UB2008R

1
UB2008R
Rotorcraft Design Project
Alex Wilkinson
Pete Mitchell, Jeremy Gadfield, Will
Stewart, Matt Hand, Dan Bowles, Helen Rollinson
2
UB2008R Project
Requirement Generation
Architectural Definition Refinement
Component Design Optimisation
Production Integration
Product Verification Certification
3
Project Scope

• 25 of 3rd Year
• 16 weeks

4
Project Scope

• 25 of 3rd Year
• 16 weeks
• 5 teams of 12

5
Project Scope

• 25 of 3rd Year
• 16 weeks
• 5 teams of 12
• Documents Given
• Specifications
• Design Manuals

6
Project Scope

• 25 of 3rd Year
• 16 weeks
• 5 teams of 12
• Documents Given
• Specifications
• Design Manuals
• Support
• Professional
• Academic

7
Timeline
Week

• 1 Market Analysis
• Competitors
• Key Design Drivers

8
Timeline
Week

• 1 Market Analysis
• 5 Concept Selection

9
Timeline
Week
Rotors

• 1 Market Analysis
• 5 Concept Selection
• 5 Specialisation

Chief Designers Group
HR
WS
JG
WC
JB
AW DB
PM
MH
JC
Structures
Avionics Systems
CH
WL
Engines Drivetrain
10
Timeline
Week

• 1 Market Analysis
• 5 Concept Selection
• 5 Specialisation
• 7 Initial Sizing

11
Timeline
Week

• 1 Market Analysis
• 5 Concept Selection
• 5 Specialisation
• 7 Initial Sizing

PDR Wk 8
12
Timeline
Week

• 1 Market Analysis
• 5 Concept Selection
• 5 Specialisation
• 7 Initial Sizing
• Iterations
• Final Design

PDR Wk 8
14
15
13
Timeline
Week

• 1 Market Analysis
• 5 Concept Selection
• 5 Specialisation
• 7 Initial Sizing
• Iterations
• Final Design

PDR Wk 8
14
15
14
Timeline
Week

• 1 Market Analysis
• 5 Concept Selection
• 5 Specialisation
• 7 Initial Sizing
• Iterations
• Final Design

PDR Wk 8
14
15
FDR Wk 16
15
UB2008R
Rotorcraft Design Project
Alex Wilkinson
Pete Mitchell, Jeremy Gadfield, Will
Stewart, Matt Hand, Dan Bowles, Helen Rollinson
16
Kingfisher
Rotorcraft Design Project
Alex Wilkinson
Pete Mitchell, Jeremy Gadfield, Will
Stewart, Matt Hand, Dan Bowles, Helen Rollinson
17
Market Analysis

• Global Overview
• Markets in Detail
• Operators
• Competitors

18
Global Overview
19
Markets in Detail

• UK SAR
• Oilrig Crew change

news.bbc.co.uk
20
Markets in Detail

• UK SAR
• Oilrig Crew change

21
Operators

• CHC
• Bond
• Bristow

22
Operators

• CHC
• Bond
• Bristow

23
Operators

• CHC
• Bond
• Bristow

24
Competitors

• S-92 Helibus
• EC225 Super Puma
• AW139

25
Competitors

• S-92 Helibus
• EC225 Super Puma
• AW139

26
Competitors

• S-92 Helibus
• EC225 Super Puma
• AW139

27
Weight Breakdowns
28
Performance
29
S-92 Cabin Layout
www.sikorsky.com
30
EC225 Cabin Layout
www.eurocopter.com
31
S-92 Cost Breakdown
32
Conclusions

• Main Competitors
• S-92
• EC225
• Smaller Reference
• AW139
• Key Design Drivers
• Speed
• Payload/Range
• ECS

33
Concept Selection

• Initial Brainstorm
• Down-select
• Qualitative
• Quantitative
• Project Risk

34
Initial Brainstorm
www.worldskycat.com
www.boeing.com
www.sikorsky.com
35
Qualitative Down-select
36
Quantitative Down-select
37
Final Risk Down-select
Impact Impact Impact Impact Impact
1 2 3 4 5
Likelihood 5
Likelihood 4
Likelihood 3
Likelihood 2 A
Likelihood 1 B C,D E
Impact Impact Impact Impact Impact
1 2 3 4 5
Likelihood 5 Y Z
Likelihood 4 X V
Likelihood 3 W U
Likelihood 2
Likelihood 1
Single Main Rotor
Tilt Wing
38
Tail Rotor Selection

• Conventional

39
Tail Rotor Selection

• Conventional
• Ducted fan
• Lower noise
• Improved safety

40
Tail Rotor Selection

• Conventional
• Ducted fan
• Lower noise
• Improved safety
• Coanda boom
• As ducted fan
• Thrust compounding?

41
Tail Rotor Selection
Ducted Fan

• Conventional
• Ducted fan
• Lower noise
• Improved safety
• Coanda boom
• As ducted fan
• Thrust compounding?

B
C,D A

Likelihood
Coanda Boom


Y,Z W
X

Impact
Likelihood
Impact
42
Tail Rotor Selection
Ducted Fan

• Conventional
• Ducted fan
• Lower noise
• Improved safety
• Coantail
• As ducted fan
• Thrust compounding?

B
C,D A

Likelihood
Coantail


Y,Z W
X

Impact
Likelihood
Impact
43
Initial Sizing
44
Final Design
45
Final Design

• General Characteristics

46
Final Design

• General Characteristics
• Design Breakdown

47
Final Design

• General Characteristics
• Design Breakdown
• Performance
• Spec Compliance

48
Final Design

• General Characteristics
• Design Breakdown
• Performance
• Spec Compliance
• Project Risks
• Growth Plan

49
General Characteristics

• Single Aircraft, Adaptable roles
• MAUM
• Rotor Diameter
• Disc Loading

• 14 Civilian seats, 12 seat SAR capacity
• 9600kg, 21000lb
• 18.0m, 59ft
• 37.6kg/m2, 7.71lb/ft2

50
Internal Design
51
Internal Design
Requirement Specification Kingfisher
Cabin Height 1830mm (72) 2030mm (80)
Seat Pitch 710mm (28) 710mm (28)
Aisle Width 380mm (15) 410mm (16)
Civilian Variant considered as it represents the
critical design specification
52
Structural Design
53
Composite Material
Titanium/Carbon Fibre

• High Specific strength
• Good Fatigue resistance
• Corrosion resistance
• High Natural damping

Kevlar/Carbon Fibre
GFRP
Kevlar/Nomex/Carbon Fibre
54
Composite Material
Metallic Style Architecture
Composite Style Architecture
55
Structural Architecture

• Sizing cases
• 12g crash
• 3.5g manoeuvre

56
Engine and Gearbox
57
Engine Choice

• 2 x R-R RTM322-01/9
• Removable VortexSeparator
• 30 minute takeoff rating
• Initial upgrade to 01/9a
• 7 power increase

58
Engine Integration

• Engines
• Roof mounted
• Aft of hub
• APU
• Aft
• Between engines
• Smaller gearbox
• Angled exhausts

59
Drive Train

• 5 stage 921
• 2 bevel
• 1 helical
• 2 epicyclic
• Magnesium alloy casing
• Designed for first engine upgrade

60
Drive Train

• Integrated accessory drives
• Placed forwards
• Direct Coantail drive
• No additional gearboxes

61
Main Rotor System
62
Blade Sections

• Thin tip (6 t/c)
• Advancing blade high drag rise Mach No.
• High lift mid (9 t/c)
• Good all round performance
• Reflex camber inboard (10 t/c)
• Reduced pitching moment

63
Blade Features
30 degree sweep
12 degrees linear twist
64
Blade Construction
Titanium leading edge De-Icing mat
Carbon fibre skins spars
High density foam
Honeycomb support structure
65
Blade Geometry

• Radius 9m, 29.5ft
• O 226 rpm
• VTIP 213m/s, 699ft/s
• Chord 0.55m, 1.8ft

66
Hinge Design

• Flap _at_ 5
• Lag _at_ 5
• Feather _at_ 8
• Elastomeric hinges
• Elastomeric lag damper

67
Tail Design
68
Coantail Anti-torque
Main Rotor Downwash
45 kg/s
15 kg/s
30 kg/s
69
Coantail Anti-torque
70
Coantail Key Benefits

• Increased safety in confined spaces
• FOD resistance
• Elimination of potential tail rotor vortex ring
  state
• Elimination of common failure points

71
Avionics and Systems
72
Fuel System Design

• Tanks
• 2 under floor (main)
• 1 rear fuselage
• 2 sponson
• 1 optional ferry
• Main tanks feed
• Engines
• APU

73
Environmental Control System

• De-humidified cooling
• Avionics
• Cabin
• 24.3kW
• All electric

74
Health and Usage Monitoring
HUMS functionality contained in single accessible
LRU
75
Core Service Systems Electrical
76
Core Service Systems - Hydraulics
77
Core Service Systems IMA
78
Fly By Wire Control System
79
Operational Performance
80
Operational Performance

• Flight Envelope
• Dual Role
• Civilian/Paramilitary Transport
• Specified mission
• Actual performance
• Search and Rescue
• Specified mission
• Actual performance

81
Flight Envelope
(MAUW, ISA)
Rotor Limit
Engine Limit
82
C/PT Design Mission

• Range 300nm
• Block Time 2.25hrs

(ISA20)
83
C/PT Performance

• Range 300nm or 470nm
• Block Time 2.25hrs 3.47hrs
• Block Fuel 1253kg 1880kg

78 kts
140 kts
4000ft
3000ft
5 min HOGE
1.5 min HOGE
(ISA20)
300 nm
(20 min)
84
C/PT Performance
85
C/PT Performance
86
SAR Design Mission

• Radius of Action 200nm
• Time on Station 15min

(ISA20)
87
SAR Performance

• Radius of Action 200nm, 222nm or 203nm
• Time on Station 15min 15min 30min

(ISA20)
88
SAR Performance
89
Operating Economics COC/hour
All US2008

• Major saving points
• More efficient engine
• Lower maintenance
• Coantail
• Lower rotor maintenance

Maintenance 650
Crew 225
Fuel 397 (2.50/gallon)
90
Project Risk, Profit Growth
91
Project Risk Management

• Coantail
• Composites
• Design
• Manufacturing
• Gearbox
• Reliability
• Materials

92
Coantail

• Yaw rate responsiveness
• Scalability
• NOTAR is subject to patents
• Partnership

www.mdhelicopters.com
93
Composites Design

• Composite main load path
• Metallic architecture
• Lay up manipulation
• Accommodate stress concentrations
• Taylor fibre direction
• Match main load paths

94
Composites Manufacture

• Risk sharing
• Industrial partner
• Outside specialist knowledge
• Limit manufacturing complexity
• Careful design

95
Gearbox

• 5 stages
• More parts to go wrong!
• MRGB magnesium casing
• Salt water corrosion

96
Cumulative Cash Flow
1000
600
(M)
0
-400
2024
2040
2008
2015 (in service)
97
Future Growth

• Structures
• Growth built-in
• Gearbox
• Stressed for first engine upgrade
• Engines
• First upgrade selected
• Advanced rotors
• Avionic upgrades

98
And Finally
99
Kingfisher
Rotorcraft Design Project
Alex Wilkinson
Pete Mitchell, Jeremy Gadfield, Will
Stewart, Matt Hand, Dan Bowles, Helen Rollinson
100
(No Transcript)