The main objective of this paper is to describe a methodology to be applied in the preliminary design of a tiltrotor wing based on previously developed conceptual design methods. The reference vehicle is the Next-Generation Civil Tiltrotor Technology Demonstrator (NGCTR-TD) developed by Leonardo Helicopters within the Clean Sky research program framework. In a previous work by the authors, based on the specific requirements (i.e., dynamics, strength, buckling, functional), the first iteration of design was aimed at finding a wing structure with a minimized structural weight but at the same time strong and stiff enough to comply with sizing loads and aeroelastic stability in the flight envelope. Now, the outcome from the first design loop is used to build a global Finite Element Model (FEM), to be used for a multi-objective optimization performed by using a commercial software environment. In other words, the design strategy, aimed at finding a first optimal solution in terms of the thickness of composite components, is based on a two-level optimization. The first-level optimization is performed with engineering models (non-FEA-based), and the second-level optimization, discussed in this paper, within an FEA environment. The latter is shown to provide satisfactory results in terms of overall wing weight, and a zonal optimization of the composite parts, which is the starting point of an engineered model and a detailed FEM (beyond the scope of the present work), which will also take into account manufacturing, assembly, installation, accessibility and maintenance constraints.

The tiltrotor wing structure is one of the most critical and heavily investigated structures in design due to the fundamental need to consider the interactions between the wing, pylon, and rotor systems to achieve aircraft aeroelastic stability. Indeed, in high-speed forward flight, wing flexural and torsional stiffness have fundamental roles in pitch-whirl stability. Another specific concern of tiltrotors is dynamic mode placement; it is necessary to properly place wing bending modes away from prop-rotor forcing frequencies. The main aeroelastic stability and dynamics requirements and the wing design process flow for the next generation civil tiltrotor are presented in this work. In this context, the use of composite materials plays a fundamental role in the attempt to satisfy the requirements, with the perpetual aim of minimizing the structural weight. An overview of the idealized and adopted models for strength, aeroelasticity, and whirl flutter analysis is provided. The primary focus was on the aeroelastic tailoring process. To satisfy, at the same time, all of the structural dynamic and aeroelastic stability requirements, the best compromise, with an acceptable weight penalty, was the mixture of two methodological solutions: adding unidirectional tape in the zones of the upper and lower skins for flexural out-of-plane frequency and adding a proper number of ±45° fabric layers at the locations of the skin with the highest value of strain energy for in-plane torsional modes. The results show that the proposed method based on modal strain energy analysis enables a tiltrotor aeroelastic tailored wing design. It can be easily employed in similar applications (e.g., vehicle scale-up/down) with the advantage of using the stiffness requirements derived directly from the aeroelastic ones (i.e., structural frequencies). The specific wing achieved aeroelastic clearance by adding only 2.7% of extra mass.

Weight-on-Wheels (WoW) systems are aimed at indicating if the aircraft weight is loading onto the landing gear and its wheels, even partially. These systems are an integral part of the actuation system for safety-critical applications and shall provide reliable information on the actual operational status of the LG. That information reveals if the vehicle is in flight or on the ground. In this way, several kinds of accidents may be prevented, relating for instance, to the incorrect deployment of the landing gear, or even manoeuvres to a certain extent, therefore protecting the aircraft from dangerous damage. There are different architectures that have been proposed in the bibliography, some of them based on strain gauges deployed on the structure, or on proximity sensors installed on the wheels. Being this device and considered critical for safety, it is convenient to couple it with complementary measurements, recorded and processed by different sources. In general, it can be stated that such an intelligent sensor network may be seen as a fundamental support for proper landing gear deployment. The presented paper reports the results of a preliminary investigation performed by the authors to evaluate the possibility of deploying fibre optics on the landing gear structure as part of a WoW system to retrieve the required information. This choice would have a remarkable effect in terms of significant cabling reduction (a single array of sensing elements could be deployed over a single line), and cost abatement from both a manufacturing and operational point of view. There are many other benefits also when referring to an optical instead of a standard electrical sensor system. Due to its small size and ease of integration into different families of materials, it could be considered a system for monitoring the operating status of most actuators on board modern aircraft.

This paper is focused on structural scalability studies of a new generation of civil tiltrotor wingbox structures. Starting from a reference wingbox, developed under the H2020 Clean Sky 2 NGCTR-TD T-WING project, a geometric scaling was performed to upscale the concept up to a larger class tiltrotor named “NGCTR”. Given the wing and the wingbox geometry, a multi-objective optimization, based on genetic algorithms, was performed to find for the NGCTR, among different materials and layups, the best composite wing in terms of weight that satisfies stiffness and crash requirements. The crash requirement plays an important role in regards to wing weight performance. It was found that not all materials investigated in this study succeeded in satisfying both stiffness and crash requirements. The results in terms of minimum structural mass as the target of the optimization process show that the mass ratio of the optimized up-scaled wing is near the geometrical scale factor: 1.58 vs. 1.29. Furthermore, the solution found by the optimizer NGCTR upscaled wing is comparable with other tiltrotor data coming from a literature study. The difference in terms of the ratio between wing structural weight and tiltrotor MTOW is Δ% = +1.4: an acceptable small overestimation of weight compared to a design, optimization, and scalability method that is easily adaptable and effective. The study presented in this work is, in fact, part of a broader activity on scalability and constitutes its first phase, based on low-fidelity models. The scalability study will continue with a further phase (indicated as “phase 2”), in which more reliable models will be set up, allowing a better estimation of the wing’s structural weight and further optimization. The results shown in this manuscript concern phase 1 only and can be considered a starting point at the System Requirements Review level of the up-scaled wing. This phase allowed for a fast exploration of the available solutions by making a first assessment of the main requirements and by aiding in the material choice at the very beginning of the design.