Activities and concepts

Citation

(2005), "Activities and concepts", Aircraft Engineering and Aerospace Technology, Vol. 77 No. 1. https://doi.org/10.1108/aeat.2005.12777aac.002

Activities and concepts

Activities and concepts

Keywords: Conferences, Aircraft, Aerospace industry

Products on display at Farnborough 2004 showed the companies' abilities as well as possession of the inherent know- how required to fully exploit the emerging technologies of the years ahead. Nowhere was this more evident in the civil field than in the advances in materials, engines and systems for the Airbus A380 which will make its first flight in 2005 and enter service in 2006, and the forthcoming Boeing 7E7 due for delivery in 2008. Major products of Bombardier and Embraer also added to the wealth of expertise illustrated against a background of substantial orders for the future.

Launch engine for the A380 is the Rolls-Royce Trent 900 which follows on previous designs and incorporates the largest fan in this series of powerplants with a diameter of 116in. (29.5 m) giving a bypass ratio of 8.5-8.7. Flight testing is currently under way with certification later this year. The engine features an eight-stage intermediate compressor (IPC), six-stage high pressure compressor (HPC), single- stage high pressure turbine (HPT), single-stage intermediate pressure turbine (IPT) and five-stage low pressure turbine (LPT). It will produce up to 76,500 lb thrust for initial application in 2006 but will be certificated up to 80,000 lb. Inlet mass flow is 2,655-2,745 lb/s.

The competitive engine for the A380 is the Engine Alliance GP 7200 being developed by General Electric and Pratt & Whitney. Ground testing is being carried out and flight in a testbed aircraft will be this year with certification in November 2005 and entry into service in October 2006, also at a thrust of 76.500 lb with clearance to higher values. It follows on previous successes of the two companies and incorporates a five-stage LPC, nine- stage HPC, a two-stage HPT scaled from the GE90-115B and a six-stage LPT.

Another area of competition concerns the Boeing 7E7 for which Rolls-Royces is developing the Trent 1000. It has new technology features and includes HP centra-rotation and IP offtake. Thrust will be 53,000-70,000 lb with a fan diameter of 112 in. and the engine will have a bypass ration of 11.1, the highest in the Trent series. It incorporates an eight-stage IPC, six-stage HPC, single- stage HPT and IPT and six-stage LPT. Certification is set for 2007 with entry into service the following year. The General Electric powerplant for the 7E7, the GEnx will produce 55,000- 70,000 lb thrust, the first complete engine going on test in 2006. It is being designed to bring a 15 per cent improvement in specific fuel consumption compared with the GE CF6-80C2 and by the end of 2004 the technology programme will be completed and initiation of the certification process (Plate 1).

Orders continue for Embraer's larger aircraft with the flight test programmes of the 175 and 190 running simultaneously and one pre-series 195 expected to fly before the end of 2004. Evaluation of the General Electric CF34-10E engine for the 190 has been completed and certification of the aircraft is expected late in 2005 with deliveries to the first customer, Jet Blue Airways, soon afterwards. Bombardier has announced a new aircraft programme known as the CSeries. These include two 110- passenger aircraft with ranges of 1,800-3,250 nm, respectively, and two 135-passenger models with ranges of 1,800-2,800 nm, respectively. Engines for these will be the subject of competing proposals in the future.

Plate 1 Rolls-Royce Trent 900

Engine research is proceeding to satisfy future requirements for a wide range of thrusts and major manufacturers are collaborating in many areas. The SNECMA range of companies, as well as in-house and French initiatives, is participating in several international research programmes including CLEAN and power optimised aircraft (POA) focusing on the development of more- electric aircraft (MEA). Other major manufacturers are also engaged in this project which can include a power source embedded in the engine, or fan shaft driven generator (FSDG). This concept will be further tested on the Rolls-Royce POA during 2005.

Although there were no Russian aircraft at the show, manufacturing companies of the CIS were well represented. The first order for 50 of the Sukhoi Russian Regional Jet (RRJ) was signed by Siberia Airlines. The aircraft will be powered by two SNECMA/NPO Saturn SM146 turbofans and flight development is due to start in 2006 for certification by Russian, US and European authorities the following year. Aircraft from the Ukraine were present, including the Antonov An-140-100 and An-74TK-200 STOL passenger/ freight transport.

A project that may be some way off was unveiled by Lockheed Martin with various configurations of supersonic passenger aircraft. Various illustrations were shown, the one illustrated is a supersonic business arrow-winged twin jet. It is 130 ft long with a span of 55 ft and weighing about 130,000- 140,000 lb at takes-off. A cruise speed of Mach 1.8 or less is quoted, the latter making it easier to achieve noise, efficiency and durability targets. The company says that the aircraft would meet Stage 4 noise rules and use conventional low-cost metallic construction.

Systems integration

The new models from Airbus and Boeing provide suitable opportunities for the launch of major developments in distribution and the embodiment of advances in avionics. As noted elsewhere, the A380 is the first MEA commercial transport. The conventional three hydraulic systems of the FBW arrangement are replaced by two hydraulic systems and two electrical systems. The active actuators are servocontrols and the stand-by actuators are electrohydrostatic actuators (EHA). In some locations on the aircraft, electrical back-up hydraulic actuators (EHBA) are fitted which provide power either from a hydraulic system or from an electric system. The design of the Airbus A400 M military transport also makes use of these developments. Another first in civil aviation is the use of 5,000 lb/sq in hydraulic systems on the A380 which allow the use of smaller and lighter components.

Goodrich is supplying the main landing gear for the A380, the first for the test rig having been delivered at the end of last year with further sets supplied for qualification testing and the flight test programme during 2004. Messier Dowty will provide the nose landing gear for this aircraft, the largest ever at 4.8m tall. This company is also involved in many other programmes including the Boeing 7E7 main and nose landing gear, the former baseline arrangement being a four-wheel truck tripod with oleo-pneumatic shock strut and dual folding and rolling braces. The 7E7 nose gear features a forward retracting cantilever gear with push- pull steering concept. On the military side, products include the landing gear system for the A400M military transport, comprising dressed main and nose gears, extension and retracting system, kneeling and raising system, and the steering system.

New design features incorporated for soft-field landing capability include each of the main landing gears consisting of three independent twin- wheel assemblies housed in fuselage sponsons. The twelve-wheel configuration contains the “high flotation” characteristics necessary for landings on unprepared terrain.

Hamilton Sundstrand provides the design and development of cockpit controls and the trimmable horizontal stabilizer actuator for the A380 and is also involved with a number of other systems on this aircraft including the air generation which will provide the cabin air conditioning control, the latter also managing the temperature of the aircraft's cargo compartments. The ram air turbine (RAT) providing emergency electrical power to flight controls and other essential electrically powered functions, will, also be provided. Hamilton Sundstrand also participates in many other programmes including those in the regional sector, among these being the large electromechanical flight control systems for the Bombardier CRJ-700/ 900 and Embraer 170/190 slat/flap units.

Honeywell will deliver 12 products and systems for the A380 which include the new flight management system (FMS) with graphical interfaces and reduced pilot workload and the aircraft environment surveillance system (AESS) which provides information about traffic, weather and terrain. Also supplied is the SATCOM system developed with Thales which includes a six MCU satellite data unit (SDU) and a four or eight MCU high power amplifier. The SDU provides overall system control and monitoring, data modulation and demodulation, data synchronization decoding, voice coding, decoding for the cockpit voice and data services. The high power amplifier is a linear instrument which provides the power gain to generate the required output power for broadcast towards the satellite. The system can be supplied with either type of high power amplifier according to requirements.

Also available is the RDR-4B which offers protection from windshear, protection from dangerous terrain, protection from cruise altitude turbulence and is supplied with terrain based auto tilt. This feature is also known as an automatic setting of antenna tilt angle. By interfacing the RDR-4B with the enhanced ground proximity warning system (EGPWS), the system will automatically select the optimum tilt setting for weather detection based on the aircraft's geometric altitude and terrain conditions ahead. This set-up does away with the over-scan and under- scan associated with manual tilt control. It also overcomes the introduction of ground clutter that can occur when using a tilt setting that fails to account for the terrain ahead.

Among many other products, Honeywell produces a digital head-up display (HUD) developed in partnership with Electrooptics Industries that incorporates an LCD projection system and is completely compatible with forward-looking infrared (FLIR) sensor systems. The FLIR-based enhanced vision system (EVS) improves operational efficiency and the conformal HUD symbology and Flight Plan Vector help to improve situational awareness during critical phases of flight. The EVS “sees” through the fog and presents a monochromatic image of the runway and surrounding terrain, as in the illustration.

Rockwell Collins illustrated the Head-up Guidance System HGS-500 developed by its Flight Dynamics business, which is among products certified and operating on business, airlines and military transport aircraft. An HGS is being developed for the Embraer 190 which, when it is operational in 2005, will mark the first commercial use of dual head-up displays. It uses LCD-based technology of enhanced image quality and improved reliability and provides pilots with improved situational awareness in all phases of flight. The HGS also gives Category IIIA guidance-to-touchdown for operations in poor weather conditions as well as for low-visibility take-off. The system will be integrated with the Honeywell PRIMUS Epic avionics systems on the Embraer 190 for Jet Blue Airways.

Smiths Aerospace will develop and supply the advanced common core system (CCS) for the Boeing 7E7. It will host all of the aircraft's avionics and utilities functions and will replace many standalone computers and databuses. This will include the leading and trailing edge high lift systems, main gear actuation and brake control monitoring and flight deck interface, nose gear steering, actuation and brake control, enhanced airborne flight recorder, as common computing resources. The company will integrate third party supplier-developed applications and associated software into the CCs in its role as first-tier integrator. Smiths will be responsible for the design and development of the systems integration and programme management, hydraulic actuation, electronics and software control.

The Canadian CMC Electronics company has produced the CMA-900 GPS (FMS) which is the first of its kind certified for GPS primary-means navigation in oceanic/remote areas. Designed for operation in the evolving FANS, CNS/ATM and Eurocontrol environments, it incorporates future datalink capability as well as wide and local area differential GPS navigation for precision approaches. The system's features include en-route and terminal area flight planning and navigation, GPS instrument approaches, VNAV approach guidance, autopilot coupling, RNP/ANP, and RTA. Among other products this company has the CMA- 2600 SureSight I-series Enhanced Vision System Infrared (EVS-IR) Sensor which has one dual-band focal plane array to support certified approach and landing systems without the need for fusion hardware/software. It is compatible with a video Head- Down Display. An Electronic Flight Bag (EFB) Class 2 is also available, which consists of two LRUs, a lightweight, compact and self- contained Electronic Display and Processing Unit and a companion Power and Expansion Module Unit.

The US L-3 Communications company now includes the activities of many organisations and its L-3 Aviation Recorders (L-3AR) division is a leading manufacturer of solid state cockpit voice and flight data and other recorders as well as automatic identification systems and digital selective calling radios for civil and military applications. Among its products is the combination FA2100 Cockpit Voice and Data Recorder (CVD) which has a capability of 30min voice and 25 h flight data, which can be expanded to 2 h voice and 25 h flight data. It is directly interchangeable with previous models of Fairchild cockpit voice recorders and all ARINC flight data recorders. It has a guaranteed 25,000 h minimum and weighs only 9.9 lbs (4.49 kg). For data retrieval is a hand-held portable interface device which provides digital data copy of CVR or FDR data with time tag from the FA2100 recorder. A high capacity PC card allows storage of data from multiple aircraft flights.

Other products include the Stormscope WX-500 Weather Mapping Sensor which displays lightning information at ranges of 25-200 n miles and is designed to interface with multi- function displays (MFD), either on a dedicated page or overlaid on the moving map. By adding the WX-500 to another system, SkyWatch, traffic and lightning can be displayed simultaneously, the range and operating modes of the two systems being directly controlled through the multi-function display or radar indicator. The WX-500 features a display of airspace in 1208 forward and 3608 surrounding views. Also illustrated was the Landnark system which is an integrated system that provides TCAS II, Class A Terrain Awareness Warning System (TAWS), and GPS functions (optional) in a single LRU. The T2CAS is a combination of the proven ACSS TCAS 2000 and the thales ground collision avoidance module (GCAM).

Miscellaneous and research

The Italian Finmeccanica company is increasingly international with group companies and joint ventures which include Agusta Westland, Alenia Aeronautica, Aermacchi. Alenia Spazio, Telespazio, Marconi Selenia Communications, Galileo Avionics, Avio, AMS and MEDA. Particularly notable are the EH101 and AB139 helicopters and the forthcoming B609, the first tiltrotor specifically designed for the civil market. Marconi Selenia has a huge range of airborne, land and naval communications systems which covers a range including navigation and identification, HF and V/UHF radios, multi mode receivers, autonomous navigation, etc. Alenia Aeronautica's main activities include civil and military aircraft and the production of aerostructures for a variety of companies. Alenia Spazio is a leading company in the design and planning of space systems and the development of satellite technology. The activities of these and other companies give an idea of the enormous scope of interests of the Finmeccanica group.

GKN Aerospace is prominent in four fields of expertise: advanced composites, high performance propulsion systems, aircraft transparencies, and 24h engineering and support. The company is to establish a composites facility on the Isle of Wight for the development of the next generation of design and manufacturing technologies for these materials. It will begin operations in 2005 and one of the most significant contracts is the wing spars for the Airbus A400 M – the first time composites have been used for such key primary structure. GKN also supplies engine nacelles and structures to the major aero-engine manufacturers and following the acquisition of Pilkington Aerospace in 2003, is now the world's leading supplier of military transparencies and the second largest in the civil market. The company is also prominent in engineering support and maintenance, repair and overhaul (MRO) with support capabilities worldwide.

Lord Corporation of the USA will provide vibration solutions for the Airbus A380. It can be powered by GP7200 engines and Hamilton Sundstrand selected Lord Corporation to design and supply the necessary isolators and mounting system for the engine oil tank to mitigate excessive dynamic engine fan blade-out loads. The company has extensive vibration solution expertise in both the fixed and rotating wing areas and has brought this background to the design of a complete oil tank mounting system for the engine including a rigid hard mount and bracket with the isolators to be made with silicone elastomer that will meet the engine and aircraft life requirements.

Dunlop Aircraft Tyres Ltd (DATL) has had many years of experience in manufacture and retread activities and has recently been awarded accreditation to AS9100 RevA:2001 which is the new standard specific to the aerospace industry. The company produces a comprehensive range of bias and radial tyres at its manufacturing and retread facility in Birmingham. The retreading plant processes Dunlop casings and also many from other suppliers. In another area of activity, Dunlop Aerospace and Crane Hydro-Aire will jointly market Dunlop's Taxi Select Brake which is designed to give aircraft brakes significantly longer life. This system employs software logic that applies alternate brakes when the brake pedal is applied. It is only used during taxiing, when full braking is not required, and it significantly reduces brake wear. Also, Dunlop Aerospace Braking Systems (DABS) has completed the first residual energy rejected take off (RTO) test of its prototype electric brake. This brake has a re-designed torque plate with electro-mechanical actuators replacing the hydraulic actuation.

Aircraft Braking Systems Technology (ABSC) is another supplier in the field of wheels, brakes and brake control systems for civil and military aircraft, including those for Embraer 190/195 and Bombardier CRJ-700. The company emphasises that the best combination of aerodynamic drag, reverse thrust and braking action reduces the amount of heat that brakes must absorb and the each force's effectiveness varying during the landing sequenced. Thus, aerodynamic drag and reverse thrust are most effective during the high speed portion of the landing and braking is used for the completion of the stop.

The UK company Doncasters is supplying leading edge slat track cans to the Airbus A380 wing build facility at Broughton. Titanium super plastic forming technology is used to manufacture the track cans and after fabrication the cans are extensively chemically milled to produce components with the high degree of strength and structural integrity demanded in services. Twenty six tracks cans are required per aircraft which has a win span of 79.8 m. These are located in the main spar and extend into the main fuel cell, their function being to house the tracks in which the leading edge slats extend and retract when deployed during the take-off and landing. These are some of the wide range of components that Doncasters produce which includes precision forged and rolled rings and castings (near net shape rolling), complex fabrications and engine ready parts, including exhaust assemblies, and other components. A nickel alloy plating process has been developed for shielding composite structures, which is suitable for high volume applications.

Hampson Industries in the West Midlands manufacture and supply high precision components for many aerospace uses, a recent long-term contract being with MTU Aero Engines for engine parts. This covers supply of products for the Engine Alliance GP7200 and the Pratt & Whitney PW600 powerplants over a six-year period. The company will continue to supply pre-production development parts through 2004 until production launch by MTU at the end of the year. Another recent contract is with the manufacturers of the Eclipse 500, in which Hampson will produce the empennage assembly, including the components parts and items requiring large stretch forming. Completed assemblies will be delivered to Eclipse Aviation's facility in New Mexico. The company is also a supplier to Airbus, Boeing and Rolls-Royce.

The first company in the Russian federation to develop FBW control systems for domestic aircraft is JSC MRPC “Avionica”. One of these, EDSU-200, is the redundant digital- analog remote control system for the BE-200 amphibian. This system is divided into main and back-up (by digital section failure) modes. The FBW system operation in the main mode supports the required characteristics of stability and controllability in manual control and in the main and back-up modes, the capability of aircraft control either by both pilots or by one only. The control system in the back-up mode supports the acceptable characteristics of stability and controllability in manual control. The system readiness time (after hydraulic and power supply are engaged) is not more than 3min and continuous operation of the system is possible for not less than 8 h. The company also produces the SARD automatic cabin pressure regulation system. To facilitate operational reliability, the system includes a duplicated computer and built-in damper actuator (two automatic channels and one manual emergency channel). It conforms to AP-25 and FAR-25 standards with accuracy characteristics being three to four times better than analog systems.

A range of activities sometimes undertaken with QinetiQ, is carried out by Roke Manor Research of Romsey. This body has been instrumental in developing many systems and provides leading edge communications technology, of particular interest being the incorporation of Galileo capability into existing Roke Manor Research GPS antennas/receivers, interference cancellers and beamforming subsystems. It is also part of a consortium formed to develop SAR monitor stations under the Sixth Framework Programme funding. Other work involves beacon/transmitters using COSPAS/ SARSAT and a bid for an Inmarsat Dþ variant. In addition, developers of GPS/Galileo systems and services need generators to provide test signals with the appropriate carriers, modulation, coding, encryption and data format. A test signal generator system has been developed which has been used to determine the effects of Galileo signals on other systems sharing the same frequency.

Other work includes miniature radar altimeters designed for unmanned air vehicles and based on the company's radar design for the defence sector. Owing to the success of this product, a further unit has been produced, the significant difference being that the new unit is smaller and has an integral antenna which makes it more compact. Another of many developments is an Agile Phased Array Antenna which is a prototype antenna which produces a high gain, electronically steered beam with no moving parts. This novel and patented antenna system has been developed jointly by Roke Manor Research, QinetiQ and BAE Systems over recent years.

Highlighting the largest contingent of aerospace companies at Farnborough 2004 was the Northwest Aerospace Alliance with over 50 featured and demonstrated by an on-stand virtual reality map which uses satellite mapping data to show the size and breadth of the industry in the northwest. The Alliances represents over 1,000 companies and covers all areas of aerospace activity from prime manufacturers such as Rolls-Royce, Airbus and BAE Systems right through the supply chain to small subcontractors. Among many products and companies, mention may be made of EDM's highly detailed model of the Rolls-Royce Trent which includes animated video graphics. The RLC Engineering Group (which incorporates three companies) illustrated its comprehensive capabilities. The range of products is large and the Alliance has recently signed a partnership agreement with the Canadian Alliance which should assist companies from Canada and the UK to gain broader market access to each country to the mutual benefit of both.