Compliance to SAE AS9100.
Experience of aeronautic rules, certification processes and quality requirements.
Experience in design, validation, manufacturing and qualification (environmental / functional) of airborne and non-airborne equipment, according to RTCA-DO-160, RTCA-DO-178 and RTCA-DO-254 (or other civil or military equivalent standards) for safety critical equipments.
Familiarity with EMI compatibility issues: capacity to design complex electronic HW in compliance with EMC guidelines, and experience in performing EMC justification analyses and experimental assessments according to RTCA-D0-160, EUROCAE ED-107/ARP-5583, ED-81/ARP-5413 and ED-84/ARP-5412 or equivalent civil or military standards.
Experience in research, development and manufacturing in air compressor, fuel inerting system (nice to have) and aircraft pressurization system (nice to have).
CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 136 Design Organization Approval (DOA) nice to have.
Experience in Safety assessment process according to SAE-ARP-4754 and SAE-ARP-4761 standards, willingness to interact closely with TM safety specialists in order to produce the necessary outputs (safety and reliability reports and fault trees/analyses).
Shape, component design and structural analysis using CATIA V5 R22, NASTRAN, Matlab or equivalent software.
Capability to optimize the HW and SW design, to model mathematically/numerically complex mechatronic systems with suitable simulation tools (Matlab/Simulink) and to analyze both simulation and experimental results to ensure that the various required performance goals are met.
5. Abbreviations
EMC Electro-Magnetic Compatibility EMI Electro-Magnetic Interference NDA Non-Disclosure Agreement NGCTR Next Generation Civil Tiltrotor FMEA Failure Mode and Effect Analysis FHD Finmeccanica Helicopter Division HW Hardware
SW Software TM Topic Manager
CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 137
II.
High Voltage Energy Storage
Type of action (RIA or IA) IA
Programme Area FRC– WP 1.1 and 1.6 [NextGenCTR Demonstrator Tiltrotor] Joint Technical Programme (JTP) Ref. JTP V5
Indicative Funding Topic Value (in k€) 850 k€ Type of agreement Implementation Agreement Duration of the action (in Months) 60 months Indicative Start
Date21
Q2 2017
Identification Title
JTI-CS2-2016-CFP04-FRC-01-12 High Voltage Energy Storage Short description (3 lines)
Design, development, testing and flight qualification of a high voltage energy storage device to be used on the Next Generation Civil Tilt Rotor for engine starting and for emergency operation
CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 138
1. Background
The aim of the Fast Rotorcraft (FRC) project is to use technologies developed through the Clean Sky Programme to demonstrate a compound rotorcraft configuration that combines the vertical lift capability of the conventional helicopter with the speed capability of a fixed wing aircraft in a sustainable way. In the framework of Clean Sky 2 FRC IADP, the present Call requires Partner(s) (company or consortium) to provide innovative engineering solutions for a HVDC energy storage solution for use on the Tiltrotor NextGen CTR demonstrator. The present document describes also the general requirements that JU shall consider for the selection of the appropriate Partner(s) for this technology development.
2. Scope of work
The main objective of this CfP is to design, develop, manufacture, test and qualify for safety of flight an innovative energy storage system for integration within the aircraft HVDC (+/- 270VDC) electrical power generation and distribution system. This system shall be able to provide the following functions:
Supply power to the aircraft systems when on the ground prior to engine start and with no external power source available.
Provide HVDC power for APU starting on the ground and in flight.
Provide time limited emergency power to the essential loads following the main generation system failure and prior to APU start.
Control the recharge of the system in flight or on the ground when supplied from the HVDC bus.
Improve network power quality including voltage holdup during high power load switching.
Provide a means of regenerative energy absorption
Supply comprehensive status and BIT data to various aircraft systems. APU Starting
The energy storage solution should consider the worst case APU starting requirement provisionally considered to be:
5 minutes ground operation – 3kW
20 seconds ON (failed APU start) – 15kW peak, 7kW average
20 seconds OFF – 3kW
20 seconds ON (failed APU start) – 15kW peak, 7kW average
20 seconds OFF – 3kW
20 seconds ON (failed APU start) – 15kW peak, 7kW average
20 seconds OFF – 3kW
CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 139 Emergency Operation
During emergency operation the energy storage unit shall be able to supply the aircraft essential loads of 5 kW for a minimum of 15 mins, together with the ability for 3 APU start attempts as per above. Additional intermittent loads of up to 15 kW should also be considered.
The energy storage system should take into account the effects of the environmental conditions expected in service:
Operating temperature range of -55 °C/+55°C;
Soak (non-operating/storage) temperature range of -60°C/+85°C; Operating altitude range of -2000ft/30000ft.
As detailed by DO-311, the energy storage system shall include on-board electronics to support the safe operation of the system, with the ability to automatically isolate itself from the aircraft power bus in the event of a potential ‘unsafe’ condition being detected. Any software or complex hardware within the unit shall be certified to the requirements of DO-178B or DO254 as applicable, at a Design Assurance Level sufficient to meet the safety objectives of the aircraft’s System Safety Assessment. In addition the integrated electronics shall also automatically control the charging rate of the system and provide operational status, and BIT information, including state of charge, via databus and discrete connections.
The detailed requirements and system interfaces with the aircraft and system performance shall be part of dedicated discussion with selected Partner(s), following the signature of dedicated NDA or equivalent commitment. However as a first step of the design process the Partner(s) shall perform a trade study, in association with the TM, to determine the optimal solution to meet the specified requirements. As a minimum, the following shall be considered:
Battery chemistry options available, being cognisant of the aircraft safety requirements whilst minimising weight and space envelope.
The use of a hybrid solution including supercapacitors/ultracapacitors to supply high power transitory loads.
Recharging characteristics, considering both slow and fast charge options.
Operational performance limitations in cold/hot temperatures.
The system shall be designed such that the main functionalities and performance are guaranteed throughout the whole aircraft flight operation, whilst ensuring adequate safety levels are maintained. Consideration needs to be given to the requirement for civil certification, safety, electrical power supply quality, mission reliability and availability, testability and maintainability.
It is extremely important that the operational status of the energy storage system is understood during all the flight phases and operational conditions of the aircraft. Therefore the equipment needs to incorporate extensive health monitoring, including PBIT, CBIT and IBIT, that can be used to optimize maintenance actions and failure detection.
CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 140 Mathematical modelling and simulation tools shall be used from the onset of the design, and throughout the design process, so as to explore system concepts, predict operational behaviour, correct design errors, eliminate prototyping steps and reduce the overall component and system test cycles. These models shall be developed using an electrical simulation tool agreed with by TM.
Qualification activities for the energy storage system shall be conducted to enable experimental flight approval of the equipment for fitment on the prototype Tiltrotor NextGen CTR aircraft. Qualification shall consist of both hardware and software verification, taking into consideration RTCA DO-311, RTCA DO-254, RTCA DO-178 and RTCA DO-160G, to show the correct system performance and functionality in accordance with the appropriate system specifications.
Work Packages and Tasks Tasks
Ref. No. Title - Description Due Date
[T0+mm] T0 Conceptual Design / Trade Study
Review high-level system requirements to provide a definition of the equipment configuration through detailed system requirements and appropriate trade studies.
T0+3
T1 Preliminary Design
Development of the Energy Storage system configuration and support of Preliminary Design Review.
T0+6
T2 System Modeling
Definition and development of detailed simulation models and analysis tools to validate specific functions and requirements
T0+12
T3 Detail design
Continued design and development of the system leading to CDR when the equipment design is ready for manufacture.
T0+18
T4 Prototype Manufacture & Testing
The manufacture and test of a fully representative prototype/rig units.
T0+24 T5 Test Readiness
Agreement of qualification test procedures and support to Test Readiness Review for EFA qualification.
T0+36
T6 EFA Qualification
EFA qualification testing (environmental and functional qualification of HW, formal SW testing and qualification). Manufacturing of EFA flight- worthy units. Preparation of Qualification Test Reports and Declaration of Design and Performances (DDP) to allow experimental flight trials on the demonstrator aircraft.
T0+42
T7 Support to aircraft installation
Support to integration into the aircraft by TM, required flight activities and continued airworthiness
CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 141
3. Major deliverables/ Milestones and schedule (estimate)
Deliverables
Ref. No. Title - Description Type Due Date
[T0+mm]
D.1 Initial System Definition / Trade Studies R T0+3
D.2 Configuration development and Preliminary Design Review deliverables
R / RM T0+6 D.3 Detailed HW and SW design, Critical Design Review deliverables R / RM T0+18 D.4 Fully representative rig units provided (3 off) D T0+24 D.5 Technical documentation supporting TRR, Qualification Test Plan
and Procedures
R T0+36
D.6 Qualification Test Reports, EFA DDP R T0+42
D.7 EFA shipset and spare units D T0+42
D.8 Amended design documents according to flight trials results R T0+60 *Type: R: Report - RM: Review Meeting - D: Delivery of hardware/software
Milestones (when appropriate)
Ref. No. Title – Description Type Due Date
[T0+mm]
M1 System Requirement Review RM T0+3
M2 Preliminary Design Review RM T0+6
M3 Critical Design Review RM T0+18
M4 Test Readiness Review RM T0+36
M5 Experimental Flight Approval R / D T0+42
*Type: R: Report - RM: Review Meeting - D: Delivery of hardware/software
4. Special skills, Capabilities, Certification expected from the Applicant(s)
As a general remark, it is highly recommended that the proposed technologies have at least TRL 4 at T0. Moreover, the Applicant(s) shall own the following pedigree and special skills:
Compliance to SAE AS9100.
Experience of aeronautic rules, certification processes and quality requirements.
Experience in design, validation, manufacturing and environmental/functional qualification of airborne equipments, according to RTCA-DO-160, RTCA-DO-178 and RTCA-DO-254 (or other civil or military equivalent standards) for safety critical equipments.
Familiarity with EMI compatibility issues: capacity to design complex electronic HW in compliance with EMC guidelines, and experience in performing EMC justification analyses and experimental
CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 142 assessments according to RTCA-D0-160, EUROCAE ED-107/ARP-5583, ED-81/ARP-5413 and ED- 84/ARP-5412 or equivalent civil or military standards.
Experience in research, development and manufacturing (or integration) in high voltage rechargeable batteries including the requirement to show compliance with the applicable aerospace standards.
Well proven engineering and quality procedures capable to produce the necessary documentation and means of compliance to achieve the “Safety of Flight” with the applicable Airworthiness Authorities (FAA, EASA, etc.).
Design Organization Approval (DOA) desirable.
Experience in Safety assessment process according to SAE-ARP-4754 and SAE-ARP-4761 standards, willingness to interact closely with TM safety specialists in order to produce the necessary outputs (safety and reliability reports and fault trees/analyses).
Shape, component design and structural analysis using CATIA v5 and NASTRAN, or compatible SW tools.
Capacity to optimize the HW and SW design, to model mathematically/numerically complex mechatronic systems with suitable simulation tools (Matlab/Simulink, Dymola/Modelica, etc.) and to analyze both simulation and experimental results to ensure that the various required performance goals are met.
Capacity to repair “in-shop” equipment due to manufacturing deviations.
Detailed Quality Assurance Requirements for Supplier will be provided to the selected Partner(s) following the signature of dedicated NDA or equivalent commitment.
5. Abbreviations
APU Auxiliary Power Unit BIT Built In Test
CDR Critical Design Review CBIT Continuous Built In Test
CTR Civil Tilt Rotor CS2 Clean Sky 2
DC Direct Current
DDP Declaration of Design and Performance DMU Digital Mock Up
DOA Design Organization Approval EFA Experimental Flight Approval EMC Electro-Magnetic Compatibility
EMI Electro-Magnetic Interference FRC Fast RotorCraft
HVDC High Voltage Direct Current HW Hardware
CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 143 IADP Innovative Aircraft Demonstrator Platform
IBIT Initiated Built In Test
MTBO Mean Time Between Overhaul NDA Non Disclosure Agreement NGCTR Next Generation Civil TiltRotor
PBIT Power Up Built In Test PDR Preliminary Design Review SRR System Requirement Review
SW Software TBC To Be Confirmed TBD TM To Be Defined Topic Manager
TRL Technology Readiness Level TRR Test Readiness Review
CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 144
III.
Innovative Fire Extinguisher System for Next Generation Civil Tilt Rotor
Type of action (RIA or IA) IA
Programme Area FRC– WP 1 [NextGenCTR Demonstrator Tiltrotor] Joint Technical Programme (JTP) Ref. JTP V5
Indicative Funding Topic Value (in k€) 1300 k€ Type of agreement Implementation Agreement Duration of the action (in Months) 40 months Indicative Start
Date22
Q2 2017
Identification Title
JTI-CS2-2016-CFP04-FRC-01-13 Innovative Fire Extinguisher System for Next Generation Civil Tilt Rotor
Short description (3 lines)
The present activity involves the design, development, manufacture, testing, validation and full flight qualification of an unharmful, eco-friendly, low weight and pyrotechnics-free fire extinguisher system for Designated Fire Zone on Next Generation Civil Tilt Rotor applications.
CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 145
1. Background
In the framework of Clean Sky 2 FRC IADP, the present Call requires Partner(s) (company or consortium) to design, develop, manufacture, test and validate a new generation of fire extinguishing system for the NGCTR program.
2. Scope of work
In the frame of the CleanSky2 – Next Generation Civil Tilt Rotor project, this Call is requiring Partner(s) to perform the design, development and validation activities necessary to achieve the full qualification for experimetal flight activities of an innovative fire exinguishing system for aircraft Designated Fire Zone(s). In particular, the next generation fire exinguishing system shall achieve same or better efficiency and effectiveness of typical halon-based systems fire suppression capabilties, and be:
Eco-friendly;
Unharmful;
Lightweight;
Non-corrosive;
Pyrotechnic cartridge-free;
Long shelf life;
Low maintenance;
Compatible with NGCTR aircraft attributes definition (e.g.: EMI/EMC requirements, vibratory environment, etc..).
A trade off between suitable technologies shall be performed in order to identify the appropriate solution for the NGCTR according to the above performance objectives.
The selected technology shall be then qualified for the installation on NGCTR DFZs as per DO-160 rotorcraft environmental requirements, and shall ensure a mean to identify the system operability before take-off and throughout the flight operations under all foreseable operating conditions, such as, but not limited to:
Exposure to harsh environment;
Rain, snow and icing conditions;
Altitude envelope of -2000ft / 30000ft;
Storage temeprature of -60°C / +85°C;
Operating temperature of -55°C / +120°C (as a minimum).
Following the design phase, a dedicated development and qualification process supported by appropriate testing campaign on fire rig test bench rpresentative of actual aircraft DFZs, as defined by FHD, shall be performed to achieve Experimental Flight Approval (EFA) with EASA.
CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 146 At the end of the design and development phase, all the evidences necessary to achieve system EFA qualification shall be produced and provided to FHD, together with shipsets and spare parts for flight test activity on NGCTR.
Support to validate the system installation and effectiveness in flight shall be provided as well.
Additional evidences to successfully complete the full flight qualification process and issuance of relevant DDP can be obtained and documented in parallel to the NGCTR flight test activities.
Tasks
Ref. No. Title – Description Due Date
[T0+mm]
T01 System Definition(1) T0
T02 Trade Off Study T0 + 06
T03 Design Architecture Definition T0 + 10
T04 Delivery of Design Documentation T0 + 20
T05 End of Testing Activity for EFA T0 + 32
T06 EFA Qualification Achievement T0 + 40
(1): High-level System Requirements will be provided to the selected Partner(s), following the signature of dedicated NDA or equivalent commitment, as part of the technical discussions between the Partner(s) and AW that will take place after the selection phase (T0).
3. Major deliverables/ Milestones and schedule (estimate)
DeliverablesRef. No. Title - Description Type Due Date
[T0+mm]
D01 Trade Studies Results Report REPORT T0 + 06
D02 Preliminary 3D models and layout drawing CATIA FILES and
DRAWINGS T0 + 10
D04 Qualification program plan (QPP) REPORT T0 + 10
D05 Development test plan (DP) REPORT T0 + 10
D06 Interface Definition Documents REPORT and
CATIA FILES T0 + 10
D07 Preliminary Reliability and FMEA REPORT T0 + 10
D08 Reliability and FMEA REPORT T0 + 20
D09 Failure Modes, Effect and Criticality Analysis (FMECA) REPORT T0 + 20
CS-GB-Written Procedure 2016-09 Amended WP & Budget 2016-2017 147 Deliverables
Ref. No. Title - Description Type Due Date
[T0+mm]
D11 Acceptance Test Procedures (ATP) REPORT T0 + 20
D12 Qualification Test Procedures (QTP) REPORT T0 + 20
D13 Qualification by Similarity and Analysis (QSAR) REPORT T0 + 20 D14 Final 3D models and layout drawing CATIA FILES and
DRAWINGS T0 + 20 D15 Production and Spare units, and relevant Data Conformity
Documentation
HARDWARE and
REPORT T0 + 32
D16 EFA Documentation REPORT T0 + 32
D17 Guidelines on requirements for development of ICA MANUAL T0 + 40 D18 Qualification by Similarity and Analysis (QSAR) REPORT T0 + 40 D19 Acceptance and Qualification Test Reports REPORT T0 + 40 *Type: R: Report - RM: Review Meeting - D: Delivery of hardware/software
Milestones (when appropriate)
Ref. No. Title – Description Type Due Date
[T0+mm]
M01 Kick-off meeting DESIGN REVIEW T0
M02 System Concept Review DESIGN REVIEW T0 + 06
M03 Preliminary Design Review DESIGN REVIEW T0 + 10
M04 Development unit ready to development tests HARDWARE T0 + 14
M05 Critical Design Review DESIGN REVIEW T0 + 22
M06 Equipment Test Readiness Review DESIGN REVIEW T0 + 22
M07 First Article Inspection DOCUMENT T0 + 32
M08 Aircraft Test Readiness Review DESIGN REVIEW T0 + 32 M09 Production units delivered to FHD for flight tests HARDWARE T0 + 32 M10 Experimental Flight Approval (EFA) release DOCUMENT T0 + 40 *Type: R: Report - RM: Review Meeting - D: Delivery of hardware/software