Passenger Transport Aircraft Concept Design-Final

Jeff Ayscue
Alex Esche
Jurmeyne Espina

Overview
 Design Requirements
 Flight Performance
 Design Evolution
 Aircraft Configuration
 Detailed Design
 Maintenance Improvements
 Requirements Verification

Design Requirements
• Passenger transport
• 250 – 400 passengers depending on configuration
• Operating altitude = 50,000 ft
• Reduced fuel consumption, 20% less than 777
• Range min 4500nm
• High speed subsonic M=.95
• Major maintenance span increased 25% over B777

Challenges
 Cruising altitude at 50,000 ft
 Air has lesser density; Reduced max velocity
 High speed subsonic M=0.95
 Drag coefficient dramatically increases at Mach number
M = 0.9 to 1
 Major maintenance span increased 25%
 Maintenance frequency is subject to Operator
discrepancy

Drag coefficient vs. Mach number

Boeing 777-200LR Standard Configuration
Cruise Altitude 35,000ft
Cruise Speed 0.84 Mach 290 Knots CAS at 35,000ft
Max Capacity 301 pax
MTOW 766,000lbs
Empty Weight, Operating 320,000lbs
Fuel Capacity 327,567lbs 47,890 Gallons
Fuselage Length 209ft
Fuselage Diameter 20ft 244 Inches
Wingspan 212ft
Wing Area 4,605ft^2
Lift Coefficient
35,000ft .084 Mach .660379
50,000ft .095 Mach 1.12763
Max Cruise Thrust 110,000lbs 2 Engines = 220,000lbs total

Boeing 777-200LR Maximum Performance

Boeing 777-200LR Standard Configuration

Test 1 Parameters
Relevant Changes From Original:
• Decreased Fuel Capacity
• Decreased MTOW
Test 1 Original Difference Requirement
Altitude 50,000ft 49,200ft + 800ft Met
Max Speed 0.948 Mach 0.835
Mach
+ 0.113 Mach -0.002 Mach
Max Capacity 301 pax 301 pax - -
MTOW 569,459 766,000lbs -196,541 -
Empty Weight,
Operating
240,000lbs 320,000lbs -80,000 -
Fuel Capacity 131,026lbs 327,567lbs -196,541 -
Fuselage Length 209ft 209ft - -

Test 1.2 Parameters
Relevant Changes From Previous Test:
• Extended Fuselage Length by 86ft
• MTOW Increased to account for longer fuselage
Test 1.2 Previous
Test
Difference Requirement
Altitude 50,000ft 50,000ft None Met
Max Speed 0.942
Mach
0.948 Mach - 0.006
Mach
-0.008 Mach
MTOW 574,459 569,459 + 5,000 -
Empty Weight,
Operating
245,000lbs 240,000lbs + 5,000 -
Fuel Capacity 131,026lbs 131,026lbs - -
Fuselage Length 295ft 209ft + 86 -

Test 2.1 Parameters
• 4 New Engines = GEnx-1B54
• Increased Thrust
• Decreased MTOW
Test 2.1 Original Difference Requirement
Altitude 50,000ft 49,200ft + 800ft Met
Max Speed 0.932 Mach 0.835 Mach + 0.097 Mach -0.018 Mach
Fuel Capacity 131,026lbs 327,567lbs - 196,541 -
MTOW 585,037lbs 766,000lbs - 180422 -
Empty Weight, Operating 255,578lbs 320,000lbs - 64,422 -
Max Cruise Thrust 229,576lbs 220,000lbs + 9,576 -

Test 2.2 Parameters
Test 2.2 Previous
Test
Max Speed 0.949 Mach 0.932 Mach + 0.017 Mach -0.001 Mach
MTOW 590,037lbs 585,037lbs + 5000 -
Empty Weight, Operating 260,578lbs 255,578lbs + 5,000 -
Max Thrust 229,576lbs 229,576lbs None -

Test 3.1 Parameters
• 1 Additional Engine = GEnx-1B78/P2
• Increased Thrust
• Decreased MTOW
Test 3.1 Original Difference Requirement
Altitude 50,000ft 49,200ft + 800 Met
Max Speed 0.966 Mach 0.835 Mach + 0.131Mach + 0.016 Mach (Met)
Fuel Capacity 131,026lbs 327,567lbs - 196,541 -
MTOW 583,011lbs 766,000lbs - 182,989 -
Empty Weight, Operating 253,552lbs 320,000lbs - 66,448 -
Max Thrust 288,789lbs 220,000lbs + 57,594 -

Test 3.2 Parameters
Test 3.2 Previous
Test
Max Speed 0.977 Mach 0.966 Mach + 0.011 Mach + 0.027 Mach (Met)
MTOW 588,011lbs 583,011lbs - -
Empty Weight, Operating 258,552lbs 253,552lbs - -
Max Thrust 288,789lbs 288,789lbs - -

Test 3.3 Parameters
• Delta Main Wing
• Removed Horizontal Stabilizer
Test 3.3 Previous Test Difference Requirement
Max Speed 1.110 Mach 0.977 Mach + .133 Mach + 0.160 Mach (Met)
MTOW 588,011lbs 588,011lbs - -
Fuselage Diameter 20ft 20ft - -
Wingspan 216ft 212ft + 8ft -
Wing Area 12,960ft^2 4,605ft^2 + 8,355ft^2 -

Test 3.4 Parameters
• Extended Fuselage Length
• Decreased Fuselage Diameter
Test 3.4 Previous Test Difference Requirement
Max Speed at 100% Power 1.223 Mach 1.110 Mach + 0.113 Mach + 0.273 Mach (Met)
Max Cruise at 90% Power 1.131 Mach - - + 0.181 Mach (Met)
MTOW 588,011lbs 588,011lbs - -
Fuselage Length 315ft 295ft + 20ft -
Fuselage Diameter 15ft 20ft - 5ft -

Test 3.4 Performance
Max Speed
At 100% Power
Cruise Speed
At 90% Power

Inboard Profile
 Cabin Length – 173’-11’’
 8 Exits – 6 Door and 2 Over the wing
 8 Lavatories

Cabin Layout
 305 Maximum passenger capacity
 3-class Configuration
 First class cabin at 60in pitch
 24 seats
 Business class cabin at 38in pitch
 54 seats
 Economy class cabin at 31-32in pitch
 227 seats

Cabin Cross Section
 Cabin Max Width
 14’-4.9”
 Maximum Height
 6’-9”
 Economy class seating
 7 abreast configuration
 Seat width 18.2”

Cabin Cross Section
 Business class seating
 Seat width 22”
 First class seating
 Seat width 29”

Inputs
- Atmospheric Conditions
- Chosen Sweep Angle, Thickness
ratio, Taper Ratio, CLmax
- Wing Loadings and Aspect Ratios
- Initial Gross Weight estimate
Computed Values
- Surface Areas
- Wing and Tail Spans and Areas
- Chord Lengths
- Mean Aerodynamic Chords
1) Required Thrust
for Takeoff
Calculated required thrust for
takeoff (T1) using selected CLmax
and predicted GW
2) Engine Sizing
Calculate size of engines from
required power
Initial Flat Plate
Drag Estimate
Calculate equivalent flat-plate
area and drag from aircraft
parameters
3) Thrust
Calculate Thrust for Vmax (T2)
during takeoff, and thrust at
ceiling altitude (T3)
Is T1 greater than
or equal to T2,
T3?
NO
Re-iterate with a thrust
greater than previously
calculated thrust
IF YES, Engine
size is correct!
Estimate
Empty Weight
Calculate using Raymer
weight equations
Calculate fuel
required for
design mission
Calculate the
Gross Weight
- Add payload, crew, fuel and
empty weight
Is the Calculated
Gross Weight =
Guessed Gross
Weight?
YES. Feasible
Design!
NO
Re-iterate using
newly calculated
Gross weight
Iterative Sizing

Weight Breakdown
Component Weight (lb) Component Weight (lb)
Wing 68,368 APU 930
Vertical Tail 1041 Instruments 3,212
Winglets 1,079 Hydraulics 6,139
Fuselage 124,394 Basic Electrical 4,419
Surface Controls 5,310 Avionics 4,989
Engine Install 16,997 Furnishings 12,200
Engines (QTY 3) 42,630 A/C 7,930
Fuel System 1,178 Oil 372
Batteries 300 Miscellaneous 600
Max Takeoff GW Empty Weight Fuel Weight PAX Crew
521,703 lb 231,740 lb 212,487 lb 60,200 lb 1,600 lb

Aircraft Systems
 Aircraft Systems have been upgraded to the new
technology of the Boeing 777x
 Integrated Systems – Critical Systems are integrated into
one cabinet
 Central Maintenance Computer
 Thrust Management System
 Flight Data Recorder System
 Primary Display System
 Data Communication Management
 Flight Management Systems

Fly-By-Wire (FBW)
 Mechanically signaled flight controls are replaced by
digital controls
 Flight Control Systems
 Actuation Systems

Propulsion System
 Engines - Rolls Royce Trent UltraFan
 Offers at least 20 per cent better fuel burn and CO2
emissions than the first generation of Trent engine
 Increased bypass ratio to 15:1

Alternative Jet Fuel
 Bio-SPK – 50/50 Blend of Jet A fuel and Jatropha Oil
 Jatropha Oil
 From Jatropha Curcas plant – resistant to drought and
can be planted in desert climates; can grow anywhere
 Compatible with current aircraft systems
 Engine ground tests showed reduction in fuel flow due
to higher heat of combustion
 Could possibly reduce carbon emissions by up to 80%

Approach
 Identified and addressed holes in systems and
processes that currently are in use.
 Incorporated existing materials, technology and data
analysis technique to improve airplane designs and
maintenance processes/programs
 Expected results is a overall improvement to not only
maintenance but operational efficiency as well.

 Listed improvements could extend major maintenance
by 25%
 Use of Composite Material in airplane design
 Redesign of Turbine Engine Blades
 Improve capabilities of Boeing’s Airplane Health Management
System (AHMS)
 Improvements in Maintenance Programs
 Condition Based Maintenance: based on data collected and
analyzed from (AHMS)
 use of “Machine Learning”.
 Key is some improvement require time to see results
Improvements

Composites
 Composites materials consist of a fibrous
reinforcements bonded together with a matrix
material
 Allows the stiffness and strength of the material to
change with direction of loading

Composites
 Beneficial characteristics
 Heat Resistance
 Weighs less than traditional materials
 Corrosion resistance
 Strength and durability
 Part consolidation
 A single piece made of composite materials can replace an entire
assembly of metal parts.

Composites
 Most efficient use of advanced composites in aircraft
structure is in applications with:
 Highly loaded parts with thick gages.
 High fatigue loads
 Areas susceptible to corrosion
 Critical weight reduction
 Major part of heavy maintenance is structural
inspections.
 Expanding the use of composites can contribute to
improvement and expanding on inspections intervals

Turbine Engine Blades
 Build hollow turbine blades
 Being developed at Iowa State University
 Benefits
 Coolant is blow through an arrangement of holes
 Creates a cooling film between the blades
 Reduces heat, allowing blades to retain there shape and strength.
 Better cooling equals fuel savings, longer lasting parts, cuts cost
• Improvements could reduce maintenance and inspections

Airplane Health Management
System
 What is it?
 Airplane Health Management System uses real-time airplane data to
provide enhanced fault forwarding, troubleshooting, and historical
maintenance information.
• Valuable decision making support tool
 Fix or fly mentality

Enhancements
 Current capabilities
 Engine monitor/flight parametric data such as fuel flow, fuel mileage,
thrust deviation.
• Enhancements
 Pinpoint vibrations
 Expand system to include flight controls and structural vibration monitoring.
• Why flight controls and structural?
 Detection depends entirely on crew
 Response to vibration is a exercise in airmanship
 Monitoring and reducing vibrations can reduce structural fatigue. This
could lead to reduction in schedule and unscheduled maintenance repair
time and cost
 Extend structural intspections
 Identifying and correcting the cause of in-flight airplane vibration often is accomplished
through trial and error, which can consume many maintenance hours (Hence pinpoint
vibrations)

Results
• AHMS = reduction in schedule interruption, increase
in maintenance and operational efficiency.
 Valuable data can be obtain for use in optimizing
maintenance.
• Key
 The system and its architecture must be developed with
clear requirements and metrics.

Challenges
 Requires a strong commitment
 Looking passed upfront cost and seeing future savings
 System development is an intensive and time
consuming process
 Results may take years

Improve Maintenance Programs
• Boeing currently conducts a review of maintenance
processes
 Improve the process
• How?
 Incorporate AHMS data
 Develop and system which
incorporates machine learning

Improve Maintenance Programs
 Optimization of maintenance programs will be based
on:
 Results from analysis
 Fleet Trends
 Real world outcome
 Evaluation of 400 task on Boeings 777
 Resulted in the extension of the maintenance inspection
intervals.

DATA!
• Power of Data
 Statistical approach
 More methods of analyzing data than one can imagine
• System requirement?
 Data and than more data
 Must be good data (garbage in garbage out).
 Current Boeing method relies on the
 Collection of Service data
 Analysis of Service data
 Both Positive and Negative
 Results
 Provides necessary information to make decisions and
recommendation

Enhanced Maintenance Programs
 Take it one step further
 Use AHMS data
 Machine Learning “Big Data”
 Use machine learning to optimize a predictive maintenance
schedule

MACHINE LEARNING
 Machine learning
 Part of artificial intelligence, concerns the construction and study of
systems that can learn from data.
 Some machine learning systems attempt to eliminate the need for
human data analysis, while others adopt a collaborative approach
between human and machine.
 Uses algorithms to learn from data.
 Aids in identification of key trends that otherwise may be missed
 Can contribute to the modification of maintenance programs to
improve efficiency

Conclusion
 Everything discussed builds on one another
 Impact is not just limited to Maintenance

Requirements Verification
• Passenger transport
• This aircraft can operate as a commercial passenger carrying flight and an
extended range of passenger carrying operations.
• 250 – 400 passengers depending on configuration
• Aircraft can carry a maximum of 305 Passengers
• Operating altitude = 50,000 ft
• Cruise altitude is at 50,ooo ft
• Reduced fuel consumption, 20% less than 777
• Fuel consumption is 20% less per engine
• Range min 4500nm
• Aircraft range is 4500nm
• High speed subsonic M=.95
• Aircraft cruise speed is in High subsonic region at M=0.9
• Major maintenance span increased 25% over B777
• Major maintenance span increased

References
Bertin, John J., and Cummings, Russell M., Aerodynamics for Engineers, 5th Ed., Pearson,
New Jersey
Component Weights." n.d. Document. 15 September 2011.
<http://adg.stanford.edu/aa241/structures/componentweight.html>.
Allen, Mike. "Alternative Fuels to Gasoline - Cost of Alternative Fuels - Popular Mechanics."
Automotive Care, Home Improvement, Tools, DIY Tips - Popular Mechanics. Popular
Mechanics, 1 May 2006. Web. 19 Oct. 2011.
<http://www.popularmechanics.com/cars/alternative-fuel/news/2690341>.
"Jatropha Advantages - Benefits." PlantOils.in - The Home of Plant Oils Online. Oil from
Jatropha. Web. 19 Oct. 2011.
<http://www.plantoils.in/portal/jatropha/add/adv/adv.html>.
Kinder, Dr. James D., and Timothy Rahmes. "Evaluation of Bio-Derived Synthetic."
Evaluation of Bio-Derived Synthetic. The Boeing Company, June 2009. Web. Oct. 2011.
<http://www.ascension-publishing.com/BIZ/Bio-SPK.pdf>.
Raymer, Daniel P. Aircraft Design: a Conceptual Approach. Washington, D.C.: American
Institute of Aeronautics and Astronautics, 1989. Print.
Rolls Royce UltraFan. Rolls Royce. Web. 12 Mar. 2014. < http://www.rolls-
royce.com/news/press_releases/2014/260214_next-generation.jsp>.

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