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Air Power: Farnborough 2004 - Prizes Galore

By Robin Ashby, Director, UK Defence Forum
15 Nov 2004

If it is possible to steal an air show from the ground, Thales was the defence ‘thief-in-chief’ at Farnborough 2004. The apogee of their week was the multiple whammy, which vindicated Chairman Denis Ranque’s multi-domestic strategy.

UK Defence Secretary Geoff Hoon came to praise them while announcing that they’d been downselected for the Watchkeeper unmanned aerial reconnaissance programme. Coincidently, overnight, they’d won another $295M chunk of the US Joint Tactical Radio System. ‘We don’t control our industry’s announcement timetable’, said Ranque, but he was clearly delighted with the coincidence.  

A few hours later they added to their haul with an €85M demonstrator scanning radar order for the Rafale combat aircraft. The next day a further €130M started their way for three different contracts for A400M. While others were counting their losses in the defence capability review, Thales picked up a £180M order for Starstreak, which will keep their Belfast factory in business until 2020.

Ranque was still grinning when he presided over the biggest of the Farnborough parties a few hours later. No wonder one wag quipped that the Watchkeeper must be amphibious because it was launched on a sea of champagne.

After their memorable Hampton Court Palace bash last Farnborough, BAE Systems decided to pass on the major hospitality stakes this time. Pity!

 

More Winners

The other company satisfied by the defence capability review must be AugustaWestland. The MoD review confirmed there’s a £3bn helicopter market in the UK for them to aim at over the next 10 years.

Apart from these defence industry high spots, it might be thought Farnborough was all sound and fury – especially when Super Hornet and Eurofighter hit the end of the runway – but with not much that was new or concrete.

For once this gave UK companies a chance to take one step forward from the ranks. There were a number of regional groupings, like Northern Defence Industries, to give the little companies a chance to make their pitch.

 

Like 23-strong Scarborough firm Unison Ltd, who claim to have taken the Black Art out of tube bending. Airbus certainly thinks so. Having bought three of their bending machines for use on A380 wing components, saving £60,000 per wing set and improving quality, the company ordered another three during the show.

 

Tubes bent by Unison machines are also used in A330, so the company has a small stake in the outcome of the negotiations for the future Strategic Tanker Aircraft programme too.

 

Another less glamorous announcement about improvements to manufacturing processes came from TT Electronica. Available in standard man-operated, robotic or customised variants, the company launched its Halosensor hole position locating system.

 

Like much technology, it solves problems mere mortals don’t even know exist. In this case it is the inaccuracy and waste resulting from drilling holes from inside an aircraft rather than from the outer surface of an aircraft’s skin. BAE Systems, Bombardier and Airbus beat a path to the West of England Aerospace Forum where this process was shown off for the first time.

 

The North West Aerospace Alliance hosted another product of European funded research on the holes issue. Unimerco has recently opened a new £8M UK plant near Lichfield. It brought to Farnborough first fruits of the €4.1M Macharena project, a diamond hard coating for carbide drill tools that can triple life, double cutting speeds and reduce drilling costs by 80 per cent.

 

Lockheed Martin’s Ian Stopps was quoted during the show as saying: ‘We will continue to bring technology into the UK from the vast resources of the US, use it for ourselves and with our partners and indigenise it’.

 

A small Glasgow family firm, Walker Precision Engineering, has gone one step further. Under a technology transfer deal with Millimetre Wave Technology Inc. of New Jersey, it has just introduced an improved hand-held reflectrometer to test the absorbency of radar-absorbing material. It is hoping it can sell replacements for some 200 previous-generation models.

 

Protectionism and Global Industries

 

Considerable concern has been expressed in the UK defence industry about the growing protectionist mood in the US. Lord Bach gave the firmest steer yet on the way the wind might blow when he told a newspaper just before the show: ‘If your companies can’t deal with (American ones) at a level, then inevitably we will look towards Europe as the sole source of the foreign supplies we need’.

 

So it was particularly welcome to hear the views of Lockheed Martin’s Bob Trice, senior vice president for business development. He pointed out clearly that the use of foreign sources has not negatively impacted US national security. Despite massively higher spending on procurement and R&D by the US, ‘No industry is bigger than the global market. If you don’t adapt, you go away’.

 

His thesis was that a multinational aerospace and defence industry provides a net positive to the US economy. It sustains the US industrial and technology edge and enhances allied political, military and industrial partnerships.

 

More Winners

 

Nimrod MR4A might only be half the number it once was, but the lessons learned will be applied elsewhere, although the benefits to Britain are not all they might be.

 

Having signed a contract for system development and demonstration of the 737-based Multi-mission Maritime Aurcraft (MMA), Boeing were in buoyant mood. Their point man, Tim Norgart, stressed their solution had ‘benefited from the team’s experience with the Nimrod mission system’.

 

Now Boeing is working with the US Navy to offer MMA to 15 countries who between them operate 225 P3 Orions. On the podium during the pitch was Captain Steve Eastburg in uniform. He described how the US Navy’s policy position would define ‘in the next couple of weeks, the extent to which we can partner with allies for co-development’. There seems to be a remarkably close relationship between contractor and customer, which should yield significant benefits to US Inc. in the future.

 

Represented on the programme is U.K’s Smiths Aerospace with both cockpit equipment and the digital stores management and flight management systems. As Smiths’ development programmes continue (some with US DARPA funding), the digital and solid state revolutions have opened up new markets for them with JSF, UCAVs and C-130J as well as numerous civil programmes.

 

Evidence that the UK has something to offer the US was provided by Raytheon Systems Ltd. With engineering leadership from Harlow and subassembly in Glenrothes, RSL has won a competition from the US Air Force to develop a next generation GPS advanced digital anti-jamming system.

 

If all the systems are taken up, the work is worth around $50M, with development running through next year and the first of 1300 units being delivered in 2007. The production run should last six years.

 

This anti-jam system has developed and enhanced the company’s GPS anti-jamming system, which the USAF has been buying for the past six years. RSL suggests it has no problems with export compliance rules at either end of the process.

 

How did they win? 100 per cent on-time delivery over the last two-and-a-half years, on cost, with a technological edge backed up by 6-sigma quality control run by a close knit team. That’s what the company claims, and they have this new persuasive evidence to back it up.

 

Birds, Wind Farms and Intruders

 

During the summer, concerns were expressed in Parliament about the interference the growing number of wind farms can induce in radars. (A large wind turbine blade at maximum speed can mimic a light aircraft.)

 

Before the RSPB became involved there seemed to be a potential conflict between BAE Systems and the Eurofighters testing out of Warton on the one hand, and the potential for the windy assets of Morecambe Bay on the offer.

 

AMS, from its Isle of Wight facilities, has come up with an answer. Working with the British Wind Energy Association and with MoD background research, they have devised algorithms to filter out such interference.

 

The capabilities underlying their “ toolkit “ can also be integrated with combat management systems, such as Type 45, so that military controllers have a full picture of civil airspace. The self funded technology could be available as an evaluation system post Farnborough.

 

Amongst the more esoteric technologies on show for the first time was Scarecrow Bio – Acoustic Systems Ltd. This “ humane and inoffensive” (!) system plays high fidelity distress calls to birds at naturally experienced sound levels.

 

More airfield management technology unveiled was Tarsier from QinetiQ, a runway debris detection, high-resolution millimetre wave radar. Following successful trials, scanning speeds have improved, and bolts, birds and ‘ bad boy’ intruders can be detected at two kilometres range. A system for military or civilian use could be market – ready within 9 months, either as supplied equipment or as a service provision.

 

Other ‘bad boy’ underwater intruders in ports, waterside airports and military installations can be detected by QinetiQ’s Cerberus. This sonar is undergoing trials with unnamed potential customers, and could be in production within 12 months.

 

And yes, it can tell the difference between a man, a dolphin and a big fish!

 

 

Search Techniques

 

Early entry to the show was a security nightmare, with half-hour long queues and manual bag searches. This was hardly a welcome to a high technology event, especially when exhibitors had solutions on offer.

 

QinetiQ’s ‘kerbside to airside’ approach tackles security, safety and passenger experience issues, and includes a millimetre wave imager that detects metallic and non-metallic threats concealed under clothing. A similar QinetiQ technology has already produced results – its Borderwatch product has detected thousands of illegals trying to enter Britain hidden in the back of lorries. Note to organisers: the weapon-detection imager is expected to be market-ready within a year. They could easily do away with people in rubber gloves rummaging through brief cases but not opening sealed packages. And the queues would move quicker!

 

AMS are also starting to stake out territory in homeland security, particularly by linking legacy systems and over-the-horizon surveillance.

 

Centres of Excellence (CE) are in vogue at this year’s Farnborough. £30M is to be spent on a university-linked Aerospace Innovation Centre in Lancashire. Three universities – Newcastle, Durham and Warwick, supported by Thales – are forming one in prime contract management.

 

GKN Aerospace managed to avoid using the CE phrase about its new, advanced composites facility on the Isle of Wight.

 

UAVs

 

This is another interesting ‘world class’ capability – not just public/private funded, but with the trade union Amicus being involved too. The Watchkeeper announcement put UAVs front and centre. Despite the Northrop Grumman failure to impress with its unmanned helicopter Fire Scout, there seems to be mileage in the UAV market.

 

The US Coast Guard’s $17bn Deepwater project includes the Bell Helicopter-Textron Eagle Eye.

 

Somerset-based Claverham announced their first production contract in this market, £1M worth of its Deadlock vehicle-retaining systems for this shipborne UAV. So pleased was the customer that prototypes were shipped from Farnborough to an exhibition in Anaheim, USA, the following week.

 

An emerging issue in UAVs is the need for routine non-segregation of operations. BAE Systems is thinking about what would be required to realise the vision of UAVs operating out of Heathrow.

 

They are working through the DTI’s Aerospace Industry Growth Team to tackle the infrastructure issues. This could see a five-year £75M programme, part-funded by industry, to come up with solutions. Regional development agencies – including Wales, who recently launched their Parc Aberporth Centre of Excellence – are expressing interest too.

 

Dual Technology Centres

 

UAVs are one of the technologies that could come under the umbrella of the fourth Dual Technology Centre, whose launch is expected soon. It will cover systems engineering and systems integration for autonomous vehicles (reconnaissance assets to you and me).

 

Managed and matched funded by industry, this will be a £5m-a-year, six-year programme. Thales and BAE Systems are the competitors waiting for a result at ‘the end of the summer’.

 

DTCs seem to be a Good Thing, with industry reporting they’re working well. Academics and SMEs get fully funded contracts to tease out innovation, while UK industry gets access to it.

 

As someone close to the process remarked: ‘DTCs show that investing in research and technology doesn’t have to be anti-competitive’.

 

Growth and Change

 

Like Topsy, Farnborough just growed. There was a Space Pavilion, a Formula 1 car tearing down the runway again and a motor-sports area.

 

One interesting crossover was highlighted by Meggitt Defence Systems’ Voodoo aerial target system. Its engine is a ‘special’ from Mercedes Ilmoor in Northampton, which also builds the power for Messrs Coulthard and Raikkonen. And the composite body is made by CTS, a subsidiary of Lola Cars!

 

Meggitt are undergoing another growth spurt at the moment. As a result their acquisition of Western Design Howden and Howden Air Dynamics, last year the US Department of Defense was their biggest customer. During Farnborough they secured shareholder agreement for a £400M purchase of parts of Dunlop Standard Aerospace Group. This should boost sales by 30per cent.

 

Another drone programme, Flight Refuelling Aviation’s Blackjack special mission airborne threat simulator, uses a newly announced UK-developed miniature radar altimeter from Roke Manor Research (now part of Siemans). It can simulate a sea-skimming missile attack against ships.

 

The jaundiced on the show bus from the station might ask themselves why they’re there – especially by Friday. But Farnborough first-timer, St. David’s Assemblies, had no doubts. After 50 years their high-volume, quick-changeover machining business is under threat from outsourcing to China.

 

Their search for new markets led them to Farnborough. Two walk-ons to the Aerospace Wales Forum stand they shared made the journey from Wales’ smallest and furthest west city worthwhile. And the irony was that one of them had been let down by his new Chinese supplier …

 

It might cost mega bucks. It might be overweight. It might (perish the thought) be late. But thanks to a component storage and control system developed from a supermarket peanut dispenser, 1650 fastenings used to build JSF will be traceable and its supply chain a little leaner. Hurst Green Plastics in Lancashire has only eight employees, but with Eurofighter as a launch customer plus a repeat order secured at the show from Lufthansa Technik, company boss Steve Clarke shows British innovation at its best.

 

Despite the positive news for C-17 in the defence capability review, A400M continues on its way. The Doncasters Group announced a €7.5M order for titanium components for the TP450 turboprops engine. They put their win down to specialist casting technique, metals handling and rapid prototyping. The first flight of A400M is scheduled for 2007 with an ISD of 2008.

 

And finally … talk was that 2004 could be the last Farnborough Air Show in its present form. Certainly RIAT had a better military flying display programme to which the military and trade visitors brought their spouses for a splendid day out at Fairford. The trade show could be anywhere, anytime, and less interruption (as on the first VIP day) would be welcome to many trying to do business in the afternoon.

 

Despite the theme of this review, there was a huge and welcome U.S. presence. Undoubtedly, Farnborough is a key transatlantic bridge, given the sniping about Paris. The willingness of U.S. executives to take a public stance about the insular industrial initiative behind Buy America shows their realisation of the direct and indirect dangers to them of a reactive Buy Europe policy.

 

So long may it evolve. Viva Farnborough!

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