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The Engine Tests For the Il-112 Have Begun
Tuesday January 24, 2017 09:50 MSK / Roman Gusarov
On September 15, 2016 the United Engine Corporation started testing a new turboprop TV7-117ST engine intended for the prospective Russian light military transport aircraft Il-112V. The product is developed by the team of JSC Klimov, however commercially TV7-117ST will be made in the extended cooperation between enterprises of the UEC where are JSC Salyut Gas Turbine Engineering Research and Production Centre, JSC MMBE named after. V. V. Chernyshev and others included.

The turboprop engine TV7-117ST expands family of gas-turbine TV7-117 engines. The family also includes engines TV7-117 TV7-117S and TV7-117SM for regional passenger aircraft IL-114 and helicopter engine TV7-117V installed on the new Mi-38 helicopter. The advanced technical and constructive solutions are implemented in this product. The engine has high power and efficiency. Thus, the power at maximum take-off is 3 000 hp, at an elevated emergency mode - 3600 hp. With the dry weight of no more than 500 kg the engine has a specific fuel consumption of less than 200 grams per hp an hour.

The new light Il-112V military transport aircraft is intended for transportation and air landing of light weapons and military equipment, freights and staff, and also for transportation of of a wide range of different loads in case of commercial operation of the aircraft. The Aviation Complex of S. V. Ilyushin is engaged in its development and in 2017 it is planned to finish the assembly of the first aircraft.

The declared parameters of the new engine will be checked at the test bench, as an example of industry innovations. "Its features allow to test the engine unit directly with the propeller, nacelles and other components of the aircraft (part of the wing and fuselage). During the upgrade performed in the shortest possible time, the complex which is initially constructed as experimental for testing of power aggregates of helicopters was completed with the modern control and measuring equipment", - the General Designer of JSC Klimov Alexey Grigoriev tells.

During the creation of the engine developers were guided by the ideology of a basic gas generator. As a result the whole family of helicopter and aircraft engines with a very high proportion of unification is created which is especially important in the current market conditions.

The engines of the TV7-117 family have a complicated destiny which in many ways reflects the history of domestic aviation engine-building. The first aircraft modifications were designed during the industry crisis, practically only on the enthusiasm of developers. Despite the fact that TV7-117S engine for regional passenger aircraft Il-114 was created not in the best of times for the country, in many ways it was one of the best world samples in its class. Its further development - the TV7-117SM engine is constructed on a modular scheme, which reduces the material and time costs of repair and service, takes a leading role on the ratio of capacity and weight. In 2015 the AR IAC Type Certificate was received by the TV7-117V turboshaft engine, intended for use in the propulsion system of the newest Russian helicopter Mi-38.

"Today, when favourable conditions for development of domestic science, technologies and production are created, we can use our experience even more efficiently. This clearly confirms the success of United Engine Corporation in the implementation of the project TV7-117V for the newest domestic helicopter Mi-38. I am sure that TV7-117ST for Il-112B will be a model of good design ideas and effective industrial cooperation ", - said the Executive Director of JSC Klimov Alexander Vatagin.

TV7-117V engine made it possible for the helicopter Mi-38 to increase flight safety, including cases of emergency situations, by introducing emergency mode capacity to 3750 hp, also to expand the range of applications, including the method of reducing fuel consumption. UEC and Russian Helicopters concluded a contract to supply 50 TV7-117V  engines for installation on Mi-38 helicopters. The work of serial production of TV7-117V is developed in full on the new production site of JSC Klimov in St. Petersburg.

Also on TV7-117V engines is installed a new digital electronic control and monitoring system with digital FADEC control unit of a new generation BARK-6B, developed by JSC Klimov. The electronic control system BARK-65STM for TV7-117ST is also constructed based on BARK-6V. Adaptation to this type of the engine is performed by completion of the software. ACS now controls not only the engine but also the propeller, that is, the entire power unit of the aircraft. The developer and manufacturer of hydromechanical aggregates of ACS for the TV7-117ST engine is one of the Perm enterprises UEC - JSC UEC-STAR.

Engines of the TV7-117 family are made completely from the Russian parts, components and accessories. It became possible with the creation of effective cooperation network within the competence centres of technological industrial enterprises included in the structure of the UEC. JSC Klimov i is a subdivision of JSC United Engine Corporation (part of the Rostec State Corporation). The UEC is an integrated structure specialising in the development, serial production and maintenance of engines for military and civil aviation, space programs and the Navy, and also in the oil and gas industry and power. One of priorities of UEC is the implementation of comprehensive programs of development of the industry with the introduction of new technologies that meet international standards. Revenue of the company in 2014 constituted 199,9 billion rubles.

«The test run of TV7-117ST is a significant event not only for domestic engine-building industry, but also for the entire aviation industry - said the CEO of JSC UEC Alexander Artyukhov. - New engine in terms of power and economy, no doubt is one of the best examples in class. I am confident that the combination of technical characteristics of TV7-117ST with advanced decisions put in Il-112V are going make the aircraft a worthy transport platform for Russian Air Forces».

The production of key components of the new turboprop TV7-117ST is developed by JSC Moscow Machine-Building Enterprise named after V.V. Chernyshev. There are produced turbocharger components and the free turbine. The company has an experience in the production of engines within the family - there exactly before the beginning of the 2000s the release of TV7-117S engine was organised. «The creation of the power plant for the Il-112V aircraft is one of the key programs of the UEC in engines for military purposes, - the CEO of JSC UEC Alexander Artyukhov says. - Terms of development of production of the engine is very tight. Despite this MMBE named after VV Chernyshev successfully fulfils all its obligations under the development of this product. Largely due to the work of the enterprise the production of an equipment of TV7-117ST for testing is ensured».

Another company in the cooperative chain for TV7-117ST engine is one of the largest enterprises of the UEC - Moscow JSC Salyut Gas Turbine Engineering Research and Production Center. Production of four units of TV7-117ST engines is assigned to the Salut: the central wheel-case, the reducer, the upper and lower gearboxes. Salute also has an experience in the production of engines within the family - at its Omsk branch Оrganization and Methodology Department of P. I. Baranov the release of TV7-117S was organised earlier.

«Taking into account current trends of engine production and tight deadlines of implementation of this project in case of production TV7-117ST are used the strongest competences of Salute and enterprises of the defence industry of the country. – the Deputy General Director, Managing Director of JSC Salute Gas Turbine Engineering Research and Production Centre Vitaly Klochkov speaks. - The geography of internal cooperation on this product is very wide – in addition to the head Moscow platform of Salute and the Omsk branch OMD of P. I. Baranov participate such companies as the Pribor Plant, VSW Salute, ICD Horizon and a number of the affiliated companies of Salute, such as JSC Agat, JSC Agregat, JSC NFMZ».

And the JSC Klimov which is the head company developer of engines of the TV7-117 family takes its part in this project. JSC Klimov has a great history. It was founded in 1914 in St. Petersburg as Russian Renault joint-stock company. Production of cars and aviation engines of Renault, including the first-ever heavy four-motor bombers Ilya Muromets was a main type of its activities then. During the WWII the company issued piston engines of the VK-100 series developed by Vladimir Yakovlevich Klimov on which 90% of destructive aircraft flew. During war the plant was evacuated to Ufa, thereby having laid the foundation for future Ufa engine building.

After war in 1946 in Leningrad under the leadership of Klimov was created the Experimental Design Bureau. The first domestic turbojet VK-1 was designed there. The fifties and sixties were marked by the development of gas turbine power plants for helicopters and airplanes, the liquid-jet engines for missiles for various purposes.

The factory created the engines and gear for the Mi-2, Mi-8, also the TV3-117 engine which was installed on the majority of domestic middle-class helicopters like Mi and Ka. Currently helicopters with power plants on the basis of engines of the TV3-117 family are operated in more than 60 countries of the world, they have equipped more than 90% of the Russian helicopter fleet.

Also the power-plant created by Klimov for MiG-29 - RD-33 and box units KCA-2(3) have entered the history of engine-building not only at home, but also worldwide. And in the 1970s Sergey Izotov's group has created the tank gas-turbine engine GTD-1000T. Works on the engine came to an end in 1976 with the legendary T-80 tank in the Soviet Army. And absolutely unusual development – a torch of Olympic flame of the Moscow Olympic Games in 1980.

The beginning of a new century for JSC Klimov was noted by the development of the VK-2500 turboshaft helicopter engine for the Mi and Ka helicopters. Earlier the country shipped Klimov engines of the TV3-117 family made in Ukraine. VK-2500 is a further development of this engine. The advantages of VK-2500 are high fuel profitability, increased power characteristics, he use of modern automatic control system. Speaking about combat helicopters in the framework of the state defence order today all of them are equipped only with Russian VK-2500.

Today the main activity of the company is the development, production and servicing of turboshaft engines for helicopters, turboprop engines for transport and passenger aircrafts, jet engines for fighter aircrafts, automatic control systems and engine control.

JSC Klimov has its own design office, up-to-date production and experimental bases. The developments of JSC Klimov successfully compete with products of global manufacturers of aviation engines. The engagement of JSC Klimov covers the entire life cycle of products of its own design, including the construction of a modern system of after-sales service.

As part of the strategy of development of the aviation industry of the Russian Federation was implemented a large-scale national project St. Petersburg Motors with funding of more than 7 billion rubles. Its purpose is to establish innovative helicopter engines on the basis of JSC Klimov design-industrial complex (CPC). Production and administration buildings were built In Shuvalovo near St. Petersburg with all the engineering infrastructure, also was acquired a modern high-technology equipment, completely management system was renewed. New industrial site combines a modern design office with a flexible, well-equipped mass production, powerful testing facilities and strong service team. The total area of ​​the CPC is about 50 thousand sq. m.

The production system of the CPC is simulated in such a way that allows to create not only new products but also to expand its capacity to mass production of innovative products. The use of the most modern technologies both in the fields of development and production, and in management also was the main objective of updating of the company. The use of modern CAD/CAM/CAE of systems at a design stage, the use of the latest equipment (which is often custom-made just for JSC Klimov) are only a small part of global transformations which were implemented in this complex. A special place in the development of the company takes the increase in the proportion of use of additive technologies.

Today the complex reaches the estimated capacity of the first stage. It will allow UEC to produce TV3-117/VK-2500, TV7-117 engines and also to perform research and development activities, including assembly and tests on engines of the VK-2500, TV7-117 and RD-33 class at the same time. In plans of the second stage essential modernisation of testing facilities and also the increase in capacities to secure the production of engines.