Large Aircraft Research Articles

Heuristic approaches for a multi-mode resource availability cost problem in aircraft manufacturing

A multi-mode time-constrained project scheduling problem with generalized temporal constraints arising in aircraft manufacturing is studied in the paper. We propose a priority rule-based heuristic (PRH) and a biased random-key genetic algorithm (BRKGA) for its solution. A serial generation scheme (SGS) is used for computing schedules from a priority order of the tasks with given resource capacities and mode assignments. The SGS cannot guarantee that the maximum project duration and maximum time lags are respected. Starting with the highest possible resource capacities, the PRH performs the SGS in a repeated manner, reducing the least used resource capacity by one unit until the schedule becomes infeasible. Different priority rules are used for determining both mode assignments and task priority orders. We encode these two decisions as well as the resource capacities in the BRKGA and apply the SGS for decoding. Project duration and maximum time lag violations are penalized in the fitness function. Extensive computational experiments based on problem instances motivated by settings found at a large aircraft manufacturer demonstrate that the BRKGA outperforms the PRH under almost all experimental conditions, especially for problem instances with more complex networks and shorter maximum project durations.

Exploring airborne wind energy: A comparative study and the potential for implementation in Jordan

Airborne Wind Energy (AWE) technologies are fundamentally new and different from traditional wind turbines which have a tower and blades, (AWE) has other unique features regarding cost, transportation, installation, and even the method of generation.(Weber et al., 2019.) Many companies across the globe are developing large kites and aircraft to capture wind energy high up in the sky, these kites and aircraft can reach an altitude up to half a mile above the ground, (Gordon 2023) The generating stations are either based on the ground or airborne, so what are the differences between all of them and which is better? Wind energy has emerged as a promising renewable energy source worldwide, and Jordan is no exception. With its vast potential for harnessing wind power, Jordan has been actively exploring the possibilities of integrating wind energy into its energy mix. For that providing a wind distribution map for all Jordan governorates, to know the possibility of implementing the airborne energy project in Jordan.

Critical machining parameters for large aircraft casing production considering the influence of clamping systems

AbstractIn recent years, there has been a notable initiation or acceleration in the production of new aeronautical engines. This surge is coupled with a global commitment to reducing emissions and mitigating noise generated by gas turbines used in aeronautical applications. A critical component in this context is the aeronautical casing. The manufacturing process is intricate and time-consuming, compounded by the complexity of the clamping system, which poses a significant challenge to productivity. This study undertakes a comprehensive analysis of the critical variables essential for the optimal manufacturing of a zero-defects large-scale casing. The examination encompasses design criteria, raw materials, constraints related to clamping systems and tooling, and process monitoring. Ultimately, the exploration extends to the examination of more sustainable manufacturing techniques. To facilitate this, a case study involving the fabrication of a life-size aeronautical casing is undertaken.

Assessing the Impact of Hybrid Propulsion Systems on the Range and Efficiency of Aircraft

The demand for aviation continues to grow, posing issues in terms of fuel consumption, environmental effect, and operational efficiency. In addition, the COVID-19 pandemic has also highlighted the need for sustainable solutions in the aviation sector. To address these issues, hybrid electric propulsion systems have emerged as a potential option. Hybrid electric propulsion systems have the potential to improve airplane performance while reducing environmental impact. This article looks into the effects of hybrid electric propulsion technologies on optimal aircraft range. The study looks at aviation's environmental impact, several hybrid aircraft prototypes, and battery capacity and density challenges. Fuel usage increases in proportion to the weight of the aircraft. As a result, the range is shorter. In modern technology, along with to the added weight of batteries used as energy storage in hybrid propulsion systems, there are low battery densities and capacities. When the researches were reviewed, it was discovered that overcoming these limitations was easier for small aircraft and more difficult for large aircraft. As a consequence of the studies and research conducted, the development of light and reliable batteries with high energy density and capacity would expand the range of hybrid aircraft and allow them to be used more efficiently over long distances.

Research on Large Hybrid Electric Aircraft Based on Battery and Turbine-Electric

Hybrid electric aircraft use traditional engine and electric propulsion combinations to optimize aircraft architecture, improve propulsion efficiency, and reduce fuel consumption. As a new technology, the fuel and energy consumption calculation of hybrid electric aircraft is more complicated than traditional aircraft due to the usage of different energy forms. The purpose of this paper is to develop the analytical method for fuel and energy consumption for hybrid electric aircraft. This paper summarizes the working principle of hybrid electric aircraft, including the system architecture and power conversion mechanism. The calculation of fuel and energy consumption for hybrid electric aircraft is carried out in detail. In order to evaluate large hybrid electric aircraft, the architecture, based on energy flow, is established, and turbofan engine, electrical system, electric duct fan, and aerodynamic model characteristics are established. With a single-aisle aircraft as an example, the fuel and energy consumption under the 800 nautical mile range is performed. It shows that fuel consumption can be reduced by 10% and energy consumption by 4.7% compared with a traditional aircraft. The effects of different range and battery ratios are analyzed. The payload range for the hybrid electric aircraft is analyzed. The results show that even though the hybrid electric aircraft reduces the payload and range, it can significantly reduce fuel and energy consumption.

Analysis and suppression research of high lift device noise based on large aeroacoustic wind tunnel test

The exterior noise of large aircrafts is an important aspect for the airworthiness certification. The high-lift device is one of the key noise sources for large aircrafts, thus the analysis and reduction of high-lift device noise is important and meaningful. Based on the 5.5m×4.0m Aeroacoustic Wind Tunnel and a half model for the aeroacoustic study of large scale aircrafts, the high-lift device noise properties were studied experimentally. First, the experimental platform, the test model, the test system and noise reduction design were introduced. Then, based on the experimental results, the noise characteristics of the high-lift devices were analyzed. The effects on the noise from the angle of attack and the wind speed were compared. The effects on the high-lift device noise from the noise reduction design on slat and flap were investigated. The results show that, the high-lift device noise has a broad frequency spectrum, with some peak frequency components. As the angle of attack is increased, the noise of the model is generally increased in the medium to high frequency range. With the wind speed increased, the noise is increased dramatically, and the frequency spectra keep a good similarity. The peak noise is suppressed by the noise reduction design.

Large commercial business aircraft acoustic design with SEA

As air travel becomes more frequent, customers are demanding a quieter cabin environment. Over the past two decades, Gulfstream has developed a suite of predictive tools based on Statistical Energy Analysis (SEA) to create a quiet cabin on business aircraft. This paper discusses the most recent collaboration between Gulfstream and Jet Aviation to develop an acoustic design for a large commercial business aircraft. SEA analysis played a key role to identify the risks, determine the driving mechanisms, and develop solutions to meet the established target. Besides SEA model development and analysis, this paper will also discuss some unique challenges to this aircraft and some innovations that were developed to mitigate them. One year after the acoustic design was released, flight test data on the completed aircraft confirmed the success of the acoustic design as the quietest cabin to date on the specific aircraft type.

Adaptive positioning of large-scale aircraft components using a simplified image-based visual servoing via online measurement of ball-head center

In digital alignment systems, ensuring fast and accurate alignment between the ball head on large aircraft components and the ball socket of the positioner is the key to aircraft assembly efficiency and quality. Image-based visual servoing is one of the most advanced techniques with high efficiency and positioning accuracy, but it does not account for measuring the ball-head position. Moreover, variable target positions, similar feature interference, and poor lighting conditions pose great challenges to the fast and robust visual measurement of ball-head position. Hence, an online visual measurement method is introduced to measure the absolute position of the ball head in real time. An adaptive region of interest extraction algorithm and an improved edge following method are introduced to extract the elliptical contour from the ball-head image, and ellipse detection is achieved through a simple triplet selection algorithm. A geometric model based on the perspective projection of the sphere is established for estimating the ball-head center. Then, the simplified image-based visual servoing method is developed by constantizing the image Jacobian matrix. Next, an adaptive positioning method of large-scale aircraft components with multiple ball heads is proposed from a holistic perspective. Finally, experiments show that the final positioning accuracy of each ball head in the X/Y plane is less than ± 0.05 mm, with an efficiency almost ten times that of the conventional method. After adaptive adjustment, the position and angle errors of the simulated component are reduced within 0.6 mm and 0.3°, respectively.

Aircraft Electrothermal Pulse Deicing

Abstract Ice formation and accumulation on aircraft is a major problem in aviation. Icing is directly responsible for aircraft incidents, limiting the safety of air travel and requiring expensive, and sometimes ineffective deicing strategies. Furthermore, electrification of aircraft platforms leads to difficulties with integration of legacy deicing methods such as pneumatic boots. In this work, we study electrothermal pulse deicing capable of efficient and rapid removal of ice from aircraft wings. The pulse approach enables the efficient melting of a thin (<100 μm) ice layer on the wing surface to limit parasitic heat losses. Only the interface is melted, with the rest of the ice sliding on the melt lubrication layer due to aerodynamic forces. To study pulse deicing, we developed a transient thermal-hydrodynamic numerical model that accounts for multiple phases and materials, specific and latent heating effects, melt layer hydrodynamics, as well as boundary layer effects. To identify optimal deicing strategies, we use our model to study the effects of heater thickness (50 μm < th < 1 mm), substrate electrical insulation thickness (10 μm < ti < 1 mm), pulse duration (0.4 s < Δtpulse < 4.5 s), and pulse energy. Optimum operating points are identified for large (Boeing-747), midsize (Embraer-E175), and small (Cessna-172) aircraft. The scale-dependent thermal-hydraulic model results are used to estimate input conditions required for deicing and integrated into an electrical model considering energy storage, power electronics, integration, and layout, to achieve overall volumetric and gravimetric power density optimization.

Global calibration method for multi-view-based vibration measurement of large structures

A multi-view global calibration method is proposed to overcome the limitations of overlapping regions in multi-view structural vibration measurement. This method establishes a mapping relationship from image points to experimental model points at the outset of vibration measurement, enabling a one-time global calibration of multi-view vibration response data. Furthermore, an image point detection method based on shape-function matching is designed to improve global calibration accuracy. Experimental results demonstrate that the proposed method excels in point detection and global calibration. Finally, the feasibility of this method is validated through vibration experiments on large aircraft fuselage structures.

Digital twin technology facilitates precision improvement in complex product assembly: A progressive deduction method of data-driven tolerance allocation

Advancements in aerospace technology have significantly increased the demands on assembly precision, particularly for large aircraft models. These developments require sub-millimeter precision to be achieved in assembly, posing new challenges for conventional tolerance allocation methods, which rely heavily on theoretical models and static simulations. To address these limitations, this paper proposes a digital twin system for online deduction of assembly tolerances (DTS-ODTA) using point cloud registration and free-form deformation (FFD). The proposed method includes three key innovations. First, a digital twin (DT)-based assembly process control framework supports the simulation of assembly deviations by integrating virtual and actual data. Second, a data-driven method models the actual surface shapes, ensuring synchronization between physical and digital states. Third, a progressive deduction strategy for tolerance allocation combines virtual and actual information, providing effective inputs for real-time assembly process control. This approach was validated through an industrial case study, achieving a prediction accuracy of 91.64 % for assembly precision and effectively preventing out-of-tolerance issues during product assembly. By promptly identifying and addressing potential assembly discrepancies, this method enhances the overall assembly quality and provides critical support for design decisions. In summary, this paper introduces a novel DT-based tolerance allocation method that shifts from traditional open-loop design to closed-loop control, thereby meeting the high precision demands of modern aerospace manufacturing.

Phased Array Ultrasonic Inspection of Composite Fuselage Panel

Abstract The composite fuselage panel is a crucial component in large civil aircraft, necessitating higher detection rates and efficiency. Phased array ultrasonic testing can enhance the efficiency and defect detection rate; however, it is essential to consider the structural characteristics of the fuselage to ensure reliable identification of design defects. Based on the material properties, structural features, and defect detection requirements of composite fuselage panels, a test block reflecting their characteristics was designed and fabricated with various prefabricated defects. Ultrasonic phased array method was employed for a series of testing parameter optimization experiments and defect detectability analysis. The detected flaws were quantitatively analyzed and compared with those obtained using conventional ultrasonic automatic scanning techniques to validate the effectiveness of the developed ultrasonic phased array method. The feasibility of utilizing phased array ultrasonics for nondestructive evaluation of wide-body airliner composite fuselage panels is confirmed.

Oxygen accumulation and associated dangers in rescue helicopters

BackgroundAt the time of the COVID-19 pandemic, devastating incidents increased due to frequent oxygen administration to patients. The dangers associated with the use of oxygen, especially through local enrichments and formation of “oxygen clouds”, have been well understood for years. Nevertheless, dramatic incidents continue to occur, since fire hazard increases exponentially with oxygen concentrations above 23%. Rescue helicopters are at a particular high risk, because of technical reasons such as oxygen use in a very small space, surrounded by kerosene lines, electronic relays and extremely hot surfaces.MethodsIn this study three different sized rescue helicopter models (Airbus H135, H145 and MD902) were examined. Oxygen enrichment in the cabin was measured with an oxymeter during a delivery rate of 15 l/min constant flow for 60 min. Furthermore, the clearance of the enriched atmosphere was tested in different situations and with different ventilation methods. To make the airflow visible, a fog machine was used to fill the helicopter cabin.ResultsOxygen accumulation above 21% was detected in every helicopter. After 10–15 min, the critical 23% threshold was exceeded in all three aircrafts. The highest concentration was detected in the smallest machine (MD902) after 60 min with 27.4%. Moreover, oxygen clouds persisted in the rear and the bottom of the aircrafts, even when the front doors were opened. This was most pronounced in the largest aircraft, the H145 from Airbus Helicopters. Complete and rapid removal of elevated oxygen concentrations was achieved only by cross-ventilation within 1 min.ConclusionsOxygen should be handled with particular care in rescue helicopters. Adapted checklists and precautions can help to prevent oxygen accumulation, and thus, fatal incidents. To our knowledge, this is the first study, which analyzed oxygen concentrations in different settings in rescue helicopters.

Team personality characteristics and performance in a simulated largeaircraft instrument control task

We investigated the relationship between personality characteristics and performance on a simulated large-aircraft instrument control task. The sample comprised 155 undergraduates in China, who completed the Cattell Sixteen Personality Factor Questionnaire to assess personality characteristics, and were randomly allocated to one of 31 teams of five people. We used multiple regression analysis to establish a predictive model of team performance based on team personality elevation and team personality diversity integration models. The results showed that when the team personality elevation integration was used as the independent variable, an increase in rule consciousness led to improvement in team performance, whereas an increase in vigilance, dominance, and social boldness led to a deterioration in team performance. When team personality diversity integration was used as the independent variable, an increase in warmth and openness to change led to improvement in team performance, and an increase in sensitivity led to deterioration in team performance. The simulation task designed in this study provides a specific tool for research involving flight crews on large aircraft. The findings provide a theoretical reference for optimum allocation of flight crews.

Revealing failure law of single-track traffic-loaded concrete airport pavement from a thermodynamic perspective

ABSTRACT With the growth of global air traffic and the popularity of large aircraft, the design and life prediction of airport pavements have received increasing attention from scholars. However, concrete airport pavement evaluations based on cracking patterns are often uncertain. A thermodynamic-based failure analysis of the FAA Phase 4 Construction Cycle 8 (CC8) strength and fatigue traffic test is conducted in this work to investigate the failure laws of airport concrete pavements. First, this work equates concrete pavement failure to a phase transition. It converts strain data from full-scale traffic tests into state variables. Based on the Wilson theory definition of phase transition, network-free renormalisation is applied to reveal the concrete slab stressing state evolution and phase transition features. The clustering algorithm that utilises the attractor effect of phase transition points determines characteristic points. In summary, this work applies network-free renormalisation and clustering algorithms to reveal robust concrete pavement failure points, which can provide a reference for airport pavement design, assessment, and failure warning. Furthermore, this work further validates the stressing state theory and network-free renormalisation under high-speed time-varying conditions.

Precise Motion Compensation of Multi-Rotor UAV-Borne SAR Based on Improved PTA

In recent years, with the miniaturization of high-precision position and orientation systems (POS), precise motion errors during SAR data collection can be calculated based on high-precision POS. However, compensating for these errors remains a significant challenge for multi-rotor UAV-borne SAR systems. Compared with large aircrafts, multi-rotor UAVs are lighter, slower, have more complex flight trajectories, and have larger squint angles, which result in significant differences in motion errors between building targets and ground targets. If the motion compensation is based on ground elevation, the motion error of the ground target will be fully compensated, but the building target will still have a large residual error; as a result, although the ground targets can be well-focused, the building targets may be severely defocused. Therefore, it is necessary to further compensate for the residual motion error of building targets based on the actual elevation on the SAR image. However, uncompensated errors will affect the time–frequency relationship; furthermore, the ω-k algorithm will further change these errors, resulting in errors in SAR images becoming even more complex and difficult to compensate for. To solve this problem, this paper proposes a novel improved precise topography and aperture-dependent (PTA) method that can precisely compensate for motion errors in the UAV-borne SAR system. After motion compensation and imaging processing based on ground elevation, a secondary focus is applied to defocused buildings. The improved PTA fully considers the coupling of the residual error with the time–frequency relationship and ω-k algorithm, and the precise errors in the two-dimensional frequency domain are determined through numerical calculations without any approximations. Simulation and actual data processing verify the effectiveness of the method, and the experimental results show that the proposed method in this paper is better than the traditional method.

Improved Multi-Body Dynamic Simulation of Landing Gear Drop Test Incorporating Structural Flexibility and Bearing Contact

The investigation of multi-body dynamics (MBD) modeling for landing gear drop tests is a hot topic in the realm of landing gear design. The current results were primarily focused on the multi-rigid body simulation or a simple multi-flexible body simulation, with little regard for the correctness of longitudinal loads and their experimental confirmation, particularly wheel–axle loads. Based on a genuine oleo-pneumatic landing gear drop test of a large civil aircraft, enhanced multi-body dynamics simulation research is carried out, considering the structural flexibility and bearing support by adopting flexible multi-bodies modeling and rigid-flex coupling contacts. When compared to the test data, which purposefully measured the longitudinal wheel–axle loads, the simulation results show that the loads, shock absorber compression, and shock absorber inner pressures are all within good agreement. Furthermore, the influence of structural stiffness and bearing contact was investigated by adjusting the model settings to confirm their importance.

Comprehensive crashworthiness simulation analysis of a large aircraft fuselage barrel section in various crash scenarios

To utilize computational techniques in investigate and evaluate the crashworthiness of typical fuselage section of a large transport aircraft in various crash scenarios, the finite element model of fuselage section was modeled and validated based on the vertical drop test of fuselage section at 6.02 m/s. The crash simulation analysis in various crash scenarios (such as concrete ground, soft soil grounds and water) were further conducted based on the validated model of fuselage section, and the crash response characteristics (deformation and failure mode, acceleration response and occupant injury risk, energy-absorbing characteristics) were analyzed and compared. The results show that the finite element model can accurately simulate the unrolling failure mode (three plastic hinges failure mode) of fuselage section and the failure of the connections of cargo floor crossbeams and fuselage frames, and it is in good agreement with the test results in terms of impact velocity and acceleration response. In the case of various soft soil grounds impact scenarios, the partial impact energy is absorbed by the soft soil ground, resulting in slightly different failure modes of fuselage section and a reduction in the peak acceleration. The water-entry impact failure mode of fuselage section is consistent with the rigid ground impact failure mode, the overall deformation degree of fuselage section decreases, but the degree of bending and upturning of fuselage frames increases with the increasing of the water-entry impact velocities The safety of occupants can be effectively protected in the soft soil ground and water-entry impact scenarios. The unrolling failure mode of fuselage section can be changed to the flattening failure mode (multiple plastic hinges failure mode) through the reasonable design to avoid the rupture of cargo floor crossbeams, and the more crash energy can be absorbed due to the production of more plastic hinges for the flattening failure mode, and the crashworthiness of fuselage section can be significantly improved.

Multiscale Progressive Failure Analysis for Composite Stringers Subjected to Compressive Load.

The fiber-reinforced composite stringer is commonly used in large civil aircraft wing structures. Under compression loads, it exhibits complex failure modes, with matrix cracking being one of the most common. The quantitative analysis of matrix failure is important and difficult. To address this issue, a multiscale method combining the generalized method of cells (GMC) and macroscopic FEM models is employed to quantitatively predict matrix damage and failure. The extent of matrix damage in the composite structure is represented by the number of failed matrix subcells within the repeating unit cells. The 3D Tsai-Hill failure criterion is established for the matrix phase, and the maximum stress failure criterion is applied to the fiber subcell. Upon meeting the criterion, the stiffnesses of the failed subcells are immediately reduced to a nominal value. In the current study, the ultimate loads, failure modes and load-displacement curves of composite stringers subjected to compressive load are obtained by the experiment approach and the proposed multiscale model. The experimental and simulation results show good agreement, and the multiscale analysis method successfully predicts the extent of matrix damage in the composite stringer under compressive load. The number of failed matrix subcells quantitatively evaluates the damage extent within a 2 × 2 GMC model. The findings reveal that matrix subcell failures primarily occur in the 45° and -45° plies of the middle part of the stringer composite.

Construction of a measurement system and analytical solution for docking pose of large aircraft components based on draw-wire displacement sensors

Abstract Relative pose detection is a key technology in large component automatic docking systems. In this paper, a measurement system has been developed to detect the relative pose of large aircraft components with draw-wire displacement sensors, while an analytical calculation method has been proposed to determine the docking pose of large aircraft components. This method establishes a measurement model for the docking pose of large components and separates the position and orientation solutions based on the distances between seven sets of measurement points measured by the draw-wire displacement sensors. First, the principle of three-dimensional rendezvous positioning is refined to ascertain the relative position of the components. Then, by analyzing the properties of the rotation matrix and the coupling relationship between the position and orientation variables of the movable component, 15 compatible equations containing only two variables with a maximum degree of four are obtained. Based on this set of equations, a unique solution for the rotation matrix was obtained through the variable substitution method, gradually eliminating higher-order terms. Finally, the correctness of the method is verified through numerical examples. Unlike typical parallel mechanism models, this model can directly obtain 15 compatible equations without the need for methods such as Gröbner bases. Moreover, compared to the measurement method using six draw-wire displacement sensors, a unique solution can be directly determined, solving the problem of multiple solution selection. This measurement method only requires measuring the distance between measurement points to solve the relative pose, with low equipment costs and less susceptibility to external environmental factors.