Airbus RACER Helicopter: Who Supplies Components?

The Airbus RACER helicopter represents a paradigm shift, redefining the boundaries of helicopter speed and efficiency. However, this is not solely an Airbus endeavor; rather, it is the result of collaborative efforts involving numerous companies and specialists. Discerning the roles and contributions of these suppliers is crucial to understanding the intricacies of this advanced machine. Let's delve into the network of component suppliers behind the Airbus RACER helicopter.

Key Takeaways

• The Airbus RACER helicopter distinguishes itself with a unique rotorless tail system, exhibiting an asymmetrical design for enhanced control and efficiency.
• Advanced materials – think titanium alloys and composites – manufactured via cutting-edge methods like 3D printing and resin transfer moulding, contribute to weight reduction and performance optimization.
• A hybrid-electric engine configuration enables the deactivation of one engine during cruising, yielding substantial fuel savings and emissions reductions.
• Safran Helicopter Engines is the provider of the hybrid system's engines, while Aernnova assumes responsibility for the complex tail assembly.
• The RACER project underscores a robust collaborative spirit between Airbus and its global partners, including specialized Italian firms, illustrating how teamwork propels innovation.

Safran Helicopter Engines' Propulsion Systems

Safran Helicopter Engines occupies a pivotal role in the RACER project, supplying the fundamental propulsion units that distinguish this helicopter. They furnish the Aneto-1X engines – remarkably powerful turboshafts. What makes these engines truly compelling is their integration with the hybrid-electric architecture.

Hybrid-Electric Architecture

The RACER incorporates a hybrid-electric system – a significant advancement in helicopter technology. This configuration allows for sophisticated power management, enhancing the helicopter's performance across various flight regimes. A notable feature is the "Eco-Mode," conceived in collaboration with Safran. This mode facilitates the shutdown of one of the two Aneto-1X engines during cruise, yielding benefits in both fuel consumption and CO2 emissions. The system is engineered for rapid engine restart when required, ensuring both safety and responsiveness.

Engine Management and Integration

Effective engine management is just as critical as the engines themselves in optimizing the RACER's performance. The bespoke engine management system synergizes with the hybrid-electric architecture to maximize propulsion efficiency. What does that mean for you? It involves modulating power output to achieve the desired speed while minimizing fuel consumption. Testing indicates that this approach can yield notable fuel savings – potentially up to 20% less fuel per mile compared to older helicopters operating at lower speeds. Furthermore, the system governs power distribution to both the main rotor and the side pusher propellers, essential for the helicopter's high-speed capabilities.

The integration of Safran's Aneto-1X engines into the RACER's hybrid-electric architecture serves as a salient example of how advanced propulsion systems are redefining the future of rotorcraft.

Engine Model	Type	Power Output (each)	Quantity	Notes
Safran Aneto-1X	Turboshaft	1,900 kW (2,500 hp)	2	Supports hybrid-electric operation.

Aernnova's Tail Assembly Expertise

Aernnova assumes responsibility for assembling the intricate tail section of the RACER helicopter. This encompasses the design and fabrication of a rotorless tail system – a marked departure from conventional helicopter designs – aimed at improving efficiency and speed.

Rotorless Tail System Development

The RACER's tail system constitutes a defining characteristic. In lieu of a traditional tail rotor that counteracts the main rotor's torque, this design employs a specialized aerodynamic configuration. It is meticulously engineered to manage yaw (the helicopter's rotational movement) and ensure stability, particularly during high-speed flight. The development process involved extensive optimization to realize the most aerodynamically efficient solution for a compound helicopter incorporating a rear propeller. The overarching objective was to maximize aerodynamic efficiency while maintaining optimal pilot control.

Advanced Composite Structures

The construction of these tail components necessitates the use of advanced composite materials. These materials are selected for their inherent strength and lightweight properties – critical attributes for aircraft performance. Aernnova's contributions include the fabrication of elements such as the horizontal stabilizer's torsion box. This was achieved using resin transfer moulding (RTM) in a 'one-shot' process. That is to say, the entire three-meter-long component was manufactured in a single step, reducing both energy consumption and manufacturing time by eliminating the need for an autoclave. The application of RTM to such a large component is noteworthy, as this technique is typically reserved for smaller parts.

Collaboration with Airbus Helicopters España

This undertaking is a collaborative effort. Aernnova collaborates closely with Airbus Helicopters España; this partnership exemplifies a broader initiative, showcasing the synergy between various companies and experts in realizing these advanced helicopter designs. It highlights the significance of teamwork in developing complex systems like the RACER.

Specialized Italian Contributions to Tail Components

Prototype Tooling Manufacture

The advanced tail sections of the RACER helicopter benefited from specialized manufacturing in Italy. Two smaller firms, OMPM and Metitalia, were instrumental in this process. They were entrusted with the fabrication of the specialized tooling required for producing the initial prototypes of the tail components. Think of it as preparing the precise molds and jigs prior to commencing mass production. This step is vital for ensuring seamless integration later in the production cycle.

Flexible Assembly Tool Chain

These Italian partners also developed a flexible system for assembling the tail components. They established a method for assembling the tailboom, stabilizers, and other components that could be adjusted as needed. This adaptability is particularly valuable in aerospace projects, where design iterations may occur during development. It underscores the importance of engaging partners capable of addressing the practical aspects of assembling complex structures.

OMPM and Metitalia's Role

OMPM and Metitalia were central to these efforts, contributing to projects like OLFITT and OLTITA. Their primary function was to manufacture the prototype tooling for various tail components, ranging from the main tailboom to the smaller stabilizers and control surfaces. Their capacity to produce precision tooling and an adaptable assembly process proved critical during the early phases of the RACER's tail development.

The contributions of these specialized Italian firms underscore the value of focused manufacturing expertise in intricate aerospace projects. Ensuring the tooling and assembly process are optimized from the outset mitigates potential challenges and saves time.

Avio Aero's Transmission Components

Avio Aero plays a significant role in the RACER helicopter, focusing on the design and production of key transmission components. The company has focused on developing advanced gearboxes that can handle substantial power while incorporating innovative materials for improved performance and durability.

Main and Lateral Gearbox Design

Avio Aero is responsible for the design of both the main and lateral gearboxes for the RACER. The lateral gearboxes (LGBs) are particularly noteworthy, engineered to deliver 1MW of power. These systems are built using cutting-edge materials and manufacturing processes to meet the demanding requirements of the RACER's unique configuration.

Innovative Alloy Applications

To achieve higher wear and temperature resistance, the lateral gearboxes are constructed from an innovative alloy. The specific chemical composition of this alloy provides enhanced durability, allowing the components to withstand challenging operational conditions and extended use.

Hybrid Ceramic Bearings

Further advancements are seen in the bearings used within the lateral gearboxes. These are hybrid ceramic bearings, featuring steel rings combined with involute parts made from ceramic. This material choice offers several advantages, including better performance even with limited lubrication due to a low friction coefficient, and a lighter weight compared to all-steel bearings.

The development of these transmission components involved extensive testing at Avio Aero's facilities. This included mechanical endurance tests covering all specified flight conditions, as well as critical oil-off tests. The successful completion of the oil-off test, which simulates emergency scenarios with no oil, demonstrates the safety and reliability of the gearboxes, allowing for continued maneuverability and safe landing.

Avio Aero's involvement highlights a commitment to pushing the boundaries of helicopter transmission technology, contributing significantly to the RACER's overall performance and safety features.

Advanced Airframe and Manufacturing Techniques

Box-Wing Configuration Benefits

The RACER helicopter features a distinctive box-wing configuration – a design decision that significantly influences its aerodynamic performance. In this setup, the wings are interconnected at the tips via a vertical surface, creating a closed airflow loop. This configuration aids in reducing induced drag, a type of drag resulting from airflow around a wingtip. Reduced drag translates to enhanced helicopter efficiency, lower fuel consumption, and potentially higher speeds or extended ranges. It represents an intelligent approach to maximizing airframe performance.

Additive Manufacturing for Components

Additive manufacturing, more commonly known as 3D printing, plays a key role in fabricating certain RACER components. For instance, a specific fitting employed for a trimming tab was manufactured from a titanium alloy using selective laser melting. This method constructs parts layer by layer from powdered metal, enabling the creation of intricate geometries that are difficult to achieve through conventional methods. It also yields parts that are both robust and lightweight. Smaller components, such as brackets for cameras and antennas on the tail, also benefit from this technology, often utilizing aluminum alloys. This approach allows engineers to realize intricate designs that would otherwise be unattainable.

Resin Transfer Moulding Processes

For primary structural elements of the tail, such as the torsion box of the horizontal stabilizer, an alternative advanced technique is employed: resin transfer moulding (RTM). What's truly remarkable about the RACER is the employment of RTM in a 'one-shot' process for a component spanning approximately three meters in length. This signifies that the entire component was manufactured in a single operation, obviating the need for a large, energy-intensive autoclave. This approach conserves both energy and time. While RTM is typically employed for smaller, precision components, its application to such a large structure represents a significant achievement. Essentially, it involves injecting liquid resin into a mold already containing the composite fibers.

The integration of additive manufacturing and out-of-autoclave RTM represents a notable advancement in aerospace parts manufacturing. These techniques not only reduce production time and energy consumption but also enable the creation of lighter, more complex structures – directly enhancing the helicopter's overall efficiency and capabilities.

Here's a summary of the materials and processes involved:

• Titanium Alloy (TiAl6V4): Utilized for 3D-printed components, such as the trimming tab fitting, owing to its strength and corrosion resistance.
• Aluminum-Magnesium-Scandium Alloy: Employed for smaller tail components, offering an optimal balance of lightweight and durable characteristics.
• Out-of-Autoclave (OOA) Resin Transfer Moulding (RTM): Utilized for large composite structures like the horizontal stabilizer's torsion box, facilitating single-step manufacturing without the need for an autoclave.
• Selective Laser Melting (SLM): A 3D printing technique employed to create complex titanium parts layer by layer.

Key Partners in the RACER Project

Airbus Helicopters as Lead

Airbus Helicopters spearheaded the RACER demonstrator project, providing overall direction and integration for this advanced rotorcraft. Their responsibilities encompassed coordinating complex engineering activities and uniting a diverse group of specialists to achieve the project's ambitious objectives. This leadership proved vital in shaping the helicopter's unique design and pushing the boundaries of rotorcraft technology.

Global Collaboration Network

The RACER project exemplifies international collaboration within the aerospace sector, engaging partners from 13 countries. This expansive collaboration fostered a wealth of knowledge, technical expertise, and innovative concepts from across the globe. Such a broad network proved instrumental in developing and integrating the cutting-edge technologies that define the RACER, showcasing the potential of collaborative efforts in complex aviation programs.

Synergistic Component Integration

The success of the RACER hinges on the synergistic integration of its various advanced components. This entails a meticulous process of integrating systems provided by diverse partners, such as Safran's propulsion units and Aernnova's tail assembly. The project emphasizes a collaborative approach wherein each partner's specialized contributions are designed to complement one another, culminating in a cohesive and high-performing final product.

The RACER's development highlights a shift towards more integrated partnerships, where suppliers are not just component providers but active collaborators in the design and engineering process. This cooperative model is key to tackling the intricate challenges of developing next-generation aircraft.

Key partners and their contributions include:

• Safran Helicopter Engines: Providing the core hybrid-electric propulsion systems.
• Aernnova: Leading the development and manufacturing of the innovative rotorless tail assembly.
• Avio Aero: Supplying critical transmission components, including gearboxes and specialized bearings.
• OMPM and Metitalia: Manufacturing prototype tooling and assembly systems for tail components, supporting Italian specialized manufacturing.

This extensive network of collaborators, ranging from large aerospace firms to specialized small enterprises, underscores the multifaceted nature of modern aircraft development. Each partner's input serves as a building block in the RACER's innovative design.

A Look Back at the RACER's Team

So, the Airbus RACER helicopter is truly remarkable, wouldn't you agree? What sets it apart is the collaborative spirit behind its creation. It's a tapestry woven from the contributions of diverse individuals and businesses. Safran Helicopter Engines powers it with advanced engines, while Aernnova crafts its distinctive tail. Smaller Italian firms, such as OMPM and Metitalia, provide specialized tooling. Even Avio Aero contributes essential transmission components. This collaborative endeavor exemplifies the power of shared expertise and unified purpose, pushing the boundaries of helicopter design forward. It's a team effort, pure and simple.

Frequently Asked Questions

What makes the Airbus RACER helicopter different from other helicopters?

The RACER helicopter distinguishes itself through its design, enabling it to achieve significantly higher speeds than conventional helicopters. Featuring wings and rear-mounted propellers in addition to the main rotor, it can attain speeds exceeding 240 knots – or approximately 444 kilometers per hour.

Who is helping to build the RACER helicopter?

The construction of the RACER involves the collaborative efforts of numerous companies and specialists from around the world. While Airbus Helicopters spearheads the project, companies such as Safran Helicopter Engines and Aernnova, along with specialized Italian businesses, contribute essential components and expertise.

How does the RACER helicopter save fuel?

The RACER employs a hybrid-electric system incorporating two engines, one of which can be deactivated during flight to conserve fuel and reduce emissions. Its design prioritizes fuel efficiency, resulting in a consumption rate approximately 20% lower than that of comparable helicopters.

What's unique about the RACER's tail design?

In lieu of a traditional tail rotor for stabilization, the RACER incorporates a uniquely shaped and 'H'-configured tail. This design enhances control and optimizes high-speed flight characteristics. It also contributes to weight reduction.

What new ways of making parts are used for the RACER?

The RACER incorporates novel manufacturing techniques. Select components are fabricated through 3D printing – also known as additive manufacturing – utilizing robust metals like titanium. Other components are produced using specialized plastic and glass fiber methods referred to as resin transfer moulding, which obviates the need for large, heated autoclaves.

What is the main goal of the RACER project?

The primary objective of the RACER project, initiated under the Clean Sky 2 program, is to develop novel technologies that promote cleaner air travel. Its focus lies on creating helicopters that reduce emissions (including CO2 and noise) and decrease fuel consumption by 20% to 30% compared to older models.