20 Feb 2007 | Ref. 057/2007
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Typhoon – manufacture overcomes the pull of the moon
Warton, United Kingdom – Building one of the most advanced jet fighters in the world is a challenge for any aerospace company – but the one thing you might think you don’t have to worry about when you start such a job is the pull of the moon.
But that is exactly the challenge faced by workers at BAE Systems on the Lancashire coast every time the Typhoon build process begins – because the moon’s gravitational pull actually causes the ground to move beneath their feet.
So fine are the tolerances now used to build the Typhoon that even the movements of the tide could throw the jet fighter tolerances out.
Martin Topping, Typhoon final assembly operations manager explains: “Every time the moon pulls the tide in and out, the ground under our feet actually moves by between one and two millimetres. That might not sound a lot, but given the tolerances we are working to on Typhoon, two millimetres is two millimetres too much.”
To get round the problem BAE Systems has spent over £2.5million putting in special automated alignment facilities which use laser-trackers and computer-automated jacks. But what really ensures that each Typhoon’s airframe is built as close to perfection as is humanly possible are the giant ‘floating’ concrete rafts on which the aircraft and measuring equipment sit.
“Each of these concrete rafts is over three metres deep and 18 metres long,” says Martin. “All 9 automated jacks and both laser trackers are positioned on one surface ensuring all movement is relative, achieving a near perfect alignment whatever the moon may be doing.”
The result is one of the most perfectly aligned fast jet airframes in the world. Although 15 metres long from tip to tip, every Typhoon that leave BAE Systems in Warton varies from true no more than the thickness of a match stick – and that helps its ‘fly by wire’ computer system accurately control the aircraft, designed to be unstable but hugely agile.
Because of this build accuracy there is minimal need to ‘trim’ the flying surfaces and pilots can fly the fighter to its maximum potential. On a typical sortie, this build precision will save enough fuel to fill up an average family car (60 litres). The advanced manufacturing technology pioneered first on Typhoon is now also being used on the F-35 Lightning II. The F-35 Lightning II will be the world’s first and only stealthy, supersonic, multi-role fighter.
About BAE Systems
BAE Systems is the premier transatlantic defence and aerospace company delivering a full range of products and services for air, land and naval forces, as well as advanced electronics, information technology solutions and customer support services. With 88,000 employees worldwide, BAE Systems' sales exceeded 12 billion pounds (US22 billion dollars) in 2005, excluding the Group's former interest in Airbus.
For further information contact:
Simon Shrouder, BAE Systems
Tel: +44 (0)1772 852995 Mob: +44-(0)7793 423453
simon.shrouder@baesystems.com
Mike Sweeney, BAE SYSTEMS
Tel: + 44 (0)1252 383074 Mobile: + 44 (0)780 171 6452
mike.sweeney2@baesystems.com
Issued by:
BAE Systems, Farnborough, Hampshire GU14 6YU, UK
Tel: +44 (0) 1252 384710 Fax: +44 (0) 1252 383947
www.baesystems.com
