Innovative Eco-efficient Wingtip: AI and AM Improve Legacy Aircraft – TODAY!
How AI and AM are paving the way for future innovations and developments in the aviation industry and here in relation to the current stock of legacy aircraft.
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The figure shows the components of the Airbus A320 wingtip fence manufactured in AM (central mount/adapter and leading and trailing edges) and then glued (side panels in GRP sandwich construction, front side panel removed). Copyright by Pioneer Aeronautics Innovation GmbH -
70% of today's passenger transportation is provided by legacy aircraft. In the coming decades, these aircraft will continue to account for a significant share of global air traffic, alongside the more efficient variants (NEO/MAX). Technologies for the complete reduction of C02 emissions will only be available towards the end of the 21st century.
PAI has created a digital twin by means of comprehensive re-engineering (3D scan, analysis of structural load and associated flight tests) of the Airbus A320ceo. Considering the continuous development progress in aviation over the last two decades (focus on aerodynamics, structure/materials and manufacturing methods), implemented already in the actual aircraft models of the OEMs, legacy aircraft can also be analyzed/optimized regarding fuel-reducing modification of components.
An AI-based analysis and optimizations of the Airbus A320ceo's slats, flaps and wingtip fence was carried out through subsequent, needs-based modification. Fuel savings of over 10% can be realized for selected configurations.
The implementation of an topology and material optimized wingtip fence (replacement / retrofit) was demonstrated aerodynamically and structurally using GRP-sandwich components and additively manufactured aluminum components. With a weight saving of the component of over 25%, the manufacturing costs of the component could be reduced by 50%.
Presentation language: ENG
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