DISTRIBUTED ELECTRO-MECHANICAL ACTUATION AND SENSING SYSTEM DESIGN FOR MORPHING STRUCTURES

Smart structures, able to sense changes of their own state or variations of the environment they’re in, and capable of intervening in order to improve their performance, find themselves in an ever-increasing use among numerous technology fields, opening new frontiers within advanced structural engineering and materials science. Smart structures represent of course a current challenge for the application on the aircrafts. A morphing structure can be considered as the result of the synergic integration of three main systems: the structural system, based on reliable kinematic mechanisms or on compliant elements enabling the shape modification, the actuation and control systems, characterized by embedded actuators and robust control strategies, and the sensing system, usually involving a network of sensors distributed along the structure to monitor its state parameters. Technologies with ever increasing maturity level are adopted to assure the consolidation of products in line with the aeronautical industry standards and fully compliant with the applicable airworthiness requirements. Until few years ago, morphing wing technology appeared an utopic solution. In the aeronautical field, airworthiness authorities demand a huge process of qualification, standardization, and verification. Essential components of an intelligent structure are sensors and actuators. The actual technological challenge, envisaged in the industrial scenario of “more electric aircraft”, will be to replace the heavy conventional hydraulic actuators with a distributed strategy comprising smaller electro-mechanical actuators. This will bring several benefit at the aircraft level: firstly, fuel savings. Additionally, a full electrical system reduces classical drawbacks of hydraulic systems and overall complexity, yielding also weight and maintenance benefits. At the same time, a morphing structure needs a real-time strain monitoring system: a nano-engineered polymer capable of densely distributed strain sensing can be a suitable solution for this kind of flying systems. Piezoresistive carbon nanotubes can be integrated as thin films coated and integrated with composite to form deformable self-sensing materials. The materials actually become sensors themselves without using external devices, embedded or attached. This doctoral thesis proposes a multi-disciplinary investigation of the most modern actuation and sensing technologies for variable-shaped devices mainly intended for large commercial aircraft. The personal involvement in several research projects with numerous international partners - during the last three years - allowed for exploiting engineering outcomes in view of potential certification and industrialization of the studied solutions. Moving from a conceptual survey of the smart systems that introduces the idea of adaptive aerodynamic surfaces and main research challenges, the thesis presents (Chapter 1) the current worldwide status of morphing technologies as well as industrial development expectations. The Ph.D. programme falls within the design of some of the most promising and potentially flyable solutions for performance improvement of green regional aircrafts. A camber-morphing aileron and a multi-modal flap are herein analysed and assessed as subcomponents involved for the realization of a morphing wing. An innovative camber-morphing aileron was proposed in CRIAQ MD0-505, a joint Canadian and Italian research project. Relying upon the experimental evidence within the present research, the issue appeared concerns the critical importance of considering the dynamic modelling of the actuators in the design phase of a smart device. The higher number of actuators involved makes de facto the morphing structure much more complex. In this context (Chapter 2), the action of the actuators has been modelled within the numerical model of the aileron: the comparison between the modal characteristics of numerical predictions and testing activities has shown a high level of correlation. Morphing structures are characterized by many more degrees of freedom and increased modal density, introducing new paradigms about modelling strategies and aeroelastic approaches. These aspects affect and modify many aspects of the traditional aeronautical engineering process, like simulation activity, design criteria assessment, and interpretation of the dynamic response (Chapter 3). With respect the aforementioned aileron, sensitivity studies were carried out in compliance with EASA airworthiness requirements to evaluate the aero-servo-elastic stability of global system with respect to single and combined failures of the actuators enabling morphing. Moreover, the jamming event, which is one of the main drawbacks associated with the use of electro-mechanical actuators, has been duly analyzed to observe any dynamic criticalities. Fault & Hazard Analysis (FHA) have been therefore performed as the basis for application of these devices to real aircraft. Nevertheless, the implementation of an electro-mechanical system implies several challenges related to the integration at aircraft system level: the practical need for real-time monitoring of morphing devices, power absorption levels and dynamic performance under aircraft operating conditions, suggest the use of a ground-based engineering tool, i.e. “iron bird”, for the physical integration of systems. Looking in this perspective, the Chapter 4 deals with the description of an innovative multi-modal flap idealized in the Clean Sky - Joint Technology Initiative research scenario. A distributed gear-drive electro-mechanical actuation has been fully studied and validated by an experimental campaign. Relying upon the experience gained, the encouraging outcomes led to the second stage of the project, Clean Sky 2 - Airgreen 2, encompassing the development of a more robotized flap for next regional aircraft. Numerical and experimental activities have been carried out to support the health management process in order to check the EMAs compatibility with other electrical systems too. A smart structure as a morphing wing needs an embedded sensing system in order to measure the actual deformation state as well as to “monitor” the structural conditions. A new possible approach in order to have a distributed light-weight system consists in the development of polymer-based materials filled with conductive smart fillers such as carbon nanotubes (CNTs). The thesis ends with a feasibility study about the incorporation of carbon nanomaterials into flexible coatings for composite structures (Chapter 5). Coupons made of MWCNTs embedded in typical aeronautic epoxy formulation were prepared and tested under different conditions in order to better characterize their sensing performance. Strain sensing properties were compared to commercially available strain gages and fiber optics. The results were obtained in the last training year following the involvement of the author in research activities at the University of Salerno and Materials and Structures Centre - University of Bath. One of the issues for the next developments is to consolidate these novel technologies in the current and future European projects where the smart structures topic is considered as one of the priorities for the new generation aircrafts. It is remarkable that scientists and aeronautical engineers community does not stop trying to create an intelligent machine that is increasingly inspired by nature. The spirit of research, the desire to overcome limits and a little bit of imagination are surely the elements that can guide in achieving such an ambitious goal

Development of a dynamic tool for aircraft noise reproduction

The aircraft is surely one of the most considerable invention that changed the transport-engineering field, since flying was already an ancient dream come true just a few years ago. Now it is really easy to reach many far places even if most people have no clue how flying is possible. However, as factories do, these large and faster and faster machines return a consistent amount of pollution every day. During take-off, engines reach the highest RPMs returning the most noise possible, and during landing, mobile surfaces produce a lot of aerodynamic disturbs releasing energy in the air while landing gears constantly produce drag in both circumstances. The need to be able to predict the sound emission of an acoustic source represents an extremely current engineering challenge: in particular, a numerical code that would let the user to listen noise produced by a flyover, since acoustic reports are just numerical statistics and spectrogram plots. In this paper, a numerical formulation is suggested for the prediction of the acoustic emission in the frequency domain. The main task of the project was to develop a program that makes dynamic analysis of the signal taking into account the source movement. Moreover, the simulations predicted the noise levels, thus explicitly accounting for the scattering acoustic effects of incidence and geometrical obstacles as well. Geometrical reflections and absorptions of certain frequencies depending on the material have been comprised in the model

Simulation and experimental validation of fatigue endurance limit of copper alloy for industrial application

Fatigue resistance performance represents one of the main characteristic for flexible structures as those used in aerospace and other means of transport. For this reason, particular attentions are dedicated during the design stage to the evaluation of the lifetime resistance parameters. Many numerical and analytical approaches are actually available for this purpose, as well-standardized experimental test procedures have been assessed. With reference to a copper bar of an electric motor, the paper presents a survey of the main analytical and numerical methodologies for the prediction of the fatigue peculiarities. The estimation data have been than validated by an experimental campaign in simulated operating conditions, revealing advantage and drawbacks of different models

Sound proofing and thermal properties of an innovative viscoelastic treatment for the turboprop aircraft fuselage

Low-resilience polyurethane foams including several additive constituents were synthesized to improve their vibro-acoustic performances, as well as the thermal insulation. viscoelastic polymer additive can attenuate vibrations and absorb sound energy. the vibro-acoustic properties of two innovative viscoelastic treatments fabricated with polyurethane foams are discussed in this paper using a typical aeronautical panel test setup. Since an aircraft insulation arrangement must provide both noise and thermal insulation for the specified operating conditions and expected thermal comfort of passengers, the thermal conductivity of the samples has been examined assuming a testing range between 20 °C (room temperature) and − 40 °C (cruise altitude). the results highlighted an optimal behavior of the novel viscoelastic foams in terms of both acoustic and thermal performance, offering a very interesting self-embedded solution with a good weight to performance ratio, compared to standard blanket composed by extra viscoelastic treatments

Operational modal analysis of a spar-type floating platform using frequency domain decomposition method

System identification of offshore floating platforms is usually performed by testing small-scale models in wave tanks, where controlled conditions, such as still water for free decay tests, regular and irregular wave loading can be represented. However, this approach may result in constraints on model dimensions, testing time, and costs of the experimental activity. For such reasons, intermediate-scale field modelling of offshore floating structures may become an interesting as well as cost-effective alternative in a near future. Clearly, since the open sea is not a controlled environment, traditional system identification may become challenging and less precise. In this paper, a new approach based on Frequency Domain Decomposition (FDD) method for Operational Modal Analysis is proposed and validated against numerical simulations in ANSYS AQWA v.16.0 on a simple spar-type structure. The results obtained match well with numerical predictions, showing that this new approach, opportunely coupled with more traditional wave tanks techniques, proves to be very promising to perform field-site identification of the model structures

Progress on the experimental set-up for the testing of a floating offshore wind turbine scaled model in a field site

This document describes design and realization of a small-scale field experiment on a 1:30 model of spar floating support structure for offshore wind turbines. The aim of the experiment is to investigate the dynamic behaviour of the floating wind turbine under extreme wave and parked rotor conditions. The experiment has been going on in the Natural Ocean Engineering Laboratory of Reggio Calabria (Italy). In this article, all the stages of the experimental activity are presented, and some results are shown in terms of motions and response amplitude operators. Finally, a comparison with corresponding results obtained using ANSYS AQWA software package is shown, and conclusions are drawn. The presented experimental set-up seems promising to test offshore floating structures for marine renewable energy at a relatively large scale in the Natural Ocean Engineering Laboratory field site

Experimental and numerical assessment of innovative damping foams

The automotive industry is currently experiencing relevant technology changes in the design of the engines, transmission and total drivetrain, induced by increasing customer demand for fuel efficiency and more stringent government requirements in emissions and safety. One of the problems relating to environmental impact concerns the noise emitted by the vehicle, for which various solutions have been experimented: new and more resistant materials have been worked out in order to minimize noise pollution and the environmental impact of the vehicle, even at the end of the operating life of its components. This research illustrates a solution as a response to those requirements, as well as being a response to the targets of comfort: a viscoelastic material, appointed to increase the damping of structures involved in vibroacoustic phenomena generated in a vehicle. The performance of these innovative materials have been analyzed both from a numerical standpoint that experimental. Starting from the empirical results of tests carried out in the laboratory, finite element models have been developed in order to have a suitable numerical database for further vibro-acoustic simulations

An innovative numerical approach for railway rolling noise forecast

In recent years there has been a growing worldwide development of rail transport, mainly due to technological innovations both on armaments and on rail vehicles. Such technological issue focused almost parallel on two main fronts: on one hand the performance enhancement and on the other side the internal comfort. This technology advancement has been driven mainly by the need to move goods and passengers over long distances in a short time, making it the safest transportation system in the world thanks also to the latest monitoring systems, of which European Community is undoubtedly one of the major leaders. The passenger transport has introduced problems related to comfort: traveling so fast is the main goal so long as it is comfortable and safe. One of the requirements that mostly turned out to be significant and sometimes more difficult to satisfy is that regarding acoustic comfort and environmental impact. As known, the regulations become with the passage of time more and more stringent, and every company that wants to operate in this area is required to respect them. The acoustic comfort improvement implies the intervention as much as possible focused on noise sources, which in this case are constituted by: electric motor, pantograph, wheel-rail contact. In such research framework, the authors focused on determination of a simple, but at the same time reliable, method for radiated sound power assessment in the wheel-rail contact due to combined wheel-rail roughness in order to reduce the environmental impact of this type of transmission system. Targeted analysis were implemented in an efficient numerical investigation in MSC NASTRAN® and ACTRAN® environments providing the necessary vibro-acoustic parameters as input data for the further definition of the wheel-rail interaction force by a MATLAB® customized tool, once known the roughness profile

Vibro-acoustic response of a turboprop cabin with innovative sidewall viscoelastic treatment

In recent years, it's considerably grown the market demand for increasingly performing and comfortable aircrafts as a new mandatory design target. Among the determining factors for the internal comfort, are included the noise and vibrations, the source of which is detected mainly in the propulsion unit especially in the case of turboprop category: the most significant component of the noise perceived inside a cabin is undoubtedly the blade-passage load exerted by the propeller. Recently were therefore tested techniques, both active and passive, of vibration emission reduction and sound absorption, however the goal remains to find solutions by extremely low-weight and easy to apply on the real mock-up. As known, a damping treatment is typically used to reduce noise coming from fuselage structure vibration under acoustic loading excitation. In such research context, the vibro-acoustic performance of the viscoelastic material for replacing the conventional interior blanket of the fuselage sidewall have been investigated for the well-known higher dissipation capacity and energy storage. Starting from experimental tests by means of different measurement techniques carried out on an innovative foam sample, the dynamic parameters were estimated according to identify suitably the material performance database for further finite element analysis on a turboprop fuselage model. The outcomes achieved have emphasized a significant role of the viscoelastic foam than the standard blanket with respect to the internal sound pressure levels abatement as well as the thermal insulation. The developed foam prototype is also easily integrable with an outer layer ensuring a fully removable embedded solution for the maintenance inspections

Acoustic performance assessment of innovative blankets for aeronautical applications

Polyurethane blankets are increasingly used for many aeronautical NVH applications. These foams, generally available in various thickness and density, are great sound absorber, therefore suitable in the aircraft interior. These foams are used as replacement to traditional combination of mineral wools / rock wool along with perforated panels, which require labor and also health hazardous. Polyurethane foams are generally available in various densities and thickness. The acoustic performance of sound absorbing poroelastic materials is characterized by intrinsic physical parameters like flow resistivity, and absorption coefficient. This paper presents a detailed discussion on measurement of flow resistivity as well as acoustic absorption coefficient of PU foam samples. Such numerical database of examined samples has been then validated through other laboratories activities, which shows the good accuracy of the methodology implemented within