Overview
The ESPOSA project will develop and integrate novel design and manufacture technologies for a range of small gas turbine engines up to approximately 1000 kW to provide aircraft manufacturers with better choice of modern propulsion units.
It will also deal with engine related systems which contribute to the overall propulsion unit efficiency, safety and pilot workload reduction. Through the newly developed design tools and methodologies for the engine/aircraft integration the project will also contribute to the improved readiness for new turbine engines installation into aircraft.
New technologies and knowledge gained through the ESPOSA project will provide European general aviation industry with substantially improved ability to develop and use affordable and environmentally acceptable propulsion units and reliable aircraft systems minimizing operating costs, while increasing the level of safety. The new engine systems and engine technologies gained from ESPOSA should deliver 10-14% reduction in direct operating costs (DOC) and reduce significantly the pilot workload. The ESPOSA project is oriented on turbine engine technologies tailored for a small aircraft up to 19 seats (under CS-23/FAR23) operated on the scheduled and non-scheduled flights.
The research work comprises performance improvements of key engine components, their improved manufacture in terms of costs and quality.New engine component technologies will be backed by novel modern electronic engine control based on COTS, pioneering the engine health monitoring for small engines and providing new more electric solutions for fuel and propeller control systems.
Project activities will include extensive validation on the test rigs. The most appropriate technologies according to value/cost benefit will be selected and integrated into functional complexes and further evaluated on the engine test beds. The functionality of certain project outcomes will also be demonstrated and validated in-flight conditions.
Funding
Results
Small planes to get a big update
New research is leading to more efficient engines for small turboprop aircraft. In addition to reducing environmental impact, the comprehensive solutions will reduce the workload on pilots and enhance the safety of flight.
The aerospace industry has placed major emphasis on reducing the environmental impact of air travel. Much research has focused on large jet aeroplanes. The EU-funded project 'Efficient systems and propulsion for small aircraft' (http://www.esposa-project.eu (ESPOSA)) is filling an important gap.
A huge international consortium plans to deliver one of the smallest turboprop/turboshaft engines in the world for aircraft with up to 19 seats. The engines will provide up to approximately 1 000 kW of power and are expected to lead to a reduction on direct operating costs of 10 to 15 %. In addition, with a focus on automation, health monitoring and more-electric components to reduce the workload on pilots, the aircraft should be safer as well.
During the second reporting period, the team completed work on advanced tools and models to conduct trade-off studies regarding technical and economic factors related to the new propulsion systems. Extensive research focused on experimental and computational evaluation of new engine components to optimise engine performance.
Exploitation of lean manufacturing technologies to get the end user what he/she wants quickly while removing wasted manufacturing steps is an important pillar of the project. In addition to work on low-cost casting processes and the potential of recyclation, the team studied a variety of coating solutions to protect engine parts from the very high temperatures and from wear. Researchers also developed advanced design methods for installation in various types of aircraft.
Scientists are also developing advanced concepts for automatic control, smart health monitoring and more-electric designs. As the project nears the finish line, the team has prepared the test rig and laid the foundations for engine and system validation as well as integration in the coming months.
ESPOSA work is leading to improved components and manufacturing technologies, comprehensive design tools and best practices for installation. The project plans to make a big splash in the field of small turbine engines as well as establish links between western and eastern European countries. In sparsely populated regions, more efficient and cost-effective small planes could become like air taxis, opening a new market for manufacturers.