A400M Design Activities Realized by TAI
The A400M Transport Aircraft, which, with their high cruising speed and range, will take the places of the C-130 Hercules and C-160 Transall, which are getting older and becoming insufficient, have the capacity to carry twice the load of the mentioned aircraft.
The contract regarding the A400M program, in which TAI has been participating in the feasibility and design activities since the beginning as the “National Industrial Institution”, became effective on 27 May 2003. The contract provides for a total of 180 A400M aircraft to be delivered to the launch customers as follows: Belgium 7, France 50, Germany 60, Luxembourg 1, Spain 27, Turkey 10 and United Kingdom 25. Under the program, the first flight of A400M is scheduled to take place in 2008 and first deliveries will be realized from 2009. Being the prime contractor group, Airbus (Germany, UK, France), Flabel (Belgium), EADS-CASA (Spain) and TAI (Turkey) continue their cooperation in the industry group.
Under the A400M program, structural changes, especially in the design department, are experienced at TAI. The support, given by the Turkish Undersecretariat for Defence Industries to our Company, has been an important step in the development of not only TAI’s design activities, but national aviation industry as well. At the peak period for the design activities in 2007, a total of 140 design engineers will be working at TAI facilities for the A400M program.
With this program, TAI shifts to “build-to design” method from “buildto- print.” Being a partner of Airbus Military S.L. (AMSL), our Company will not only own design rights, but also become a partner of Design Organization Approval (JAR-21 PART JA) under AMSL since AMSL has design rights, in general, and type certificate (JAR-25). These approvals will make TAI a company, that has control over all the processes including design, test, certification and delivery. There are three main groups working on the A400M design activities at TAI:
1. Fuselage Group:
This group continues its activities under Forward Center Fuselage (FCF) Component Management Integrated Team (CMIT) and Rear Fuselage (RF) Components Component Design Build Team (CDBT) subgroups.
FCF CMIT: Under the forward center fuselage design activities, following the successful realization of the M8 milestone, ‘first component manufacturing start ‘, three Forward Center Fuselage components (MSN1, MSN5000 -Full Scale Static- as well as MSN2 aircrafts) and three Emergency Exit Doors were delivered to IFA: the fuselage pre assembly line in Bremen, as of December 2006. MSN1 is now at system installation station 600 at IFA Bremen. Next step is the Milestone M9, start of Final Assembly Line at Sevilla. This event is scheduled for mid of February 2007. The design activities for the MSN5001 -Full scale Fatigue aircraft- are on going.
RF Components CDBT: the rear fuselage components under TAI responsibility are: Section 17 Upper Shell, Left Hand / Right Hand Paratroop Doors, Rear Ditching Door and Tail Cone.
First four Section 17 Upper Shell and Rear Ditching Door components were delivered to IFA in Bremen. First ship set of Left Hand / Right Hand Paratroop Doors are planned to be delivered early January 2007. Tail Cone manufacturing activities have started. The design activities for the MSN5001 -Full scale Fatigue aircraftare on going.
2. Aileron and Spoiler Group (Aileron and Spoiler CMIT):
The M6 Preliminary Design Phase started with the successful completion of the M5 Conceptual Design Phase on 20 November 2003. For the flight control surfaces (aileron and spoiler), which are under the responsibility of TAI, all components (longeron, frame and skin fittings), except the 7050T7451 aluminum alloyed wing and actuator fittings with flap fairing, are designed as composite for the first time. This will provide an important saving in weight. Carbon Fiber/Epoxy will be used as composite material, whereas, in order to reduce lightning effects, bronze net will be used in some coating zones, which will be designated after the test results.
3. Systems Groups (Lighting & Water/Waste System CDBT):
Lighting and Water/Waste systems CDBT group is working under the CMIT Utilities. In this work package, TAI is level 1 responsible for the design and development to establish the overall design parameters to enable correct execution of design function. This responsibility includes setting design principles and instructions, defining/performing tests on complete system and certification of the systems in front of EASA authority. These will be the first certified systems of TAI.
Lighting Design Build Team (DBT):
MIL-STD-3009 compatible NVIS design based on Gen III, class B, type II Goggles has been applied on the A400M Lighting system.
Cargo Lighting: General illumination has been provided with one type of equipment with the capability of different lighting modes: Normal, NVG Compatible and Covert. Several dim levels are achievable. Floor lights are also serves for normal and NVG Compatible modes of lighting. NVG Compatible passenger signs, shape coded Aerial delivery lights are other units in the cargo area. All type of light equipment is LED technology. Cargo lights are mainly controlled from Load Master Work Station (LMWS). The lighting mode can also be overridden by cockpit crew.
Exterior Lighting: Apart from the normal mode, exterior lights are mostly Covert mode lights for NVIS operations. LED and halogen types have been used. Also NVIS Friendly Navigation Lights are used for both NVIS operations and normal civil flights. CS.25 requirements, civil and military operational needs are main drivers for exterior lighting. Exterior lights are controlled from Cockpit Controls.
Emergency Lighting: Civil CS.25 requirements are respected for the design. Service Area Lighting: LED, Halogen technologies are used. Fuel service area has been illuminated with NVG compatible light.
Water/Waste DBT:
The Water/Waste consists of “potable water”, “gray water” and “toilet” systems.
Design activities regarding the system architecture, installation and hindering the icing of the system are ongoing. New concepts are used such as semi pressurized fresh water system, wild frequency powered pumps, integrally heated/insulated composite tanks and service panel mounted light weight fill/drain valves. The water / waste system matches the technology of the modern A400M. Pre M9 studies were completed successfully.
