DEVELOPMENT OF AN EMBEDDED COMPRESSOR WASHING SYSTEM FOR ROTARY-WING AIRCRAFT: INTEGRATION OF 'BLEED AIR' AND STRUCTURAL RESERVOIRS

Abstract

This paper details the development of an innovative embedded system for washing and cleaning compressors in rotary-wing aircraft, specifically focused on the EC 725 model with Makila 2 A1 engines. The research is based on the need to overcome the limitations of current maintenance methods, which rely on bulky external equipment, known as "cleaning drums," and ground power sources. These conventional methods present significant logistical challenges, especially in operations in remote locations or in high-salinity and dust environments, where immediate post-flight cleaning is critical to prevent corrosion and fouling of the compressor blades. The proposed solution integrates structural reservoirs directly into the aircraft fuselage and uses "bleed air" technology to pressurize and, crucially, heat the washing fluid. The use of heated water optimizes the removal of impurities and avoids thermal shock to the internal engine components, which operate at high temperatures. Beyond the technical gains, the automated system, controlled via a multifunction display (MFD) by the pilots, demonstrated significant results in terms of operational efficiency and sustainability. Quantitative analysis indicated an eleven-minute reduction in engine start-up time for the cleaning procedure, which translates into an estimated daily saving of 67 liters of fuel (QAV1) and a reduction in carbon dioxide emissions of approximately 34.65 kg per day. In short, the project validates the viability of an autonomous system that increases aircraft availability, reduces maintenance costs, and minimizes environmental impact, making the engine maintenance process more agile and effective in any operating scenario.