On 21 October,
Embraer rolled out the first prototype of its new KC-390 military transport aircraft.
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| Embraer KC-390 military transport aircraft rollout. (All Photos: Pieter Bastiaans) |
The impressive roll out ceremony was done at Embraer's plant in Gavião Peixoto northwest of São Paulo, Brazil under the watchful eye of dignitaries from 32 countries. The KC-390 was developed by Embraer in response to a requirement of the Brazilian military with the Brazilian Air Force (FAB) owning the intellectual property of the aircraft programme according to
Jackson Schneider, the President and CEO of Embraer Defense & Security. Due to Brazil's national defence strategy and its increased demands for airlift and air to air refuelling (AAR), the FAB has been looking for a new aircraft with sufficient range to cover the vast expanses of the Brazilian countryside, hereby providing mobility to its scarce military resources needed to defend the country. The aircraft was required to be able to cope with the country's diversity of climate and terrain including the Amazon region and the Antarctic. With 80% of Brazilian oil production being done offshore, Embraer was also asked to take into account the fact that the new aircraft had to be capable of conducting SAR missions in Brazil's extensive exclusive economic zone. In addition, the Brazilian military wanted an aircraft that could execute missions other than war including humanitarian and disaster relief missions as well as missions in support of national commitments to the UN.
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| Jackson Schneider, the President and CEO of Embraer Defense & Security emphasised that the programme is on track with the first flight of the first prototype expected to take place in late 2014 once integrated systems and ground vibration tests are succesfully completed. |
The FAB's current (K)C-130H transport fleet has reached an average age of 37+ years, leading to lower availability and higher maintenance costs, this clearly indicating the urgent need for a modern, more advanced aircraft. The new transport is planned to complement the HERCULES fleet while also gradually replacing a number of the ageing turboprop transport aircraft. As part of its market survey, the FAB also looked into the capabilities of existing aircraft designs including the Lockheed Martin C-130J Super HERCULES. In the end the main requirements which were laid out by the FAB asked for a new airlifter with state of the art avionics that was capable of lifting 19t over 2,000nm, while also being able to conduct high altitude as well as low altitude parachute extraction system (LAPES) air drops. The ability to operate from short semi-prepared runways was also a key requirement.
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| Embraer KC-390 |
Since its foundation in 1969, Embraer has grown steadily diversifying into new markets along the way. In response to the Brazilian military's requirements the company came up with a proposal that merged advanced technology with risk reduction measures, opting for commercial off the shelf equipment whenever possible, while staying within the confines of the U$2 billion development cost estimate, this including $631 million for the aircraft's so called strategic systems. These systems include the aircraft's engines, avionics, flight controls, landing gear and mission systems, the suppliers of which are selected by the air force. According to Schneider, the KC-390 programme represents a major leap in design and manufacturing processes for the company. The aircraft's FBW system was designed by Embraer while the company has improved its experience on how to deal with composites, metallurgics, and milling processes. The contract to develop the KC-390 was signed in April 2009 with the contract for the production of 28 production aircraft for the FAB and an initial logistical support package being signed five years later, on 20 May this year. The FAB opted for basic avionics by
Rockwell Collins, turbofan engines by
International Aero Engines, a cargo handling and delivery system by
DRS Technologies, and a tactical radar by
Selex ES. A number of mission systems come from
Elbit Systems’ Brazilian subsidiary
Aeroeletronica (AEL), while
Cobham is responsible for delivering the wing air refuelling pod system.
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| Embraer KC-390 turbofan engines by International Aero Engines. |
During development Embraer has made extensive use of digital and physical mockups in order to optimize its design while also conducting a series of wind tunnel campaigns. The South American aircraft manufacturer is also using two trial bodies for fatigue and structural tests while employing smaller rigs for other trials. A joint project between Embraer and the Brazilian military, the KC-390 is the biggest aircraft ever developed by the Brazilian aircraft manufacturer having a length and a wingspan of slight more than 35 metres. Designed with a high degree of flexibility in mind, the advanced transport aircraft has been conceived to perform a wide range of missions including airlift, aerial resupply, aerial assault/infiltration, AAR of fixed wing and rotary wing aircraft, medevac, SAR, aerial fire fighting, and combating occurrences of oil spillage. As a result, the KC-390 can be configured in various ways either for carrying 80 troops or 66 paratroopers, 74 litters with two attendants, or seven 463l pallets, including two which can be carried on the rear ramp. Capable of carrying a distributed cargo load of 23t, or a concentrated payload of 26t, the new transport aircraft can also take on heavy loads, typical loads for the Brazilian military including either three HUMVEEs, a
Sikorsky S-70 BLACKHAWKhelicopter or a LAV-25 combat vehicle. During the post ceremony press conference, Schneider indicated that he also beliefs that, "
This is an ideal aircraft for special forces. This is a plane with a modular concept that is highly adaptable."
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| Christening of the Embraer KC-390 |
With its two 31,330lbs thrust IAE V2500-E5 turbofan engines enabling a maximum cruise speed of 470kts, Embraer aims to offer an aircraft that can deliver more cargo per mission and do it faster, hereby enhancing mobility of its customers. Using this concept, Embraer is convinced that greater distances can be covered in a single crew duty day and that more missions can be flown using the same amount of flight hours, hereby enhancing effectiveness and efficiency. The cargo bay area of the KC-390 has a length of 18.5m including the usable ramp area. Without the ramp that has been optimised for easy access for long heavy wheeled vehicles, the length is 12.7 metres. Operating at a maximum altitude of 36,000ft, the KC-390 typically has a range of 1,380nm with a 23t payload or 2,780nm with a 13t payload. Ferry range can be extended from 3,530nm to 4,640nm by adding internal auxiliary fuel tanks.
The requirement of being able to operate from damaged or semi-prepared runways has led to a rugged design, which according to
KC-390 programme manager Paulo Gastão Silva has, "
great protection against ingestion of FOD ( foreign object damage)," due to the engines being mounted approx. 2m off the ground. In addition to the aircraft's strong and durable airframe, future pilots operating the KC-390 will benefit from increased situational awareness because of the aircraft's state of the art avionics.The avionics architecture includes five MFDs and daylight and thermal imagery generated by a nose mounted synthetic vision system being projected on two heads up displays (HUD) in the cockpit. Fitted with a closed loop FBW system and active side sticks which enable precise aircraft control, the KC-390 also features modern electronic warfare self protection systems including ballistic protection against small arms fire, critical systems redundancy, radar, laser and missile approach warning receivers, chaff and flare and DIRCM. Introducing prognostic health monitoring, Embraer has done the utmost to limit the amount of maintenance efforts required to keep the aircraft in the air, hereby enabling longer intervals between inspections and thus reduced maintenance downtime. Embraer is aiming for a mission reliability figure equaling 95% or more and an 80% fleet availability. A one day intermediate or A check is mandatory after 600 flight hours or after a 12 months period whereas a basic or C check is needed after 3,000 hours of flying or every 60 months, this costing ten days. According to information provided by Embraer, the aircraft requires no depot level maintenance.
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With 28 firm orders to date, Embraer is now looking for further contracts. So far, five countries have signed letters of intent for a total number of 32 aircraft: Portugal (6), Argentina (6), Czech Republic (2), Colombia (12), and Chile (6) with the first three countries being involved in the KC-390 programme as industrial partners. During the press conference Embraer D&S President Schneider explained that with so many delegates from different countries being present during the ceremony: "
This shows there is a reasonable interest for the aircraft." He continued: "
This aircraft will be extremely competitive. The aircraft brings to the market a new concept. I think we have done well and that the market will recognise this." On the question of export opportunities, Schneider told his audience: "
Important is the Middle East market," and, "
Many African countries are potential customers, especially the Portugese speaking African countries, some of which were among us today." Noted during the ceremony were high ranking officials from Angola while representatives from South Africa, Kazachstan, Ecuador, Mexico, Sweden, Hungary, Poland, Turkey, Egypt, and Qatar were also said to be present. Embraer is clearly aiming at possible contracts with countries that are still operating the legacy C-130 HERCULES and that are in need of replacement aircraft. Depending on the specific mobility requirements of these nations, the KC-390 medium transport aircraft could get a significant market share. It fits in nicely between the enhanced
Ilyushin Il-476 (52t payload) and
Airbus Defence & Space (DS) A-400M (37t) heavy airlifters that are on offer today, and 5-10t class light transport aircraft such as the Airbus DS CN-235 (6t) and C-295 (9t),
Alenia Aermacchi C-27J (11.5t ) and
Antonov An-74 (10 tons). Embraer’s new airlifter directly competes with the
Lockheed Martin C-130J/J-30 which has a maximum payload of 19/20t and the 20t payload Multirole Transport Aircraft (MTA) that is currently being developed by
United Aircraft Corporation–Transport Aircraft of Russia and
Hindustan Aeronautics Limited (HAL) of India.
Silva said that possible civil applications of the aircraft were studied from the beginning: "
There is a niche market for mining companies, oiling companies, for which a civilian version would make sense, we are monitoring that." Embraer is already cooperating with US aircraft manufacturer
Boeing with regard to marketing the KC-390, however Schneider did not rule out cooperation with other companies with regard to customizing the aircraft for special missions.
Schneider emphasised that the programme is on track with the first flight of the first prototype expected to take place in late 2014 once integrated systems and ground vibration tests are succesfully completed. Assembly of the second and last protype has meanwhile commenced. Owned by the air force, both prototypes will be retrofitted once the test and certification programme is finished and will subsequently enter operational service, making a total of 30 aircraft for the Brazilian military, Schneider revealed. The trials will take two years to complete with the aircraft planned to be certified both civilian and military. Deliveries of production aircraft will commence during the second half of 2016 and last until at least 2023.
Pieter Bastiaans
