Clean Sky
The Joint Technology Initiative
For Aeronautics & Air Transport
Clean Sky
The Joint Technology Initiative
For Aeronautics & Air Transport
Eco-Design ITD
Technical Overview
Dr. Florian Mayer(Fraunhofer)
Clean Sky – Eco-Design ITD“Take off”, June 1st, 2010, Vienna
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Clean Sky – Eco-Design ITD – Technical overview2
Reduced fuel
consumption (CO2 &
NOx reduction)
External noise
reduction
"Ecolonomic"
life cycle
� Engines
� Loads & Flow Control
� New Aircraft Configurations
� Low weight
� Aircraft Energy Management� Mission & Trajectory Management
� Engines� Mission & Trajectory Management
� Configurations
� Rotorcraft Noise Reduction
� Aircraft Life Cycle
� Engines
� Loads & Flow Control
� New Aircraft Configurations
� Low weight
� Aircraft Energy Management� Mission & Trajectory Management
� Engines
� Mission & Trajectory Management
� Configurations
� Rotorcraft Noise Reduction
� Aircraft Life Cycle
Eco-Design – Objectives Eco-Design – Objectives
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview3
� 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.
Eco-Design – Objectives Eco-Design – Objectives
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview4
�To design systems for reducing use of non-renewable and nocive fluids /
materials during operations and maintenance: for Systems Application (EDS)for Systems Application (EDS)
�To design airframe for decreasing inputs, outputs and nuisances during a/c
design & production and withdrawal phases: for Airframe Application (EDA)for Airframe Application (EDA)
EcoEco--Design for AirframeDesign for Airframe
EcoEco--DesignDesign
For systemsFor systems
Inputs :
Raw materials
Water
Energy …
Outputs,
nuisances :Energy (warming)
Liquid effluents
Gaseous effluents
Solid waste …
a/c Design &
Production
Inputs :
Fuel
Lubricants
Energy …
Nuisances :Energy (warming)
CO2, NOx
Noise
Contrails
Crash waste …
a/c Use &
Inputs :
Fuel
Water
Energy …
Nuisances :
Energy (warming)
Liquid effluents
Gaseous effluents
Solid waste …
a/c
Withdrawal(Recycling)
Eco-Design – Objectives Eco-Design – Objectives
Maintenance
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Clean Sky – Eco-Design ITD – Technical overview5
2 ED ITD Leaders
IWIW
CASACASA
8 ITD Leaders
5 Associates
(Cluster) (Cluster)
Eco-Design – MembersEco-Design – Members
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Clean Sky – Eco-Design ITD – Technical overview6
� 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)
Eco-Design – BeneficiariesEco-Design – Beneficiaries
� 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
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview7
� Design airframe for decreasing inputs, outputs andnuisances during A/C design & production and withdrawal phases
� Deliver eco-design recommendations to the vehicletypes 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 designprocess
Eco-Design – EDA ObjectivesEco-Design – EDA Objectives
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview8
TECHNOLOGY AREAS
Manufacturing
Product
Use
Maintenance
Green Repair
EliminationRecycling
Eco-Design
for Airframe
Raw Materials
Area 3 : long life structure
Area 4 : end of life management
Area 2 : green manufacturing
Area 1 : new materials / new
architectures
Manufacturing
Product
Use
Maintenance
Green Repair
EliminationRecycling
Eco-Design
for Airframe
Raw Materials
Area 3 : long life structure
Area 4 : end of life management
Area 2 : green manufacturing
Area 1 : new materials / new
architectures
Lifecycle demonstration throughGlobal demonstrator Partial demonstrators
Eco-Design – EDA General IssuesEco-Design – EDA General Issues
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview9
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
� …
New emerging materials
�Composite
� Resins and fibres made from agriculture
� nanotechnology, molecular design
� Thermoplastics
� Others
�Metallic
� New light alloys
� Surface treatment, protection
Modeling
Eco-Design – EDA Area 1: MaterialsEco-Design – EDA Area 1: Materials
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview10
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
Green Factory
�Direct manufacturing
�Energy management
�Virtual Reality
�Manufacturing waste management Modeling
Rigid Tooling
AUTOCLAVE
Vacuum
pumpInjection
machine
resin injection
part to be filled
autoclave pressure
Eco-Design – EDA Area 2: ManufacturingEco-Design – EDA Area 2: Manufacturing
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview11
Test Procedures
�Relevant Vs in field experience
�Short testing cycle
�Ease of structure repair
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
Eco-Design – EDA Area 3: Long Life StructureEco-Design – EDA Area 3: Long Life Structure
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview12
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
Dismantling processes
� Low energy
� Dry Processes
� Low effluents and waste
Eco-Design – EDA Area 4: End of Life managementEco-Design – EDA Area 4: End of Life management
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview13
Materials
Manufacturing
Materials
Manufacturing
Validation article
TBD (significant representative equipped structure)
Production
Process
Production
Process
DismantlingDismantling
RecyclingRecycling
Modelling + manufacturing + testingUse
Maintenance
Use
Maintenance
Partial testsPartial tests
Eco-Design – EDA Overall Life Cycle DemonstrationEco-Design – EDA Overall Life Cycle Demonstration
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview14
Level
Recycling
concept
Separa-
bility
Recycla-
bility
Eco
Design
Guideline
Modular
structure
Types and
numbers
of joints
Tolerability
in recycling
Repair, life
span, con-
sumption
Access-
ability
Dismant-
ling depth
and time
Types and
numbers of
material
Auxilliary
agents,
processing
Separa-
bility
Time for
dis-
mantling
Materials
choice and
tolerability
Toxicity,
generation,
processing
Structure Joining
technol.
Materials Eco-Profile
materials
products
modules
sys-
tem
Eco-Design – EDA Comprehensive Eco-Friendly Materials and Manufacturing ApproachEco-Design – EDA Comprehensive Eco-Friendly Materials and Manufacturing Approach
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview15
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
Eco-Design – EDS ObjectivesEco-Design – EDS Objectives
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview16
� 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
Eco-Design – EDS ObjectivesEco-Design – EDS Objectives
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview17
LOGIC FLOW
Integration and models demonstration throughElectrical test bench Thermal test bench
ECSVented Area
Cabin
Hot Tubing
S-Duct Area
W
W
W
W
Avio
nic
Ba
y
Airframe Structure
ECSVented Area
Cabin
Hot Tubing
S-Duct Area
W
W
W
W
Avio
nic
Ba
y
Airframe Structure
Electrical bench
GENERIC ARCHITECTURE STUDIES
Thermal bench
Integration Demonstrators
Clean Sky Technology Evaluator
TECHNOLOGY DEVELOPMENT
A/C APPLICATION
Electrical bench
GENERIC ARCHITECTURE STUDIES
Thermal bench
Integration Demonstrators
Clean Sky Technology Evaluator
TECHNOLOGY DEVELOPMENT
A/C APPLICATION
Eco-Design – EDS OverviewEco-Design – EDS Overview
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview18
� 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
Eco-Design – EDS – Demonstration: Electrical & Thermal TechnologiesEco-Design – EDS – Demonstration: Electrical & Thermal Technologies
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview19
ECSVented Area
Cabin
Hot Tubing
S-Duct Area
W
W
W
W
Avio
nic
Ba
y
• Hot pressurised air for engine bleed
Airframe Structure
ECSVented Area
Cabin
Hot Tubing
S-Duct Area
W
W
W
W
Avio
nic
Ba
y
• Hot pressurised air for engine bleed
Airframe Structure
Eco-Design – EDS – Demonstration: Thermal BenchEco-Design – EDS – Demonstration: Thermal Bench
Fraunhofer Flight Test Facility FTF,Holzkirchen
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Clean Sky – Eco-Design ITD – Technical overview20
� www.cleansky.eu
� http://cordis.europa.eu/home_de.html
Eco-Design – OverviewEco-Design – Overview
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Clean Sky – Eco-Design ITD – Technical overview21
Eco-Design – CfP Topics – Call #3 2010 April-JulyEco-Design – CfP Topics – Call #3 2010 April-July
Identification topics VALUE MAX FUND
JTI-CS-ECO 4 740.000 555.000
JTI-CS-ECO-01 740.000
JTI-CS-2010-3-ECO-01-004 70.000JTI-CS-2010-3-ECO-01-005 250.000JTI-CS-2010-3-ECO-01-006 220.000JTI-CS-2010-3-ECO-01-007 200.000
JTI-CS-ECO-02
ITD - AREA - TOPIC
Clean Sky - EcoDesign
Area-01 - EDA (Eco-Design for Airframe)
Area-02 - EDS (Eco-Design for Systems)
Development and implementation of Magnesium sheets in A/C
Integration development of a wireless strain monitoring system with a simulation toolEnhanced local heating device capable of high and homogeneous temperature for the repair of large composite damagesAccelerated fatigue testing methodology for fiber reinforced laminates for aircraft structures
Next Call (#4) will be opened in July