Airbus RACER Helicopter: Top Component Suppliers?

The Airbus RACER helicopter offers a compelling glimpse into the future of aviation, boldly pushing the envelope in both speed and innovative design. This experimental aircraft relies on a sophisticated network of specialized companies, each contributing to bring its advanced features to fruition. A careful examination of the Airbus RACER helicopter component supplier landscape reveals the extensive collaborative effort inherent in the creation of such a cutting-edge machine. So, let's delve into some of the key players whose contributions are instrumental to this groundbreaking project.

Key Takeaways

• Avio Aero stands as a major partner, responsible for supplying the lateral gearboxes and lending its expertise to the main gearbox. They employ advanced materials to achieve optimal performance and weight savings.
• Safran furnishes the powerful Aneto engine—a critical component that underpins the RACER's high-speed capabilities and impressive efficiency.
• The ASTRAL consortium takes charge of the innovative, aerodynamically efficient wings, constructed with environmentally conscious materials.
• The ANGELA consortium shoulders the responsibility for developing and manufacturing the landing gear system, meticulously designed for minimal drag and dependable operation.
• The RoRCraft consortium undertakes the construction of the central fuselage, a feat of engineering that showcases advanced hybrid helicopter structures.

Avio Aero Lateral Gearboxes

Avio Aero's remit encompasses a crucial element of the RACER helicopter's advanced transmission system: the lateral gearboxes (LGBs). These meticulously engineered units are built to withstand and manage a substantial amount of power—1MW, to be precise. The development phase of these gearboxes involved comprehensive testing protocols, coupled with the incorporation of innovative materials and cutting-edge manufacturing processes.

The lateral gearboxes are, notably, constructed from a specialized alloy renowned for its enhanced resistance to wear and elevated temperatures. This specific material selection is of paramount importance given the demanding operational parameters inherent in a high-speed helicopter. Furthermore, the bearings integrated within the LGBs feature hybrid designs, strategically combining steel rings with ceramic involute parts. This deliberate combination strives to optimize performance, especially in scenarios where lubrication is limited, thanks to the inherent low friction properties of ceramic. The hybrid design also contributes to a lighter overall component profile compared to solely steel alternatives.

Avio Aero's expert teams conducted stringent testing campaigns across their state-of-the-art facilities in both Italy and Poland. These exhaustive tests encompassed a wide spectrum of critical aspects, including mechanical endurance, fatigue resistance, and the overall performance of the oil system. One particularly noteworthy test was the 'oil-off' test, which replicates an emergency scenario involving an interrupted oil supply. Successful completion of this demanding test underscores the gearbox's capacity to maintain essential maneuverability, enabling a safe landing even under such critical conditions. What does that mean for you? Well, this is a significant safety feature that is often handled by the helicopter manufacturers themselves, further highlighting Avio Aero's sophisticated capabilities.

The integration of advanced materials and thorough testing—including critical safety simulations—underlines the sophisticated engineering that is the very foundation of the RACER's lateral gearboxes. This component is, without a doubt, vital for the helicopter's overall performance and its inherent safety profile.

Safran Aneto Engine

The Safran Aneto-1X engine constitutes a pivotal component in powering the innovative Airbus RACER helicopter demonstrator. Chosen back in February 2018, this engine was selected over an initially considered alternative due to its more compact design, all while delivering comparable power. Specifically, the Aneto-1X delivers an impressive 2,500 horsepower (1,900 kW), affording a tangible advantage in terms of space and weight efficiency for the RACER's distinct configuration.

A notable feature inherent in the Aneto-1X's integration within the RACER lies in its critical role within the hybrid-electrical system; that system, crucially, allows for one of the two engines to be shut down during cruise flight. This pivotal capability is absolutely central to the RACER's ambitious objective of achieving substantial fuel savings and simultaneously reducing emissions—all while aiming for a cruise speed exceeding 400 km/h, a noteworthy increase when compared to conventional helicopters.

Moreover, the Aneto engine benefits from cutting-edge technologies developed for other Safran projects, incorporating advanced solutions that directly contribute to the RACER's stated performance and efficiency goals. Its development and integration are integral parts of a broader European research initiative, underscoring a commitment to collaborative innovation in the aerospace sector.

The Aneto-1X engine's selection—and its integral contribution to the RACER's hybrid-electric system—are both absolutely central to the demonstrator's core mission of pushing the established boundaries of helicopter speed and efficiency, all while minimizing environmental impact.

ASTRAL Consortium Wings

The wings gracing the Airbus RACER helicopter are, undeniably, a standout feature, meticulously designed and expertly built by the ASTRAL consortium. This accomplished group includes AERNOVA Hamble Aerostructures alongside the University of Nottingham's distinguished Institute for Advanced Manufacturing. Their collective work centered on crafting wings that are not only aerodynamically efficient but also leverage advanced, eco-friendly materials, all in the pursuit of keeping the aircraft's overall weight to an absolute minimum. This aligns perfectly with the Clean Sky 2 program's overarching goal of tangibly reducing emissions.

The patented "double wing" or "box wing" design stands as a testament to innovative engineering. It not only contributes significantly to generating lift during flight, but also adds a crucial layer of safety when the helicopter is on the ground. These wings are specifically engineered to actively enhance the helicopter's overall performance, affording superior vertical lift and the capacity for both increased speed and extended range, especially when compared to more traditional helicopter designs.

Here's a succinct overview highlighting some of the key aspects inherent in the ASTRAL consortium's invaluable contribution:

• Aerodynamic Optimization: The carefully considered wing shape is expertly crafted to minimize drag and simultaneously maximize lift.
• Lightweight Construction: The incorporation of high-performance ecological materials serves to reduce the aircraft's overall weight.
• Enhanced Performance: The wing design demonstrably contributes to improved speed, extended range, and optimized lift capabilities.

The development of these wings represents a significant step forward in helicopter design, seamlessly blending advanced aerodynamics with sustainable materials, culminating in superior performance and notable environmental benefits.

ANGELA Consortium Landing Gear

The landing gear meticulously integrated into the Airbus RACER helicopter demonstrator represents a collaborative effort, expertly designed, manufactured, and comprehensively tested by the ANGELA consortium. This proficient group united specialized expertise from Italy's esteemed Centro Italiano Ricerche Aerospaziali (CIRA) and Magnaghi Aeronautica, alongside the contributions of Lithuania's Techno System Development.

A pivotal design objective centered squarely on minimizing aerodynamic drag when the landing gear is retracted. To successfully achieve this, the ingenious system is cleverly integrated within the wing and fuselage, leveraging a movable door system. When deployed for landing, the gear provides a wide track; this is particularly important for ensuring both stability and safe touchdowns.

The landing gear system—drawing on Magnaghi Aeronautica's extensive and valuable experience—underwent rigorous testing protocols at their specialized facility near Naples, all in the pursuit of securing crucial flight clearance. This exacting process remains vital in confirming the system's fundamental reliability and performance across a diverse range of demanding operational conditions.

The seamless integration of the landing gear into the airframe, alongside its retractable mechanism, showcases a clear and unwavering focus on optimizing aerodynamic efficiency—a critical aspect for high-speed helicopter demonstrators, such as the impressive RACER.

RoRCraft Consortium Central Fuselage

The central fuselage of the Airbus RACER helicopter demonstrator is undeniably a significant structural component, expertly designed and manufactured by the RoRCraft consortium. This consortium represents a powerful collaboration between INCAS—Romania's National Institute for Aerospace Research "Elia Cafaroli"—and the respected aerospace company ROMAERO. Their collective work on the RACER's airframe represents a notable achievement, particularly in their successful production of an advanced hybrid structure that deftly combines both metallic and composite primary structural elements. This represents a notable first for Romania in the crucial realm of helicopter manufacturing.

The RoRCraft consortium was entrusted with the critical responsibility of assembling the intermediate side shells onto the Racer airframe. These expertly crafted side shells—measuring 3.4 by 1.5 meters—are skillfully fabricated from carbon fibre reinforced plastic (CFRP). Their primary function is to connect the tail boom to the helicopter's vital cockpit area. Traditionally, large CFRP shells like these are assembled manually. However, the RACER's shell components were instead produced using a highly automated method—a new process meticulously developed by a dedicated research team hailing from the Fraunhofer Institute for Foundry, Composite and Processing Technology IGCV in Germany.

The RoRCraft consortium also plays an instrumental role in securing the demonstrator's essential flight clearance. This critically involves designing and then carrying out comprehensive ground tests, alongside performing detailed stress analysis for the necessary fuselage parts. The successful completion of the central fuselage marked a key moment, effectively signaling the commencement of the RACER's overall assembly process.

Airbus Helicopters Rear Fuselage

The rear fuselage of the Airbus RACER helicopter is undeniably a key structural element, carefully designed with a unique asymmetric cross-section. This distinct shape is specifically intended to improve the helicopter's crucial hover performance, all without negatively impacting its forward flight capabilities. Airbus Helicopters teams based in Spain—receiving crucial support from the Outcome consortium, led by Aernnova—faced considerable challenges in manufacturing this sophisticated part, primarily due to its very specific dimensional constraints and stringent weight targets.

A significant innovation here is that the RACER will proudly stand as the first Airbus aircraft to feature a primary structure made through the utilization of advanced additive manufacturing techniques. This forward-thinking approach facilitates the creation of complex geometries and, potentially, lighter components overall.

Furthermore, the rear fuselage incorporates an H-shaped empennage, along with double-tilted vertical and horizontal stabilizers. This distinctive tail configuration—a patented design developed by Airbus Helicopters and ONERA—is specifically aimed at boosting overall stability and simultaneously reducing energy consumption during flight.

The development of this rear section clearly highlights a resolute commitment to pushing the boundaries of established helicopter design, seamlessly integrating advanced materials alongside innovative aerodynamic principles, all with the ultimate goal of achieving demonstrably superior performance characteristics.

Airbus Helicopters Main Gearbox

The main gearbox (MGB) stands as a critical component meticulously integrated into the Airbus RACER helicopter—acting as the vital central link connecting the robust Safran Aneto engine and the rotor blades. This complex piece of machinery is directly responsible for efficiently transferring the engine's crucial power to effectively drive the aircraft's sophisticated propulsion system.

The comprehensive design and careful construction of the MGB represented a significant collaborative effort undertaken jointly by Airbus Helicopters and Avio Aero. This strategic partnership was undertaken with the specific aim of integrating the collective best practices from both organizations to ultimately create a supremely reliable and genuinely high-performance transmission system.

Key aspects inherent in the main gearbox encompass:

• Power Transmission: The MGB takes the high rotational speed generated by the engine and precisely reduces it to the appropriate speed required for the main rotor, while simultaneously increasing crucial torque.
• Durability and Reliability: Expertly built to withstand significant operational stresses and diverse environmental conditions, the MGB is specifically designed for a long and dependable service life.
• Integration: It must seamlessly connect with the engine, the rotor system, and all other drivetrain components.

During the exhaustive development phase, rigorous testing protocols were implemented to thoroughly validate the gearbox's overall performance and intrinsic safety. This included detailed checks for mechanical endurance, comprehensive oil system integrity, and overall operational reliability across various simulated flight conditions. The successful completion of these demanding tests—including critical oil-off scenarios—clearly demonstrates the MGB's readiness for the demanding role it is slated to play in the RACER's advanced design.

The main gearbox is expertly engineered to specifically meet the unique demands inherent in the RACER's sophisticated hybrid helicopter-plane configuration, thereby supporting its high-speed flight objectives alongside its impressive operational versatility.

ACOC Heat Exchanger

The ACOC (Air Cooler Oil Cooler) heat exchanger constitutes a key component seamlessly integrated into the Airbus RACER helicopter demonstrator. Developed by Avio Aero, this crucial part plays a vital role in expertly managing the lubrication and overall cooling systems for the aircraft's gearboxes. Its design and subsequent manufacturing showcase advanced additive technology, more commonly referred to as 3D printing.

Avio Aero notably utilized direct metal laser melting (DMLM) in order to create the ACOC. This advanced manufacturing process facilitated a highly integrated and compact design, enabling it to fit neatly within the confined space situated between the lateral gearbox housing and the aircraft nacelle. By deftly combining multiple functions into a single expertly engineered component, the ACOC simplifies the overall system architecture.

Key aspects inherent in the ACOC heat exchanger include:

• Additive Manufacturing: Expertly produced through the utilization of 3D printing, thereby enabling the creation of complex geometries and promoting optimal material efficiency.
• Integrated Functionality: Seamlessly combines key oil system functions with essential heat exchange capabilities.
• Compact Design: Expertly optimized to fit seamlessly within constrained space limitations.
• Advanced Materials: Leverages new materials and processes to deliver improved performance overall.

This truly innovative approach to heat exchanger design and sophisticated production stands as a direct result of the extensive research and dedicated development conducted within the parameters of the Clean Sky 2 program, demonstrably representing a significant step forward in overall helicopter component technology.

ONERA Empennage

The empennage—a critical aerodynamic surface seamlessly integrated into the Airbus RACER helicopter—represented a significant collaborative effort involving ONERA (the French aerospace research agency) and Airbus Helicopters. This distinctive H-shaped tail structure, featuring a double-tilted vertical and horizontal stabilizer, is a patented design carefully aimed at improving both fundamental stability and overall energy efficiency during actual flight.

This undeniably innovative empennage design stands as a significant advancement in helicopter aerodynamics. Its unique configuration adeptly helps manage airflow and simultaneously reduce drag, thereby making a vital contribution to the RACER's overarching performance goals. The comprehensive development process incorporated rigorous testing protocols and in-depth analysis to thoroughly validate its effectiveness across a diverse range of demanding flight conditions.

The seamless integration of ONERA's deep expertise in aerodynamics, coupled with Airbus Helicopters' inherent design capabilities, has resulted in an empennage that is both highly functional and also contributes to the demonstrator's undeniably advanced look. It serves as a prime example of how research institutions and leading manufacturers can effectively collaborate on cutting-edge projects.

Key aspects inherent in the ONERA empennage include:

• Aerodynamic Optimization: The carefully considered H-shape and expertly tilted stabilizers are specifically designed to enhance overall stability and minimize air resistance.
• Patented Design: The unique configuration is protected by a patent jointly held by both Airbus Helicopters and ONERA.
• Performance Enhancement: Contributes demonstrably to improved flight characteristics, including enhanced stability and the potential for reduced fuel consumption.

Clean Sky 2 Program

The Airbus RACER helicopter stands as a prime example of exactly what the Clean Sky 2 program actively aims to achieve. This critical initiative represents Europe's most significant push to thoroughly research and then develop cutting-edge technologies that will tangibly reduce the overall environmental impact of aviation. Think of it, essentially, as a large-scale collaborative effort, spanning the entire continent, all with the fundamental goal of making air travel genuinely greener.

The RACER itself is intentionally designed as a demonstrator aircraft, fundamentally meaning that its primary job is to effectively showcase new and emerging technologies within a real-world setting. It is designed specifically to fly substantially faster than typical helicopters, targeting speeds in excess of 400 km/h, which represents a significant jump up from the typical speed of 260 km/h. This crucial speed boost is derived from several key areas:

• Advanced Aerodynamics: Key features, such as its unique "box wing" design, actively help to generate lift and substantially improve overall efficiency.
• Hybrid-Electric Systems: The strategic use of engines—such as the robust Safran Aneto—coupled with an advanced hybrid-electric setup, enables one engine to be strategically turned off during cruise flight, thereby directly saving fuel and simultaneously cutting overall emissions.
• Lightweight Materials: The program actively encourages the strategic use of new materials that effectively reduce the overall weight of the aircraft, thereby further contributing to demonstrable fuel savings.

Clean Sky 2 is fundamentally all about pushing the accepted boundaries of what's actually possible in aviation technology, all in the determined pursuit of creating a more sustainable future for the industry. It effectively brings together numerous European partners, strategically pooling their collective knowledge and extensive resources to collaboratively tackle complex challenges. The program demonstrably supports projects that thoroughly explore everything from innovative new engine concepts and cutting-edge advanced materials, right through to truly innovative structural designs—all with the unwavering goal of tangibly lowering emissions and simultaneously improving overall performance.

The RACER's development within the wider Clean Sky 2 initiative highlights a clear commitment to practical, technology-driven solutions. By meticulously testing these advanced systems, the program is specifically aiming to pave the way for the next generation of aircraft, demonstrably making them faster, fundamentally more efficient, and significantly better for the overall environment.

A Collaborative Effort for Future Flight

The Airbus RACER helicopter represents a truly significant step forward in rotorcraft technology overall. Its development demonstrably showcases a broad-based collaboration across Europe, with many leading companies actively contributing specialized parts and their distinct expertise. From Avio Aero's advanced gearboxes and the cutting-edge landing gear systems meticulously designed by the ANGELA consortium, right through to the unique wings crafted by the ASTRAL group and the central fuselage expertly built by Romania's RoRCraft, the entire project effectively highlights a shared commitment to unwavering innovation. This compelling collective effort extends beyond simply building a faster helicopter; it demonstrably encompasses exploring new materials, devising efficient designs, and enabling cleaner flight—all designed to strategically set a firm course for the promising future of aviation as a whole.

Frequently Asked Questions

What is the Airbus RACER helicopter?

The Airbus RACER is, in essence, a special experimental helicopter that has been specifically designed to fly demonstrably faster than standard, regular helicopters. It exhibits a unique appearance—somewhat akin to a hybrid between a traditional helicopter and an airplane. Its core objective centers on illustrating how we can effectively make helicopters substantially quicker, demonstrably more efficient, and notably less noisy, particularly for roles such as inter-city transport and emergency response operations.

Who makes the main parts for the RACER helicopter?

A diverse array of specialized companies collaborated closely in order to construct the RACER. Avio Aero was entrusted with crafting critical parts, such as the gearboxes that are instrumental in powering the rotors. Safran provided the robust and powerful Aneto engine. ASTRAL, as a group, expertly developed the wings, while ANGELA skillfully designed the landing gear. Airbus Helicopters, for its part, skillfully built the main body, incorporating the rear section seamlessly.

How fast can the RACER helicopter fly?

The RACER is specifically engineered for enhanced speed capabilities! It is demonstrably capable of flying at a sustained cruising speed of approximately 400 kilometers per hour (equivalent to roughly 250 miles per hour). This notable speed significantly outpaces that of most traditional helicopters, which typically operate at around 260 kilometers per hour.

What is special about the RACER's design?

The RACER showcases a truly unique design that directly enables it to fly substantially faster and demonstrably more efficiently. It strategically incorporates two substantial propellers positioned on the sides—resembling wings—that actively assist in enabling rapid forward movement, effectively supplementing a traditional main rotor. This carefully optimized setup—in conjunction with the strategic utilization of specialized materials and a distinct focus on demonstrably reducing noise pollution and harmful emissions—culminates in a supremely advanced aircraft overall.

What is the role of the Clean Sky 2 program in the RACER project?

The RACER helicopter was developed strategically as a fundamental component of the broader Clean Sky 2 program. This multifaceted program represents a significant initiative spanning Europe, with a core focus on facilitating collaborative efforts between diverse companies and skilled researchers to foster the creation of innovative, cleaner, and significantly more efficient aviation technologies. The RACER effectively serves as a practical platform for rigorously testing and validating these groundbreaking concepts for future aircraft designs.

What are the benefits of the RACER helicopter?

The RACER strives to deliver a multitude of significant advantages when compared to older, more traditional helicopter designs. For instance, it offers demonstrably enhanced speed capabilities, which can directly translate into tangible time savings during operational journeys. Additionally, it is specifically designed to strategically consume less fuel, operate with reduced noise levels, and demonstrably produce fewer harmful emissions—thereby significantly minimizing its overall environmental impact. Moreover, the overarching objective is to make flying these types of advanced helicopters significantly more affordable overall.