Who Are the Top Airbus RACER Helicopter Component Suppliers?

The Airbus RACER helicopter offers a fascinating glimpse into the future of aviation. It's a machine engineered for speed, built on a foundation of innovative ideas. But how does such a groundbreaking aircraft come to be? It takes a village—or in this case, a continent of specialized companies. A closer look at the key suppliers for the Airbus RACER helicopter reveals the incredible level of collaboration required to get a project of this magnitude off the ground. Let's explore some of the major players behind this exciting venture.

Key Takeaways

• At the heart of the RACER's performance is the powerful Aneto engine, expertly crafted by Safran to deliver both speed and efficiency.
• Avio Aero takes credit for the crucial lateral gearboxes, leveraging advanced, lightweight materials to ensure peak performance.
• The innovative, eco-friendly wings are the handiwork of the ASTRAL consortium, designed for superior aerodynamic lift.
• The ANGELA Consortium engineered the low-drag, reliable landing gear, a critical component for both flight and ground operations.
• Romania's RoRCraft consortium constructed the helicopter's central fuselage, skillfully blending composite and metallic materials.

1. Safran Aneto Engine

At the very heart of the Airbus RACER demonstrator's advanced propulsion system lies the Safran Aneto-1X engine. This particular powerplant was chosen back in early 2018, primarily for its remarkably compact dimensions—a distinct advantage for the RACER's unique airframe design—while still packing a substantial punch. The Aneto-1X delivers a formidable 2,500 horsepower (1,900 kW), a figure that enables highly efficient operation within the helicopter's innovative setup.

A key feature of the Aneto-1X's role in the RACER is its integration into a hybrid-electric system. This sophisticated arrangement is designed to allow one of the two engines to be powered down during cruise flight. What does this mean in practice? This capability is absolutely central to the RACER's mission of achieving significant fuel savings and reducing emissions, all while targeting cruise speeds well over 400 km/h, a notable leap beyond traditional helicopter performance.

The Aneto engine also benefits from technologies honed in other Safran projects, bringing field-tested, advanced solutions directly to the RACER's ambitious performance and efficiency goals. Its development and integration are part of a broader European research initiative, highlighting a truly collaborative approach to aerospace innovation.

Here's a look at some of its key attributes:

• Power Output: Delivers 2,500 hp (1,900 kW), providing more than enough power for high-speed flight.
• Compact Design: Its smaller footprint compared to alternatives with similar power is vital for the RACER's aerodynamic profile.
• Hybrid-Electric Integration: Enables fuel-saving operational modes by allowing one engine to be shut down during cruise.
• Advanced Technology: Incorporates cutting-edge solutions from Safran's wider engine development programs.

The selection and integration of the Aneto-1X engine are truly fundamental to the RACER's mission of pushing the boundaries of helicopter speed and efficiency while minimizing its environmental impact.

2. Avio Aero Lateral Gearboxes

Avio Aero was tasked with a critical component of the RACER helicopter's transmission system: the lateral gearboxes (LGBs). These aren't just any gearboxes; they are engineered to handle an immense amount of power, somewhere in the neighborhood of 1 megawatt. The development journey was intensive, involving rigorous testing and the application of new materials and manufacturing techniques.

These gearboxes are constructed from a special alloy that masterfully resists wear and high temperatures, a crucial quality for a high-speed helicopter. The bearings nestled inside the LGBs are a clever mix of steel and ceramic. This hybrid design enhances their performance, particularly in scenarios where lubrication might be less than optimal, since ceramic generates less friction. As an added bonus, it also makes the parts lighter than if they were made entirely of steel.

Avio Aero put these gearboxes through their paces at facilities in Italy and Poland. They meticulously checked for durability over time, resistance to fatigue, and the integrity of the oil system. A particularly demanding trial was the 'oil-off' test, which simulates what happens if the oil supply is suddenly cut. Passing this test demonstrates that the gearbox can still allow the pilot to control the helicopter for a safe landing, even in an emergency—a significant safety feature that underscores Avio Aero's advanced capabilities.

Here's a look at some key aspects of the Avio Aero Lateral Gearboxes:

• Power Handling: Designed to confidently manage up to 1MW of power.
• Material Innovation: Utilizes a specialized alloy for superior durability and temperature resistance.
• Hybrid Bearings: Combines steel and ceramic for improved performance and a welcome reduction in weight.
• Rigorous Testing: Subjected to extensive mechanical, fatigue, and oil system integrity tests, including critical 'oil-off' scenarios.

The development of these lateral gearboxes stemmed from a close collaboration with Airbus Helicopters that began as early as 2015. This partnership was focused on integrating the best practices from both companies to forge a reliable and high-performing transmission system for the RACER demonstrator.

3. Airbus Helicopters Main Gearbox

The main gearbox (MGB) stands as a central pillar in the RACER helicopter's complex machinery. You can think of it as the vital hub that channels power from the Safran Aneto engine and distributes it to the rotor blades. It’s not just about transferring power, though; it’s about doing so with utmost efficiency and unwavering reliability.

This gearbox was the result of a joint effort between Airbus Helicopters and Avio Aero. The two companies pooled their expertise to combine their best ideas, ultimately creating a transmission system that's both high-performing and dependable. The design had to accommodate the unique demands of the RACER's hybrid plane-helicopter configuration, supporting its ambitious high-speed flight goals and overall operational flexibility.

Here's a look at what makes it tick:

• Power Management: It masterfully takes the high-speed rotation of the engine and slows it to the optimal speed for the main rotor. Simultaneously, it increases torque—the crucial twisting force needed to spin the blades.
• Built to Last: The MGB is engineered to withstand tough operational stresses and diverse weather conditions, aiming for a long service life with minimal maintenance.
• System Integration: It must seamlessly connect with the engine, the rotor system, and all the other components of the drivetrain.

The successful completion of rigorous testing, including emergency 'oil-off' scenarios, serves as a powerful confirmation of the main gearbox's readiness for its demanding role in the RACER.

The design and construction of the main gearbox represent a significant engineering achievement, perfectly balancing the need for robust power transmission with the unique demands of a novel aircraft configuration.

4. ASTRAL Consortium Wings

The wings on the Airbus RACER helicopter are a remarkable feat of engineering, and the ASTRAL consortium delivered an exceptional design and build. This group—a collaboration between AERNOVA Hamble Aerostructures and the University of Nottingham's Institute for Advanced Manufacturing—focused on creating wings that are not only aerodynamically brilliant but also utilize advanced, environmentally friendly materials. The primary objective here was to keep the helicopter as light as possible, which aligns perfectly with the Clean Sky 2 program's mission to reduce emissions.

What's truly fascinating is the "double wing" or "box wing" configuration. It's a clever piece of engineering that helps generate lift during forward flight and also adds a safety feature when the helicopter is on the ground. These wings are specifically crafted to boost the helicopter's performance, providing more vertical lift and enabling it to fly faster and farther than older helicopter designs could ever dream of.

Here's a quick look at what the ASTRAL consortium brought to the table:

• Aerodynamic Shape: The wings are meticulously shaped to minimize air resistance and maximize lift.
• Lightweight Build: Employing high-performance, eco-friendly materials is key to keeping the aircraft's overall weight down.
• Better Performance: The innovative wing design directly contributes to increased speed, longer range, and better lift capabilities.

Developing these wings marks a significant step forward in helicopter design. They've skillfully managed to merge smart aerodynamics with sustainable materials, paving the way for better performance and a more positive impact on the environment.

The ASTRAL consortium's work on the RACER's wings showcases a brilliant blend of advanced engineering and a deep commitment to sustainability, resulting in a component that significantly contributes to the aircraft's overall efficiency and performance.

5. ANGELA Consortium Landing Gear

The landing gear system for the Airbus RACER helicopter demonstrator comes from the dedicated work of the ANGELA consortium. This group brought together specialized knowledge from Italy's Centro Italiano Ricerche Aerospaziali (CIRA) and Magnaghi Aeronautica, along with valuable input from Lithuania's Techno System Development. A top priority during the design phase was minimizing aerodynamic drag when the landing gear is stowed away. To pull this off, the system is cleverly integrated into the wing and fuselage, utilizing a retractable door mechanism.

When it's time to land, the extended gear provides a wide stance, which is crucial for stability and ensuring safe touchdowns. Magnaghi Aeronautica, drawing on its considerable experience in the field, spearheaded the rigorous testing of this system at its facility near Naples. This exhaustive process was essential to gain flight clearance and confirm the system's reliability under a wide range of operating conditions.

Key aspects of the ANGELA consortium's contribution include:

• Design and Manufacturing: Magnaghi Aeronautica took the helm in designing, manufacturing, and testing the landing gear.
• Aerodynamic Integration: The system is engineered to retract smoothly, keeping drag to a minimum.
• Stability: When deployed, the gear offers a wide track for exceptionally stable landings.
• Testing and Validation: Extensive testing was conducted to ensure all performance and safety standards were met or exceeded.

The integration of this landing gear showcases a sharp focus on aerodynamic efficiency, a key requirement for a high-speed helicopter demonstrator like the RACER. The system's ability to retract cleanly and provide a stable platform for landing truly highlights the impressive engineering efforts involved.

This collaborative effort culminated in a landing gear system that is not only functional but also actively contributes to the ambitious performance goals of the RACER demonstrator.

6. RoRCraft Consortium Central Fuselage

The central fuselage of the Airbus RACER helicopter demonstrator is a major structural component, expertly designed and manufactured by the RoRCraft consortium. This group represents a collaboration between Romania's National Institute for Aerospace Research "Elia Cafaroli" (INCAS) and the aerospace company ROMAERO. Their work on the RACER's airframe is particularly noteworthy, as they produced an advanced hybrid structure that combines metallic and composite primary elements—a first for Romania in helicopter manufacturing.

The RoRCraft consortium was tasked with assembling the intermediate side shells onto the Racer airframe. These shells, which measure 3.4 by 1.5 meters, are fashioned from carbon fibre reinforced plastic (CFRP) and serve to connect the tail boom to the cockpit area. A new, highly automated method, developed by Germany's Fraunhofer Institute for Foundry, Composite and Processing Technology IGCV, was employed to produce these large CFRP shells, marking a significant departure from traditional manual assembly.

Key responsibilities of the RoRCraft consortium included:

• Designing and developing the central fuselage airframe.
• Manufacturing and assembling the intermediate side shells.
• Designing and conducting ground tests for fuselage parts.
• Performing detailed stress analysis for all fuselage components.
• Contributing to the demonstrator's overall flight clearance.

The successful completion of the central fuselage marked a pivotal moment, effectively signaling the start of the RACER's overall assembly process. This component is absolutely vital for integrating the helicopter's various other systems and sections.

7. Airbus Helicopters Rear Fuselage

The rear fuselage of the Airbus RACER helicopter is a marvel of modern engineering, designed with a unique, asymmetric cross-section. This specific shape isn't merely for aesthetics; it's strategically designed to enhance the helicopter's performance while hovering, without compromising its forward flight capabilities. The teams at Airbus Helicopters, with support from the ASTRAL consortium led by Aernnova, faced the tough challenge of building this part due to its precise dimensions and the strict requirement to keep it incredibly light.

What's especially interesting about this section is that the RACER will be the first Airbus aircraft to use advanced additive manufacturing—also known as 3D printing—for its primary structure. This cutting-edge method allows engineers to create intricate shapes that would be incredibly difficult to make with traditional techniques, and it often results in lighter parts.

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

This part of the helicopter really demonstrates how the project is pushing the boundaries of what's possible in aircraft design. It's a perfect example of combining new materials with smart aerodynamic concepts to achieve superior performance.

Key features of the rear fuselage include:

• Asymmetric Cross-Section: Designed to improve hover performance without hindering forward flight.
• Additive Manufacturing: Utilizes advanced 3D printing techniques for primary structure components, enabling complex geometries and weight reduction.
• Patented Empennage: An H-shaped tail with tilted stabilizers, developed with ONERA, to enhance stability and aerodynamic efficiency.

8. Techno System Development Landing Gear Control Unit

When it comes to the Airbus RACER helicopter, the landing gear system is a truly complex piece of machinery. While the ANGELA consortium managed much of the design and manufacturing, a specific and absolutely vital component came from Techno System Development. This Lithuanian-based company was tasked with creating the control unit for the landing gear's electro-mechanical actuator.

This control unit is essentially the brain behind the landing gear's operation, orchestrating its extension and retraction. It simply has to work perfectly every single time, ensuring the gear deploys smoothly for landing and retracts cleanly to minimize drag during flight. You can think of it as the command center that tells the landing gear precisely what to do and when to do it.

Here's a look at what makes this unit so important:

• Precision Control: It governs the precise movements of the landing gear, ensuring it locks securely in place whether extended or retracted.
• Electro-Mechanical Integration: It serves as the interface with the actuator, translating electronic commands into physical motion for the landing gear.
• Safety Assurance: The unit plays an integral role in the overall safety of the landing gear system, contributing to reliable deployment and retraction sequences.

Developing such a critical component demands a profound understanding of both electronics and mechanical systems. Techno System Development's contribution to this control unit highlights their specialized capabilities in creating sophisticated systems for advanced aircraft.

The development of the landing gear control unit by Techno System Development is a prime example of how specialized expertise contributes to a larger, more complex system. It underscores the importance of individual component reliability in the overall success and safety of an aircraft demonstrator like the RACER.

9. KLK Motorsport GmbH Canopy Structure

The canopy structure for the Airbus RACER helicopter demonstrator is another key component, and this one was developed by KLK Motorsport GmbH. They teamed up with another company, Modell und Formenbau Blasius Gerg GmbH, which also boasts extensive experience in motorsport design. Despite being relative newcomers to the aerospace world, these companies skillfully created a canopy that is both lightweight and aerodynamically efficient. It also successfully met all the stringent regulations required for aircraft parts.

This successful partnership prompted Airbus to work with them again. In 2022, they were tapped to design the aft section of the fuselage for Airbus's new CityAirbus NextGen aircraft. This repeat business speaks volumes about how well KLK Motorsport GmbH and their partner performed on the RACER project.

The development of the RACER's canopy structure beautifully illustrates how skills from the high-octane world of motorsport can be successfully applied to aviation, resulting in lightweight and aerodynamically efficient designs that meet rigorous safety standards.

Here's a quick look at what made their contribution so significant:

• Lightweight Design: They utilized advanced materials to minimize weight, a constant priority for enhancing aircraft performance.
• Low Drag Profile: It was engineered to reduce air resistance, which contributes to better speed and fuel efficiency.
• Adherence to Standards: They successfully met all the demanding safety and performance requirements set by the aerospace industry.

10. Latecoere Electrical and Mechanical Harnesses

When you admire a complex machine like the Airbus RACER helicopter, it’s easy to focus on the large, visible parts. But hidden from view is a vast network of wires and connections that keeps everything running—the aircraft's nervous system, if you will. That's where Latecoere and its subsidiary, LATELEC, come in. They are the experts responsible for designing and assembling the intricate electrical and mechanical harnesses for the RACER.

These harnesses are the unsung heroes of the helicopter. They carry power to all the different components and transmit the control signals that tell every part what to do. It’s a meticulous job, ensuring every connection is perfect so that the helicopter can fly safely and efficiently. Latecoere, a major player in aerostructures and interconnection systems, brings a wealth of experience to this critical task.

Their work is absolutely vital for integrating the power and control distribution throughout the entire air vehicle. It stands as a testament to French industrial know-how in aerospace wiring and complex systems integration.

Here's a bit more about what this kind of work involves:

• Power Distribution: Making sure that electricity gets to every single system that needs it, from the cockpit displays to the engines.
• Signal Transmission: Relaying commands from the pilots and flight computers to the various actuators and systems with zero delay.
• Environmental Protection: Designing harnesses that can withstand the harsh conditions of flight, including extreme temperature changes and vibrations.
• Weight Optimization: Ensuring the harnesses are as light as possible without compromising reliability—always a major concern in aviation.

The complexity of modern aircraft means that the design and manufacturing of these wiring systems demand an exceptionally high level of precision and specialized knowledge. It's not just about connecting wires; it's about creating a robust and reliable network that performs flawlessly under extreme conditions.

Latecoere's involvement underscores the importance of these often-overlooked components in the overall success of an advanced aircraft like the RACER.

Looking Ahead

The Airbus RACER helicopter project is a powerful testament to what can be achieved through large-scale collaboration. From the engines crafted by Safran to the gearboxes from Avio Aero and the wings by the ASTRAL consortium, it’s abundantly clear that no single company could build something this advanced on its own. This spirit of teamwork, uniting experts from across Europe, is precisely what propels aviation forward. It's about more than just building a faster helicopter; it's about discovering new ways to make aircraft more efficient and quieter by leveraging novel materials and manufacturing methods. The success of the RACER proves that this collaborative model is a robust blueprint for developing the next generation of flying machines.

Frequently Asked Questions

What is the Airbus RACER helicopter?

The Airbus RACER is a unique experimental helicopter built to fly significantly faster than conventional models. With a design that blends features of a helicopter and an airplane, its main purpose is to demonstrate new technologies that can make helicopters faster, more fuel-efficient, and quieter. These advancements could be a game-changer for services like inter-city transport or emergency medical missions.

Who are the main companies that built the parts for the RACER helicopter?

A whole host of specialized European companies collaborated to bring the RACER to life. For instance, Avio Aero manufactured key components like the gearboxes that drive the rotors, while Safran provided the powerful Aneto engine. The ASTRAL consortium was behind the innovative wings, and the ANGELA group created the landing gear. Airbus Helicopters itself took charge of building the main body and the tail section.

How fast can the RACER helicopter fly?

The RACER is truly built for speed! It's designed to maintain a cruise speed of about 400 kilometers per hour, which is roughly 250 miles per hour. That's a significant jump from most conventional helicopters, which typically cruise at around 260 kilometers per hour.

What is special about the RACER's engine?

The RACER is equipped with the Safran Aneto-1X engine, which is not only powerful but also quite compact. One of its standout features is its role in a hybrid system that allows one of the two engines to be shut down during cruise flight. This clever capability helps to save a considerable amount of fuel, reduce emissions, and achieve its impressive high speeds.

What is the role of the ASTRAL consortium in the RACER project?

The ASTRAL consortium was tasked with the crucial job of creating the RACER helicopter's wings. These wings feature a highly aerodynamic design and are built using eco-friendly materials. Their primary function is to provide lift during forward flight, which helps the RACER fly much more efficiently and at higher speeds than a typical helicopter.

What makes the rear fuselage of the RACER unique?

The rear section of the RACER's airframe has a distinctive, asymmetric shape. This design cleverly improves the helicopter's performance while hovering, without negatively impacting its forward-flight speed. It also pioneers new manufacturing techniques, making it one of the first Airbus aircraft to feature a primary structure created using advanced additive manufacturing, or 3D printing.