Research Investment & Commercial Success : Piaggio Aero Industries
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1 Research Investment & Commercial Success : Piaggio Aero Industries Piaggio Aero High Technologies Office A. Cozzolino Piaggio Aero Industries S.p.A. Vienna Jun 20 th, 2006
2 PIAGGIO S LEGACY Started aviation activities in 1915 P-108 Pioneer in design and production of air-cooled hipower piston radial engines Pioneer in design and experimentation of helicopters, well before Sikorsky s first flights More than 50 aircraft types designed and manufactured since 1915 P-7 P-23 P-148 Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 2
3 PIAGGIO AERO TODAY Piaggio Aero Industries Finale Plant Genova Plant Piaggio Naples Piaggio Rome Piaggio France Piaggio America Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 3
4 GENOVA FACILITY Total Area: sq. m Workforce: 525 Activities: Headquarters Aircraft FAL Flight Testing Aircraft Maint. Product Support Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 4
5 FINALE LIGURE FACILITY Total Area: sq. m Workforce: 775 Activities: Engineering Structural testing NDT Parts manufact. P.180 Sub-ass. Aerostructures assembling Engine Maintenance, Repair and Overhaul Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 5
6 FUTURE VILLANOVA FACILITY Planned transfer of the Finale L. facility to Villanova (Albenga area - 20 km West of Finale) Total Area: sq. m Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 6
7 ENGINEERING FINALE LIGURE / NAPOLI / GENOVA/NIZZA Structures General Systems Avionics Certification Data Management Structures General Systems Avionics and Systems Support to the shopfloor activities Research (Piaggio High Technology) Preliminary Design Flight Technologies and Aerodynamics Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 7
8 PRODUCTS AIRCRAFT P. 180 Avanti P166 DP1,SEM,APH AEROSTRUCTURES Falcon 2000 EX Baggage Door Vertical Fin C 27 J Fully equipped Center Wing Box ENGINE PARTS MANUFACTURING - Rolls Royce - Pratt & Whitney Canada -Avio Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 8
9 HIGHLIGHTS Piaggio Aero Annual Revenue Vs. Year [MEuro] Total Work Force: Annual Revenue: 170 M % 7% 11% 21% 19% 18% 15% Annual Revenue YEAR R&D % of Annual Revenue AIR TAXI SERVICES and MISCELLANEA 3% AEROSTRUCTURE 9% ENGINE MAINTENANCE and PART MANUFACTURING 19% P180 SALES and SERVICE 68% 0% 10% 20% 30% 40% 50% 60% 70% 80% Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 9
10 P180 AVANTI EXPERIENCE MAIN DESIGN DRIVERS: Low fuel consumption Maximum cabin room (stand-up cross section) Low cabin noise High cruise speed and flight altitude (jet-like) P180 AVANTI II GENERAL SPECIFICATION MTOW lbs Payload 7-9 pax + 2 (1) pilots Max Operating Altitude ft Vmo/Mmo 260 KIAS / 0.70 Max Cruise Speed 398 KTAS Max Range (LRC) 1507 nm. IFR res. Engines 2 PW&C PT6A66B (850 SHP) Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 10
11 P180 AVANTI: TIMELINE First wind tunnel test in 1979 Program launched in 1981 Gates Learjet joined in 1983 (withdrew in Jan. 1986) First flight Sept Certification March 1990 First Delivery Sept Only 32 deliveries up to 1998 Re-birth of Piaggio as Piaggio Aero Industries S.p.A. in November 1998 gave new light to the P180 program 120 P180 Avanti delivered up to present time Backlog of more than 100 a/c Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 11
12 P180 AVANTI BREAKTHROUGHS Piaggio Patented 3-Lifting-Surfaces Aircraft Concept that revolutionized conventional twin turboprop design Fastest turboprop currently in service (Max Cruise=398 KTAS) and having the highest operational ceiling (41000ft) High Aspect Ratio (12) Natural Laminar Flow Wing (50%) Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 12
13 P180 AVANTI DIFFICULTIES Unconventional 3-lifting-surface concept and natural laminar wing required extensive wind tunnel (WT) tests: 100 hours of 2D pressurized high Mach and Reynolds WT tests at Ohio State University 4000 hours of low speed WT tests at Piaggio and Wichita State University 500 hours of transonic WT tests at Boeing- Seattle (1:7 model) 100 hours of WT tests with aeroelastic 1:5.7 model at General Dynamics / Convair Division - San Diego Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 13
14 P180 AVANTI DIFFICULTIES Unconventional 3-lifting-surface concept and natural laminar wing required an extensive certification tests campaign : Numerous Special Conditions were necessary due to the unconventional 3LSC concept and laminar wing design Stall adjustment incorporated in wing 3000 flight hours were necessary to get the certification Wing structural reinforcement incorporated in wing during structural tests (fatigue) Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 14
15 P180 AVANTI LESSON LEARNED Proper risk assessment is key. New aircraft concepts and technologies need to be thoroughly investigated well before the program go ahead. Knowing the market environment and having good timing is key when defining a research strategy, and A/C specs. Robust innovative concept can survive in the years through changing scenarios Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 15
16 CURRENT RESEARCH DRIVERS Extremely Important (5) Top Two Box Mean Baggage Space Cabin Size Extremely Important (5) 31% 25% Top Two Box Cruise Altitude 24% 4.0 Direct Operating Cost 54% 4.5 Payload 38% 4.3 Price 49% 4.5 Range 42% 4.3 Runway Performance 42% 4.4 Seating Capacity 22% Speed 29% Other 46% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 16
17 PIAGGIO RESEARCH Piaggio Aero s Research Strategic Plan aims to a strong increase the competitiveness of current and future product. The key drivers to develop a technology readiness plan were selected looking to current and future needs of business aviation. Selected key drivers: Reduce Manufacturing & Operating costs. Improve Comfort and Safety. Improve Environmental Impact. Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 17
18 THE PHT GROUP Piaggio Aero Industries set in April 2001 the Piaggio Aero High Technology Research Group (PHT) in Naples. The mission of PHT is to plan and develop research projects support the company future developments provide design methods and innovative technologies. The key technology areas for research projects are: Manufacturing process Structures & Materials Aerodynamics Noise & Environment Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 18
19 ADVANCED COMPOSITES Projects (Italian Research founding cooperation with CIRA ) OBJECTIVES: Development of innovative composite structures Improvement of the Liquid Molding techniques 20% Weight Reduction 20% Cost Reduction 50% Design Time Reduction IMPLEMENTATION PROCEDURE: Use the P180 s vertical stabilizer and aileron as reference to develop the Resin Infusion and the RTM techniques structures respectively Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 19
20 ADVANCED COMPOSITES Projects (VITAS) COMPOSITE AILERON The P180 s left aileron has been designed and manufactured with the RTM technologies. All objectives ( weight/cost reduction) have been achieved The results of the test performed in PAI Lab under P180 dimensioning loads, have shown that the carbon fiber aileron has better strength behavior than the aluminum one. Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 20
21 ADVANCED COMPOSITES Project VERTICAL TAIL PANEL A vertical tail panel deriving from the P180 empennage has been designed and manufactured with the Resin Infusion technologies. More than 30% of weight and cost reduction have been achieved The results of the FEM analysis have shown that the carbon fiber panel has better strength behavior than the aluminum one. Rupture test will be performed in PAI Lab within July Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 21
22 Composite Next CESAR (IP, EU VI RTD FWK approved) Partners: PAI, CIRA,NLR etc. Objectives:Design, manufacturing and test P180 fwd wing in liquid moulding technologies Time schedule: October 2006-October 2009 TEXT-X-TRANSPORT (Italian research founding) Partners: PAI, UNINA, etc. Objectives: Design, manufacturing and test of a vertical tail / wing box in RTM/RI technologies Time schedule: Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 22
23 FRICTION STIR WELDING Project Welair High structural integration with drastic reduction of part numbers to allow: WEIGHT REDUCTION COST REDUCTION Reduced fuel consumption Higher performances Increased payload Easier assembling Easier maintenance NEW DESIGN CONCEPT Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 23
24 FRICTION STIR WELDING Project Built a Fuselage barrel to be tested under operative fatigue loads, Achieved results on the damage tolerance behavior of welded primary structures. Welded flat panel for static test Welded fuselage barrel for fatigue test Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 24
25 Friction Stir Welding Next Partners: PAI, Dassault, Airbus, Eads CRC etc. CESAR (IP, EU VI RTD FWK approved) COINS (Strep, EU VI RTD FWK approved) Objectives: Design and manufacturing typical window frames-to-skin connection (CESAR) Design and manufacturing and test of innovative FSW joint Time schedule: October 2006-October 2009 Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 25
26 MINIMUM EXTERNAL NOISE Project (VITAS) PHASE 1: Tools Development Development of user friendly numerical Tools for prediction of noise components sources and estimating overall community noise Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 26
27 MINIMUM EXTERNAL NOISE Project PHASE 2 : Computational aeroacoustics. Evaluation of aeroacoustic performance of pusher propeller Assessment of main noise sources Optimization of external noise -forward speed -propeller RPM -engine exhaust position -shape and number of propeller blades -wake effect in installed configuration Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 27
28 MINIMUM EXTERNAL NOISE Project PHASE 3 : Ground and Flight Tests Better understanding of noise generation mechanics, Validation of theoretical noise prediction methods, Definition of best flight trajectories for noise reduction in take-off and landing Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 28
29 MINIMUM EXTERNAL NOISE Project MAIN RESULTS impingement of the engine exhaust in the propeller and the wings wake is a major source of external noise Increasing the number of blades from 5 to 6, reducing the propeller RPM Blade tip sweep has a lower impact Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page db Average Noise Reduction 5.3 db Average Noise Reduction 7 db
30 MINIMUM EXTERNAL NOISE Project ONGOING RESEARCH ACTIVITIES : Improvement of Aircraft External Noise prediction capabilities by means of development of a tool aimed to predict the Wing Noise - Enhancing and Shielding effects. Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 30
31 MINIMUM INTERNAL NOISE Project ONGOING RESEARCH ACTIVITIES : Definition of a Finite Element Model for prediction and analysis of Vibro- Acoustic Behaviour of a Fuselage Aircraft Structure. Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 31
32 MINIMUM INTERNAL NOISE Project ONGOING RESEARCH ACTIVITIES : Interior Noise Sources Identifications, in-flight Measurements and Numerical Correlations with Cabin Noise prediction tool based on Energy Balancing Method. Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 32
33 Partners: PAI, CIRA, DLR etc. CESAR (IP, EU VI RTD FWK approved) Objectives: Design and test low noise propeller for P180 Minimun External Noise Next Time schedule: October 2006-October 2009 Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 33
34 NATURAL LAMINAR WING Project OBJECTIVES: Development of design & optimization methodologies and tools 2D transonic NLF airfoil design and optimisation. 3D wing design (target of 10% less drag than modern supercritical wings). Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 34
35 NATURAL LAMINAR WING Project IMPLEMENTATION PROCEDURE Application of state of the art transition prediction methods, numerical optimization tools, and innovative CFD methodologies for NLF airfoil design and optimization design 2D transonic wind tunnel tests for validating numerical methods 3D transonic laminar wind tunnel tests for validating numerical methods Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 35
36 NATURAL LAMINAR WING Project MAIN RESULTS: Integrated design and optimization tool for Transonic NLF Airfoil was developed 2D transonic wind tunnel tests validated the methods and tools used for transition prediction and airfoil optimization Design and optimization of a transonic NLF airfoil was succesfully conducted 3D wing HS wind tunnel tests (Dec.2005-Jan.2006 ) Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 36
37 Partners: PAI, CIRA, AIRBUS, etc. NLF Next Telfona (STREP, EU VI RTD FWK on going) Nacre (IP, EU VI RTD FWK on going) CESAR (IP, EU VI RTD FWK approved) Objectives: Approach required for WTT test on laminar flow wing (Telfona) Design of laminar flow wing with High Aspect Ratio ( Nacre) Test the laminar flow wing behaviour on ice accretion and manufacturing tolerance Cesar) Time schedule: Aprile 2005-Aprile 2009 Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 37
38 EU : On going activities: Status Research Jun 2006 Welair Friction Stir Welding Eads-CRC-FR I Call VI FR NACRE New Aircraft Configuration Airbus II Call VI FR TELFONA Laminar Aerodynamics Airbus II Call VI FR VORTEXCell Aerodynaimcs Uni Southampton II Call VI FR Project III Call VI FR approved CESAR Technology Small Aircraft VZLU Smart Fuel II Digital Fuel System AG COINS Friction Stir Welding Bae System AIM In Flight Measurement Techniques DLR Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 38
39 A RECIPE FOR COMMERCIAL SUCCESS? Aiming at becoming the pioneer at many different fronts can be very messy Proper risk management at the early stages of a program is essential. Commercially speaking, the early follower is in most cases more successful than the pioneer! In civil aviation evolution has being shown to be a wiser path compared to revolution given the importance of safety assurance. Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 39
40 DISCUSSION Thank you for your attention Jun 20th, 2006 Piaggio Aero Industries S.p.A. Page 40
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