requirements and challenges for functional integration … · requirements and challenges for...

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Requirements and challenges for functional integration on civil transport aircrafts

Presented by

Dipl. Ing. Thomas Kruse, M. Sc., Airframe Design - Research & Technology

September 2013 DLR Wissenschaftstag Braunschweig - Thomas Kruse - Airframe Design R&T

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Air transport today & tomorrow: Airbus today

September 2013

Passenger aircraft (*)

7,128 aircraft delivered

11,570 aircraft ordered

Order backlog of 4,444 civil aircraft

336 customers worldwide

A350 Family

A380 Family

A320 Family

A330 Family

10 Civil models

(*): status end February 2012

DLR Wissenschaftstag Braunschweig - Thomas Kruse - Airframe Design R&T


Air transport today & tomorrow: Airbus today – and also military products

September 2013

Military aircraft

Military aircraft (*)

+ 1,000 Aircraft sold

65 Countries

135 Operators

4,200,000 Flight Hours

(*): status end February 2012



Air travel has proved to be resilient to external shocks

* since 2000

World annual traffic (RPKs - trillions)

Gulf Crisis Oil Crisis Asian Crisis

WTC Attack Oil Crisis SARS

Financial Crisis

+45%

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

1970 1975 1980 1985 1990 1995 2000 2005 2010

GMF 1999 Δ<0.1%



0

2

4

6

8

10

12

1970 1980 1990 2000 2010 2020 2030

0

2

4

6

8

10

12

1970 1980 1990 2000 2010 2020 2030

Air travel remains a growth market

World annual traffic (RPKs - trillions)

20-year world annual traffic growth

4.8% ICAO

total traffic

Airbus

GMF 2011

Air traffic has doubled

every 15 years

Air traffic will double in the next 15 years

September 2013

!



What is the challenge of the future?


The challenge is that the rules have changed!

• -40% in Fuel Burn

• Operational economic two digit

improvement

• Unprecedented levels

of eco-efficiency

• lower value of weight saving

Today

Future Aircraft


The Vision:



Multifunctional Materials

Functional integrated

Design

Merging of System & Structure

New Functions for customer

Deriving the needs for future functional integration



Multifunctional Materials – requirements today


• Airbus needs more from the Material than pure strength per kilogram

• New Opportunities beside the traditional weight to cost challenge

Target for Engineering is not mono-disciplinary

• conductivity, damage tolerance, erosion resistance, vibration, acoustic damping, …

• Composites: additional challenge to be competitive with multifunctionality of metallic materials

• new integrated properties as enabler to integrate future functions (e.g. tuneable stiffness or transparent high strength materials)

Typical additional properties & functions

• Replacement of discrete functional layers (e.g. bronze mesh for lightning strike protection) by integrated functional capabilities

Intrinsic Properties




Design






Integration and combination of Functions


• More complex systems or structural parts are leading to the need of a more integrated overall design concept.

• New Technologies enabling new integrated simplified functions (e.g. piezo-actuators for morphing structures vs. traditional actuator).

• Target: avoidance of duplications, weight optimization & reduction of operating costs, reduction of maintenance afford, simplification of mechanical systems.

Functional integration to create synergies

• Different Components are handled within different Certification Framework (ATA – Split)

• Evaluation of impact on overall requirement communality and corresponding influence on qualification of individual components under the overall merged “requirement umbrella” of a multi-ATA component.

Evaluating the right level of Integration


Integration and combination of Functions

Example: Smart Leading Edge Concepts





Design






Excamples:

• Cables / fiber optics in composites

• Stringers / frames as ducting (air, fuel,…)

• Customized printing of electrics

• Integration of hydraulic reservoir in keelbeam

• SHM



Integrated hydraulic reservoir




• Merging has the highest potential in terms of part count reduction

• most advanced vision: elimination of system brackets and differential system installation

• Target: Utilize all used material for load carrying and system function

• Sensing & Reporting Integration (SHM)

Simplification & weight saving

• Damage tolerant design allows local failure of structural parts.

• New fatigue challenges on Systems (e.g. cables in composite)

• Structural & System integrated repair concepts needed

• Certification cannot be separated for Structure and Systems.

Differences in structure & system philosophy

• Careful tradeoff between integrated and differential Solutions.

• Additional sizing criteria (e.g. Buckling for integrated ducting) can make the business case difficult

Evaluation of overall business case




Design






“Out of the Box” properties, functions and integrated

solutions required to enable the long term vision and to

make it fly!

New Functions for Customer



Conclusion


Roadmap for

Functional Integration

Development of needed

Materials & Properties

Identify potential

integrated functions

Evaluation of optimum

Integration degree

Build common certification approach

(multi-ATA)

Addressing of needed generic Science

Demonstration of secured applicability


Thank you for the attention….


Dipl. Ing. Thomas KRUSE, M.Sc.

Airframe Design - Research & Technology

Phone: +49 40 743 83469

[email protected]

mailto:[email protected]



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