials choice and tolerability Toxicity, generation, processing Level Structure Joining technol. Materials Eco-Profile 14

15 Eco-Design EDS Objectives To demonstrate the feasibility and highlight the ecolonomic benefits at aircraft level of oil-less power-by-wire for small cabin aircraft. Removal of hydraulics: less environmental impact in terms of aircraft maintenance and disposal. All-electrical system: Current: different media (electric, hydraulic, pneumatic) Future: electricity as the only media Innovative energy management: new energy management, intelligent load shedding, power regeneration on actuators, sharing of Electrical Control Unit over actuators, etc. greener power efficiency and fuel consumption, reduced CO2 and NOx emissions 15

16 Eco-Design EDS Objectives Validate an a/c design methodology and tools for optimisation of Integrated Vehicle Systems Architecture Demonstrate feasibility and ecolonomic benefits of the all electric a/c concept Evaluation / maturation of electrical & thermal technologies Prepare the ecolonomic design through drastic reduction of ground and flight tests thanks to the virtual a/c concept 16

17 Eco-Design EDS Overview LOGIC FLOW Clean Sky Technology Evaluator GENERIC ARCHITECTURE STUDIES A/C APPLICATION TECHNOLOGY DEVELOPMENT Integration Demonstrators Electrical bench Thermal bench Integration and models demonstration through Electrical test bench Thermal test bench Airframe Structure W S-Duct Area Cabin Avionic Bay Hot Tubing Vented Area W ECS W W 17

18 Eco-Design EDS Demonstration: Electrical & Thermal Technologies Demonstrate an optimisation of high power electrical network operation Demonstrate optimised air circulation patterns Demonstrate passive temperature control (radiation, conduction) Demonstrate active temperature control (heat pipe,...) Demonstrate advanced materials in aircraft structures Demonstrate accurate modeling of the thermal environment, including the effects of active thermal control technologies Validate the methodology and associated modeling for the thermal side 18

19 Eco-Design EDS Demonstration: Thermal Bench Hot pressurised air for engine bleed Airframe Structure W S-Duct Area Cabin Avionic Bay Hot Tubing Vented Area W ECS W W Fraunhofer Flight Test Facility FTF, Holzkirchen 19

20 Eco-Design Overview

21 Eco-Design CfP Topics Call # April-July Identification ITD - AREA - TOPIC topics VALUE MAX FUND JTI-CS-ECO Clean Sky - EcoDesign JTI-CS-ECO-01 Area-01 - EDA (Eco-Design for Airframe) JTI-CS ECO Development and implementation of Magnesium sheets in A/C JTI-CS ECO Integration development of a wireless strain monitoring system with a JTI-CS ECO Enhanced local heating device capable of high and homogeneous temperature JTI-CS ECO Accelerated fatigue testing methodology for fiber reinforced laminates for JTI-CS-ECO-02 Area-02 - EDS (Eco-Design for Systems) Next Call (#4) will be opened in July 21