PYROTAK - Emergency Door Opening System

PYROTAK - Emergency Door Opening System

For modern aircraft manufacturing, competition and low-cost pressure are no longer unfamiliar, especially in the case of a weak dollar. Despite this, safety and technical reliability are still the top priorities. For wide-body aircraft, efficiency and environmental considerations require research and innovation in any feasible area. The Bavarian scientific industry community is trying to break the shackles of the building models for cabin doors and emergency door opening systems.

In the process of building an aircraft, minimizing weight is a huge challenge. The cabin door plays a key role in the overall weight balance. In the field of safety-critical emergency door opening systems, the requirements for weight and cost are high. This is why the PYROTAK research project was established. This research project was carried out by companies and universities in Bavaria and has been successfully implemented. The participating companies and universities, under the direction of the head of the Eurocopter Deutschland GmbH, Donauwärth society, are developing a new door actuator to open the doors of wide-body aircraft in emergency situations. In addition, this innovative concept also offers the possibility of upgrading existing aircraft. If the other applications of the starter are similar to those used in the aviation industry, this also applies to a wider range of applications in the starter field, such as the emergency opening system of airplane passenger doors. As far as the R&D and manufacture of emergency door opening systems is concerned, the positive results of this study will not only benefit the Bavarian economic zone but also the entire aviation industry.

The PYROTAK research project has an investment of 2 million euros and is expected to be completed by the end of 2010. The Bavarian Research Foundation provides 50% of the project's funding. Through the innovative research and experimentation of this passenger door emergency opening system, the status of Bavaria as an aviation region can be strengthened. At the same time, it can also create new areas for participating companies. The starting point of the project was to refer to the previously known emergency opening procedure for passenger doors of airplanes: electronically or pneumatically. But considering the weight, maintenance costs, complexity of electronic systems and energy density, these are not the best choices. Pyrotechnic propellants have not yet been fully developed in the aviation field. So far, the business potential of this drive has not yet been implemented. The purpose of the PYROTAK project is to develop a pyrotechnic rotary drive system to ensure that passenger doors can be opened automatically in case of an emergency.
The introduction of completely innovative technologies, such as the use of pyrotechnics as a rotary starter, requires the realization of superior cooperation between technology, research and industry. Eurocopter Deutschland GmbH, Donauwörth is a leading manufacturer of commercial aircraft doors and cargo doors, especially for Airbus. The pyrotechnic door actuator development also includes many famous universities and companies. The HS Product Engineering Company in Olin is responsible for the development of pyrotechnic boosters. The particular challenge is whether fireworks can be used for slow-running systems. Prof. Johann H?cherl (authentication) and Prof. Dr. rer. nat. Michael Pfitzner (thermodynamics) from the University of the Wehrmacht at the University of Neubiberg in Munich provided more scientific assistance for this project.

Prof. Dr.-Eng. Bernhard Frenzel and Prof. Dr. Peter Kurzweil of the University of Applied Sciences in Amberg-Weiden are responsible for the conception and design of the ignition device. The pyrotechnic propulsion device is activated by the ignition device and then provides the motor with the gas required for operation. The rotary actuator opens the airplane's door. In this collaborative research project, there are two different driving concepts: one is a direct gas engine and the other is an indirect gas engine equipped with an additional retarder. Prof. Dr. Eng. Andreas P. Wei? of the University of Applied Sciences, Amberg Weiden, is responsible for the design of the air flow machinery for gas engines. The engineers of the Bavarian HS Product Engineering Company are responsible for conceiving the concept of a direct gas engine.

DEPRAG's R&D laboratory is responsible for the development of an indirect pyrotechnic ignition engine with a reducer. This company in Amberg has more than 80 years of experience in producing various pneumatic motors. The central part of this device is the air motor as a drive device. Depending on the application, pneumatic motors, gears or turbine drives can be used. For this research project, the turbine drive is the most suitable because it has the highest power density and can be operated without oil.

With a suitable turbine motor, high drive performance can be achieved with a very low weight in the smallest space. The device can reach a maximum of four kilowatts and weigh less than two kilograms. DEPRAG's turbines have been used in areas such as hand-held pneumatic grinding wheels.

The advantages of low weight and high performance make DEPRAG German turbine very suitable for use in PYROTAK emergency door opening systems. DEPRAG German engineers are doing their utmost to develop this project, using a pyrotechnic gas engine with a reducer to apply its torque directly to the door open drive. Finally, the ELEKTRO-METALL company of Bavaria from Ingolstadt will complete the assembly and integration of the starter equipment. The PYROTAK emergency door opening system has advantages such as maintenance-free, reliability, and low weight, so the research community expects it to take a leading position in the expanding market. In the future, aircraft manufacturers will increasingly trust the delivery of complex systems to reliable professional system suppliers to increase their cost-effectiveness. Therefore, it can be expected that the bidding for the emergency systems of aircraft doors, door monitoring and emergency sliding systems will become one of the parts of the “whole batch”. With these forward-thinking technologies such as PYROTAK, not only Eurocopter Deutschland GmbH, but also other participating companies can expect to be protected and improved.

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