Optimising the locations of thermally sensitive equipment in an aircraft crown compartment

A Design of Experiments (DoE) analysis was undertaken to generate a list of configurations for CFD numerical simulation of an aircraft crown compartment. Fitted regression models were built to predict the convective heat transfer coefficients of thermally sensitive dissipating elements located inside this compartment. These are namely the SEPDC and the Route G. Currently they are positioned close to the fuselage and it is of interest to optimise the heat transfer for reliability and performance purposes. Their locations and the external fuselage surface temperature were selected as input variables for the DoE. The models fit the CFD data with values ranging from 0.878 to 0.978, and predict that the optimum locations in terms of heat transfer are when the elements are positioned as close to the crown floor as possible ( and ?min. limits), where they come in direct contact with the air flow from the cabin ventilation system, and when they are positioned close to the centreline ( and ?CL). The methodology employed allows aircraft thermal designers to optimise equipment placement in confined areas of an aircraft during the design phase. The determined models should be incorporated into global aircraft numerical models to improve accuracy and reduce model size and computational time. © 2012 Elsevier Masson SAS. All rights reserved.

MIXED-MODEL PRODUCTION SYSTEM DESIGN FOR AIRCRAFT ASSEMBLY

With the advancement of flexible fixture and flexible tooling, mixed production has become possible for aircraft assembly as the manufacturing processes of different aircraft/sub-assembly models are similar. However, it is a great challenge to model the problem and provide a practical solution due to the low volume and complex constraints of aircraft assemblies. To tackle this problem, this work proposes a methodology for designing the mixed production system, and a new scheduling approach is proposed by combined backward and forward scheduling methods. These methods are validated through a real-life industrial case study. Simulation results show that the number of workstations and the cycle time for making a fuselage can be reduced by 50% and 39% respectively with the newly designed mixed-model system.

Food miles or carbon emissions? Exploring labeling preference for food transport footprint with a stated choice study

The ecological footprint of food transport can be communicated using carbon dioxide emissions (CO2 label) or by providing information about both the length of time and the mileage travelled (food miles label). We use stated choice data to estimate conventional unobserved taste heterogeneity models and extend them to a specification that also addresses attribute nonattendance. The implied posterior distributions of the marginal willingness to pay values are compared graphically and are used in validation regressions. We find strong bimodality of taste distribution as the emerging feature, with different groups of subjects having low and high valuations for these labels. The best fitting model shows that CO2 and food miles valuations are much correlated. CO2 valuations can be high even for those respondents expressing low valuations for food miles. However, the reverse is not true. Taken together, the results suggest that consumers tend to value the CO2 label at least as much and sometimes more than the food miles label.

Whole-Vehicle modelling of exhaust energy recovery on a diesel-electric hybrid bus

Hybrid vehicles can use energy storage systems to disconnect the engine from the driving wheels of the vehicle. This enables the engine to be run closer to its optimum operating condition, but fuel energy is still wasted through the exhaust system as heat. The use of a turbogenerator on the exhaust line addresses this problem by capturing some of the otherwise wasted heat and converting it into useful electrical energy.

This paper outlines the work undertaken to model the engine of a diesel-electric hybrid bus, coupled with a hybrid powertrain model which analysed the performance of a hybrid vehicle over a drive-cycle. The distribution of the turbogenerator power was analysed along with the effect on the fuel consumption of the bus. This showed that including the turbogenerator produced a 2.4% reduction in fuel consumption over a typical drive-cycle.

The hybrid bus generator was then optimised to improve the performance of the combined vehicle/engine package and the turbogenerator was then shown to offer a 3.0% reduction in fuel consumption. The financial benefits of using the turbogenerator were also considered in terms of fuel savings for operators. For an average bus, a turbogenerator could reduce fuel costs by around £1200 per year.

Critical role of water in the direct oxidation of CO and hydrocarbons in diesel exhaust after treatment catalysis

CO and C3H6 oxidation have been carried out in the absence and presence of water over a Pd/Al2O3catalyst. It is clear that water promotes CO and, as a consequence, C3H6oxidation takes place at muchlower temperatures compared with the dry feed. The significant increase in the catalyst’s activity withrespect to CO oxidation is not simply associated with changes in surface concentration as a result ofcompetitive adsorption effects. Utilising18O2as the reactant allows the pathways whereby the oxidationdue to gaseous dioxygen and where the water activates the CO and C3H6to be distinguished. In thepresence of water, the predominant pathway is via water activation with C16O2and C16O18O being themajor species formed and oxidation with dioxygen plays a secondary role. The importance of wateractivation is further supported by the significant decrease in its effect when using D2O versus H2O.

Maintaining design intent for aircraft manufacture

Design and manufacture of aircraft requires deep multi-disciplinary understanding of system behaviour. The intention of the designer can get lost due to the many changes occurring to the product and the inability of the methods and tools used to capture it. Systems engineering and optimisation tools underpin industrial approaches to design, but are not without issue. The challenge is to find a route from concept to manufacture which enables designers to maintain their original intent. The novelty in this work is that the parameterisation used to build the CAD model reflects the manufacturing capability, ensuring design intent is maintained from concept to manufacture.

Automated Methods for Aircraft Design Integrated with Manufacturing

Aircraft design is a complex, long and iterative process that requires the use of various specialties and optimization tools. However these tools and specialities do not include manufacturing, which is often considered later in the product development process leading to higher cost and time delays. This work focuses on the development of an automated design tool that accounts for manufacture during the design process focusing on early geometry definition which in turn informs assembly planning. To accomplish this task the design process needs to be open to any variation in structural configuration while maintaining the design intent. Redefining design intent as a map which links a set of requirements to a set of functions using a numerical approach enables the design process itself to be considered as a mathematical function. This definition enables the design process to utilise captured design knowledge and translate it into a set of mathematical equations that design the structure. This process is articulated in this paper using the structural design and definition for an aircraft fuselage section as an exemplar.

Water efficiency as a means of reducing carbon emissions in Northern Ireland (NI) Water

The water and sewerage sectors' combined emissions account for just over 1% of total UK emissions, while household water heating accounts for a further 5%. Energy use, particularly electricity, is the largest source of emissions in the sector. Water efficiency measures should therefore result in reduced emissions from a lower demand for water and wastewater treatment and pumping, as well as from decreased domestic water heating. Northern Ireland Water (NI Water) is actively pursuing measures to reduce its carbon footprint. This paper investigated the carbon impacts of implementing a household water efficiency programme in Northern Ireland. Assuming water savings of 59.6 L/prop/day and 15% uptake among households, carbon savings of 0.6% of NI Water's current net operational emissions are achievable from reduced treatment and pumping. Adding the carbon savings from reduced household water heating gives savings equivalent to 6.2% of current net operational emissions. Cost savings to NI Water are estimated as 300,000 per year. The cost of the water efficiency devices is approximately 1.6 million, but may be higher depending on the number of devices distributed relative to the number installed. This paper has shown clear carbon benefits to water efficiency, but further research is needed to examine social and cost impacts. © IWA Publishing 2013.

Multiphysics Simulation of Thermal Plasma Produced by Lightning Strike on Aircraft Structures

A novel numerical technique is proposed to model thermal plasma of microseconds/milliseconds time-scale effect. Modelling thermal plasma due to lightning strike will allow the estimation of electric current density, plasma pressure, and heat flux at the surface of the aircraft structure. These input data can then be used for better estimation of the mechanical/thermal induced damage on the aircraft structures for better protection systems design. Thermal plasma generated during laser cutting, electric (laser) welding and other plasma processing techniques have been the focus of many researchers. Thermal plasma is a gaseous state that consists from a mixture of electrons, ions, and natural particles. Thermal plasma can be assumed to be in local thermodynamic equilibrium, which means the electrons and the heavy species have equal temperature. Different numerical techniques have been developed using a coupled Navier Stokes – Heat transfer – Electromagnetic equations based on the assumption that the thermal plasma is a single laminar gas flow. These previous efforts focused on generating thermal plasma of time-scale in the range of seconds. Lighting strike on aircraft structures generates thermal plasma of time-scale of milliseconds/microseconds, which makes the previous physics used not applicable. The difficulty comes from the Navier-Stokes equations as the fluid is simulated under shock load, this introducing significant changes in the density and temperature of the fluid.

Investigation of Aircraft Panel Deformations during Riveting Process

In collaboration with Airbus-UK, the dimensional growth of small panels while being riveted with stiffeners is investigated. The stiffeners have been fastened to the panels with rivets and it has been observed that during this operation the panels expand in the longitudinal and transverse directions. It has been observed that the growth is variable and the challenge is to control the riveting process to minimize this variability. In this investigation, the assembly of the small panels and longitudinal stiffeners has been simulated using low and high fidelity nonlinear finite element models. The models have been validated against a limited set of experimental measurements; it was found that more accurate predictions of the riveting process are achieved using high fidelity explicit finite element models. Furthermore, through a series of numerical simulations and probabilistic analyses, the manufacturing process control parameters that influence panel growth have been identified. Alternative fastening approaches were examined and it was found that dimensional growth can be controlled by changing the design of the dies used for forming the rivets.