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For naval aircraft carriers, this is a major challenge. Limited space, complex supply chains and variable operational environments make it difficult to have the right combination of aircraft ready to tackle tomorrow’s missions. But what if one type of aircraft could be quickly adapted for multiple roles?
That is the aim of Aeralis, a British aerospace company developing a modular military jet. Initially conceived by lead architect Tristan Crawford as an adaptable aircraft for both basic and advanced flight training, the concept has since advanced to encompass ‘light’ combat and other roles.
At the centre is a common core fuselage, with common avionics and mechanical systems. The wings, engine and cockpit can all be interchanged, creating a truly flexible modular aircraft.
“If you have a sudden requirement for a different operational approach, you can open a box that gives you the parts to add to your fuselage,” said head of engineering Matt Powlson. “We wouldn’t expect minute-to-minute, sortie-by-sortie role changes. But the challenge is there for us to meet.”
He added: “It’s not a Formula One pit stop. If it was on the carrier, you wouldn’t make those changes on deck, you have got to get the aircraft below. So you’re into two hours, just because you’ve got to move the thing into place. And then you’re moving significantly heavy lumps of machinery, like jet engines, and care is required. But it’s a matter of hours, not even a day.”
Pick ‘n’ mix
The interchangeability of components means that a full fleet can be maintained with fewer materials, cutting reliance on the supply chain and saving space and money. Analysis for Aeralis shows potential through-life savings of 30% for military operators using two of the variants, instead of two different types of aircraft.
The approach could bring other benefits. Trainee pilots could stay with the same fundamental aircraft type from training through to operation, for example. Modularity also means that air forces could reconfigure aircraft as new technology becomes available, such as more advanced engines.
“If you’re building everything around your power plant, then changing the power plant becomes incredibly difficult,” said Powlson. “Aeralis has a separate modular engine pod, which means that we have opportunity to adopt newer propulsion and powerplant options much more rapidly.”
The challenges of quickly reconfiguring jets should not be understated, however. “It’s not an Ikea hex bolt, it’s significant pieces of engineering,” said Powlson.
All interconnections on the engines and wings will need to be made safely and securely, regardless of which variant is being introduced. Aeralis is taking a ‘clean sheet’ approach to sensors to enable this, with plans to install “more than the usual amount” on board. Data will be analysed during and after flight, with standard trade practices used for component changes.
Industry heavyweights
Thankfully, Aeralis has some major partners to help it tackle the challenges ahead. Announcements made last year include a veritable who’s who of the aerospace elite – Rolls-Royce is supporting propulsion and digital integration, Atkins and Siemens are supporting digital enterprise, Thales in the UK is supporting development of training and simulation, and the RAF picked Aeralis for R&D work on advanced modular aircraft.
With such strong backing from partners, and significant engineering experience in the team, Aeralis is targeting 2024 for its first flight. It hopes to complete a ‘re-role’ and flight in the same year.
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Content published by Professional Engineering does not necessarily represent the views of the Institution of Mechanical Engineers.