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DAAP16048.1477058023 Blue Edge
DAAP16048.1477058023 Blue Edge
ABSTRACT
In 2015, Airbus Helicopters unveiled the secrecy around its Dauphin successor and presented the all new H160 heli-
copter. A special feature immediately attracting attention is its unusual and revolutionary fore-aft swept main rotor
blade. This design, aiming at reducing the blade-vortex interaction noise signature and also reducing fast forward
flight power requirements, finds its origins far back in the 90s, when DLR and ONERA formed a joint team to
acoustically optimize a rectangular reference rotor blade. Based on state-of-the-art comprehensive rotor codes and a
50-50 work share, the ERATO rotor blade design was developed, patented worldwide and tested on a rotor test rig
and in the wind tunnel. Airbus Helicopters took up that design, optimized hover and forward flight high lift perfor-
mance and prepared it for serial production, until it finally made it as the Blue EdgeTM rotor blade on the H160 heli-
copter. The paper covers the history and technical achievements, wind tunnel test results and flight tests.
98
Measured
Limit < 3/02 BK117C1 AS365N2 S-76C
96
3
BVI noise reduction and hence has addressed a noise source 0.3 0.1
with very impulsive character which has been mentioned
ERATO OA407
above. The excellent results triggered a follow-on project in
, ERATO
order to further raise the maturity level of this technology, in 0.2 0.0
, 7AD
OA312
which Airbus Helicopters and ONERA designed and tested a
full-scale variant of the ERATO concept. Airbus Helicopters OA409
has first shown this modified ERATO blade as its Blue 0.1 -0.1
EdgeTM design at the Heli-Expo 2010 in Houston. Now, the
7AD
Blue EdgeTM blade has found its way to the H160 helicopter
which is currently under flight test evaluation. This paper
0.0 -0.2
OA213
gives an overview on both the ONERA-DLR research pro-
OA209
ject ERATO and its results as well as the development activ- -0.1 -0.3
ities at Airbus Helicopters.
0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
THE ONERA-DLR ERATO PROGRAM
( a ) ERATO rotor blade vs. 7AD reference blade geometry.
In 1991 ONERA and DLR formed a joint team to design a Dashed: sections fully instrumented with pressure sensors.
rotor blade with reduced BVI noise signature purely by pas- 0.20
sive design, leading to the ERATO rotor blade design
(Refs. 21-27). Quarterly meetings took place to exchange
results of parameter variations and define the actions for the 0.15 thickness
next steps. Industry representatives from Aerospatiale and
MBB (from 1992 on as Eurocopter; renamed in 2014 to 0.10
Airbus Helicopters) joined the meetings as industrial observ-
ers and contributing the design optimization with their ex- 0.05
pertise. Since the rotor was to be tested in both the German
twist
Dutch Wind tunnels Large Low speed Facility DNW-LLF 0.00 7AD
on DLR’s rotor test rig (December 1998) as well as in
ONERA’s S1MA large transonic wind tunnel (March 1998) ERATO
the radius was chosen as 2.1 m and the rotational sense -0.05
counter-clockwise as seen from above. 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
The modeling and simulation codes employed were ( b ) ERATO and 7AD blade twist and absolute thickness.
mainly based on Blade Element Theory: the S4 isolated high
resolution rotor code on DLR side, and the Airbus Helicop- Figure 3: ERATO aeroacoustically optimized rotor blade
ters R85 code further improved by ONERA, which later design compared to the 7AD reference rotor blade.
formed the basis of the HOST code. DLR used a prescribed
wake method based on the Beddoes model while ONERA The design features of the ERATO aeroacoustically op-
used their MESIR free-wake. The reference flight condition timized blade are:
was a representative 6° descent condition at about 70 kts
(35 m/s) flight speed and scaled-down loading. With the • the largest chord is located around 65% radius
boundary to keep the thrust weighted solidity constant the (leading to a strong taper towards the tip) with the
following parameters were varied in work share with the goal to redistribute the lift from the tip towards
overall goal to reduce BVI noise radiation: more inboard, aiming at reducing the tip vortex
strength;
• chord distribution (taper) • a combination of fore-aft sweep with the goal to
• quarter chord line distribution (blade sweep) distribute BVI interaction topology from a quasi-
• twist distribution parallel BVI (7AD) to azimuthally/radially distrib-
• airfoil distribution uted BVI (ERATO);
• rotor rotational speed (tip Mach number) • as a side effect, sweep reduces the effective Mach
number on the blade and thus alleviates compressi-
The starting point of the optimization process was the bility effects, leading to less power drag in high
ONERA 7AD rotor blade geometry. The ERATO blade speed flight and – though no design goal – reducing
design freeze happened in 1996 and a Mach scaled model rotor power consumed;
rotor was jointly built (Ref. 21). Figure 3 shows details of • usage of modern next generation rotorcraft airfoils
the ERATO blade design, compared to the 7AD rotor refer- with high lift capability in the inner regions up to
ence blade. 70% radius; combined with linear strakes to thinner
and finally transonic airfoils at the blade tip with
4
reduced shock characteristics at high subsonic Wind Tunnel Testing in DNW-LLF and S1MA
Mach numbers (again reducing drag and power);
• usage of higher twisted blades compared to the ref- In order to get maximum use of wind tunnel tests and to
erence rotor which again aims at redistribution of understand the underlying physics, one rotor blade was
lift towards more inboard locations. heavily instrumented with 125 absolute pressure sensors and
32 strain gauges. The other blades got dummies for blade
Of course, the fore-aft swept blade design was suspected dynamics reasons and some strain gauges as well. All blades
to generate aero-elastic problems due to strong couplings of were equipped with flap, lag and pitch sensors at the articu-
especially flap and torsion modes, compared to a straight lation and pitch bearing.
blade such as the 7AD. The structural design was therefore
carefully chosen at least to avoid strong coupling at the nom- The DNW-LLF tests, where in the open jet configura-
inal rotational speed. Any flap-torsion mode proximity was tion about 78 m/s maximum wind speed could be achieved
requested not to be close to a blade harmonic number, i.e., (Figure 5), focused on rotor acoustics, vibrations, and per-
4/rev or 8/rev (as the number of blades was 4) to avoid ex- formance in hover and at low to moderate speeds. The
cessive vibration transmitted to the non-rotating frame. The S1MA tests (Figure 10) aimed at high speed flight with
computed fan diagram of both model-scale rotors, using a respect to rotor performance and noise, high lift (including
finite element beam method based on the Houbold-Brooks stall) and vibration. DNW testing (Refs. 20, 22-23) capabili-
equations is given in Figure 4. ties employed in its low back-ground noise anechoic envi-
ronment included a microphone traverse for measurement of
the noise carpet below the rotor (centered in the lower half
of Figure 5). Optical blade deformation measurements were
performed by a fringe correlation method (FCM, comple-
mentary to the strain gauges readings within the blades),
Ref. 24, that was provided and operated by DNW. With this
method it is possible to measure flapwise and torsional de-
flections along the blade span at selected azimuthal angles.
This technique is based on the fact that a grid, which is pro-
jected on the surface of a structure, will change its pattern
when the structure is deformed or displaced.
5
Furthermore, these flow field visualization measurements
have been done for getting an impression of the tip vortex
trajectories while traveling downstream the rotor disk for a
better understanding of the BVI noise phenomena. Figure 9
represents results gained by means of the LLS method.
( b ) rear view
Figure 9. Tip vortex and rotor blade location measured
with the LLS method. 1 = 23 4⁄5 , 6 = 7°.
Figure 10. The ONERA-DLR ERATO rotor mounted in
In S1MA, the test section was equipped with its “low the S1MA 8 m Ø closed test section.
speed” acoustic liners (black surfaces in Figure 10) which
can withstand Mach Numbers up to 0.32. Acoustic meas- 105
urements were realized using 10 microphones located espe-
cially in the area affected by BVI noise. Tests included also 7AD
load measurements with a 6-component rotor balance locat- 100 ERATO
ed inside the test rig, blade deformation measurements using
the Strain Pattern Analysis method (SPA), pressure meas-
urement on the blades to establish correlation between noise 95
levels and Mach number distribution on the blades. All data
were acquired by S1MA wind tunnel operators and delivered
to ONERA and DLR scientists for analysis after the test. 90 0.0625
0.0750
Wind tunnel test results
0.0875
85
Rotor Noise Radiation
-5 0 5 10 15
Typically for helicopters, the maximum BVI noise radiation climb descent
occurs in landing approach, i.e., at flight speeds of about Figure 11: BVI noise reduction potential of the ERATO
70 kts (35 m/s) and 6° descent angle. In DNW-LLF a de- rotor at 1 = 23 4⁄5.
scent angle sweep from climb to steep descent was carried
out to identify the maximum BVI noise radiation condition. At the reference 35 m/s, 6° descent condition a signifi-
This is shown in Figure 11 for various rotor loadings. cant BVI noise reduction of roughly 4 dBA was demonstrat-
ed, verifying the numerical predictions, Figure 12. One of
the major results of these tests was that noise could be re-
7
duced for a wide range of flight conditions, demonstrating a It can be observed in this figure in a qualitative manner
significant robustness of acoustic gains with respect to varia- that the blade pressure waves in the first and fourth quadrant
tions of descent angle, advancing velocity, trim conditions of the 7AD rotor appear more intense than those of the
etc. ERATO rotor. Accordingly, the noise radiation intensity of
the ERATO rotor is found significantly lower.
( a ) 7AD rotor
( b ) ERATO rotor
( b ) ERATO rotor
Figure 13: Rotor blade loading, high-pass filtered at
Figure 12: Acoustic results of DNW-LLF tests showing 10/rev, showing BVI locations and intensity.
the ERATO rotor with significantly less BVI noise signa- 1 = 23 4⁄5 , 9: ⁄; = <. <7>3, 6 = 7°.
ture compared to the straight reference blade.
1 = 23 4⁄5 , 9: ⁄; = <. <7>3, 6 = 7°. It can be seen that the ERATO rotor has less amount of
BVI in terms of number of BVI events and intensity on both
The reason of BVI noise reduction was mainly seen in a the advancing side and the retreating side of the rotor. This
different BVI topology due to the blade planform. The dou- was quantitatively confirmed by the post-treatment of LDV
ble sweep causes the BVI not to happen over a large radial measurements which emphasized the reduction of the vortex
portion simultaneously as is the case with a rectangular intensity emitted by the ERATO blades (Figure 14). A fur-
blade; rather it distributes the BVI event in time and space. ther proof of this observation is given in acoustically rele-
Figure 13 (a) shows the high-frequency, BVI-related content vant time derivative of the section loading at a representative
of leading edge pressure distributions (high-pass filtered at radial station close to 85% radius (ERATO) and 81.5% radi-
10/rev) as source of the noise and in (b) the same is shown us (7AD) in Figure 15 (a) for the advancing side of the rotor
for the ERATO rotor. and in (b) for the retreating side. In this case the time deriva-
tive is based on the 6-40 bpf of the data.
8
A vortex travelling this local down- or upwash gets addi-
tional trajectory deflections.
0.8
7AD
0.6 ERATO
0.4
0.2
0.0
( a ) 7AD rotor, ? = @. >2 4> ⁄5
-0.2
-0.4
20 30 40 50 60 70 80
( a ) Advancing side
0.4
7AD
0.2 ERATO
0.0
-0.2
( b ) ERATO rotor, ? = 2. 37 4> ⁄5
Figure 14: Velocity field and vorticity AB derived from it -0.4
around a vortex as measured by PIV.
1 = 23 4⁄5 , 9: ⁄; = <. <CD3, EF = <. 7GD, 6 = 7° -0.6
9
The low frequency content of rotor blade loading (0- the ERATO rotor was operated with different tip Mach
10/rev) is shown in Figure 17, making proof of the assump- numbers. In any condition, the rotor trim ensured the same
tion. While the 7AD rotor has a relatively smooth loading overall lift and propulsive force for both rotors. For the same
distribution with small to moderate harmonic content, the tip Mach numbers, gains are between 2 and 3 dBA, but are
ERATO rotor has stronger dynamic fluctuations, quite simi- significantly larger with reduced tip Mach number.
lar to what has been observed in the HART test using HHC
active rotor blade control.
( a ) 7AD rotor
-5
-10
10
tions (120 and 140 kts = 216 and 252 km/h), the ERATO Efficiency in Hover
rotor provides gains whatever the lift coefficient, up to 7 dB
at ⁄' = 0.0875 which corresponds to a strong BVI case. Although not part of the specifications given for the optimi-
These tendencies were confirmed by the DNW tests as zation of the rotor, hover performance assessment was done
shown in the previous section. Even if the flight conditions by Airbus Helicopters. The same 7AD and ERATO rotor
simulated in S1MA where not those for which the ERATO models as used in DNW-LLF and S1MA were installed on
design was optimized, noise reductions have been demon- the Marignane test rig, and the Figure of Merit of the two
strated for 75% of the measured points. rotors was measured for different tip Mach numbers. A sam-
ple result of these measurements is illustrated in Figure 22.
Rotor Power Consumption in forward flight Both rotors show similar performance for thrust coefficients
⁄' R 0.087, with even slightly higher efficiency for the
The high speed and high load tests at S1MA wind tunnel of ERATO rotor than for the 7AD rotor.
ONERA (Refs. 20, 25) confirmed a smaller power consump-
tion of the ERATO rotor throughout the entire range of op- 0.7
erational conditions of up to 9% compared to the reference
rotor and 5% in average, see Figure 20. 0.6
2.5 0.5
7AD
FM
0.4
ERATO
2.0 7AD
0.3 ERATO
0.2
1.5
0.1
11
elsA solver. In 2004, these methods have been applied to the
HART Baseline test-case, but no BVI was simulated due to
too coarse blades and background grids. In the framework of
SHANEL, the objectives were to capture the blade-vortex
interaction with fine reference meshes and to improve the
efficiency of the computations by applying recent numerical
methods (high-order schemes, vorticity confinement, etc.).
The simulations, using a loose CFD-CSD coupling were
then applied to the complex geometry of the ERATO blades.
The CFD results were used as input data for the noise analy-
sis and compared to the HART experimental measurements.
12
• Phase 4: Flight demonstration on a H155 demon-
strator in order to validate the aerodynamic, acous-
tic and dynamic characteristics and performance.
3
C0 ∆FM=0.01
2
1
C1 7
9
12 13 14 15 16 17 18 19 20
ZBAR
C2
Figure 28: CFD evaluation of initial blade designs in
hover conditions
C3
Since all the optimizations carried out in this first phase
of the design were done using a rigid blade assumption, the
next phase was to define blade structural data and repeat the
C4 aerodynamic and acoustic simulations using the soft blade
assumption. Taking into account the elastic blade defor-
mations did not significantly modify the good hover perfor-
mance of the optimized blade, but led to reduced acoustic
C5 gains (but still significant for descent angles higher than 6°,
see Figure 29).
14
the final Blue EdgeTM design and the spanwise extension of stacking of fabrics composing the structure of the blade.
the backward swept part of the blade was reduced. This led However, with this kind of geometry, most of the matter is
to a good aerodynamic-acoustic-dynamic compromise found behind the lift center, therefore the centers of gravity,
(Figure 30), with high expected FM in hover, and promising elastic and torsion are in a position ready to generate im-
noise reductions in low-speed descent flight. portant couplings between the flapping and torsion modes.
Although efforts were made to decrease the polar inertia of
the backward swept area and to minimize the offsets of these
centers compared to the lift center, this was not sufficient to
have an acceptable margin with the phenomenon of instabil-
ity. For the project of Blue EdgeTM blade, the design of this
zone was fundamental to improve this situation.
15
Solicited by multi-axial efforts, it passed the levels of
vibratory fatigue successfully. Measurements from flight
tests confirmed the good distribution of the constraints in the
structure and confirmed the margins of resistance. The fore-
aft swept shape was a challenge for the technological design
of the blade. This technological definition has been patented
(Ref. 33) and became a reference in the state of the art of the
design of Blue EdgeTM-type blades, from which H160’s
main rotor blades were derived.
16
A first assessment was done using near-field micro- Noise footprint assessments also shown in Ref. 34 illustrate
phones attached to the airframe. This allowed covering the the fact that the significant gains measured on the centerline
whole flight envelope in a reduced time in order to obtain and retreating side of the aircraft provide significant reduc-
comparative results of the two blade shapes in the same tions in the surface area exposed to the loudest noise con-
atmospheric conditions. The expected noise reduction was tours, which highlights the high potential of this rotor for
thus quickly confirmed in a qualitative manner, and it was community noise mitigation.
noted that impulsive noise was mostly eliminated from a
large portion of the flight envelope (Figure 36). This feature
offers greater capability for developing noise abatement advancing blade side retreating blade side
procedures which use moderate descent angles and decelera-
tion rates.
EPNL, EPNdB
0
0
5 EPNdB
0
-250
-500
-500
Blue EdgeTM
Rate of descent,
-750 -6
Baseline
-1000
level, dBA
-1500 baseline and the Blue EdgeTM rotor, from Ref. 34.
60 80
80 100
100 120
120 140
140
CONCLUSIONS
Figure 36: Difference between near-field A-weighted
sound pressure levels for the two rotors (negative values The Blue EdgeTM rotor blade is an excellent example of
where the reference rotor is louder), from Ref. 34. technology transfer from fundamental research to industrial
application. After numerical optimization of the blade geom-
Following the near-field tests, an extensive flight testing etry using state-of-the-art comprehensive codes and structur-
campaign was performed using a seven-microphone trans- al design optimization to address aeroelastic issues, Mach-
versal ground array and focusing on providing a deeper scaled model rotor blades were built and tested in large-scale
analysis of the noteworthy features previously measured. wind tunnels. The results validated numerical predictions
The flights were of course performed with both the reference and industry took over the design for adaptation and further
and Blue EdgeTM rotors during successive days, ensuring optimization with respect to industrial application. The ma-
again consistent ambient conditions. The tests with ground jor conclusions are:
microphones not only allowed quantifying the operational
noise reductions, but also were used to assess the directivity • State-of-the-art comprehensive codes completed by
patterns associated with the two rotors. high-order aerodynamic models (CFD) can success-
fully be employed for aero-acoustical optimization
The analysis focused on the flight conditions which of rotor blades with respect to BVI noise reduction.
showed the most differences between the straight blades and • Mach-scale models are invaluable to make a relia-
the Blue EdgeTM blades. This was a descent at 60 kts with an ble proof of the design and generate data for a deep
8° glideslope. In this condition, noise reductions of close to understanding of the physics involved.
5 EPNdB were measured close to the centerline, Figure 37. • Based on fundamental work performed by ONERA
The analysis showed that this noise reduction was directly and DLR within the ERATO project, Airbus Heli-
linked to a reduction of BVI noise. Interestingly, retreating copters, together with ONERA, continued research
side noise reductions were more significant than on the ad- and development with the aim of industrial applica-
vancing side. tion.
• Special attention was first given to further aerody-
Further investigations of the measurements and addi- namic refinements of the blade tip for improvement
tional computations using an acoustic solver coupled to a of hover performance with respect to figure of mer-
freewake code allowed to confirm that the blade’s backward it, modifying the twist distribution and introducing
sweep was very efficient in shifting the directivities more anhedral.
towards the advancing side of the blade, to observers directly • Special attention was given to the aeroelastic tailor-
to the side of the aircraft. These observer positions are quite ing of the blade to assure structural integrity, lead-
beneficial to noise reductions as highlighted in Ref. 34. ing to a double spar design.
17
• The results were confirmed by industry during REFERENCES
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19