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Over the last century, aerial refueling has evolved from a revolutionary concept to a cornerstone of modern-day air force missions. Since Sir Alan Cobham’s development of the pioneering hose and drogue method in 1934, which remains prevalent to this day, aerial refueling has reached new heights, extending mission range and strategic operations for armed forces worldwide.
So, what is on the horizon for aerial refueling? Increasing safety and efficiency, reducing workload and expanding military force projection over long distances are imperative for next-generation air dominance programs. The integration of automation technology makes reaching these goals more possible.
Automation isn’t new to commercial or military aviation. It already supports a variety of functions and processes, including in-flight navigation, route optimization and aircraft maintenance alerts. For example, air traffic control systems can detect weather conditions or hazards. Over long-range flights, autopilot technology, like automotive cruise control, helps control aircraft movement and maneuvers in the air with minimal pilot intervention. These automated systems support improved safety and efficiency along with reducing workload and stress on pilots.
Whether you’re using the flying boom or hose and drogue method of refueling, these missions require extensive pilot attention and focus. As a result, aerospace manufacturers are already fielding automation capabilities on the world’s largest refueling platforms. During the 2022 Farnborough International Air Show, Airbus announced its A330 Multi-Role Tanker Transport was the first tanker to be certified for automatic boom operations. Additionally, Boeing’s KC-46A tanker and MQ-25 programs will take capabilities to new heights. The MQ-25 will be the first unmanned tanker into production and has already refueled a range of receiver aircraft types.
At Eaton, our team is applying the latest digital engineering tools to assess aerial refueling system performance and develop next-generation capabilities. Most recently, enabling a successful demonstration of our actively stabilized drogue marked a milestone on the journey to automated and autonomous refueling.
The success rate of hose and drogue system refueling is high but unpredictable weather or sudden turbulence can cause the traditional drogue to lose its steadiness or balance. Although rare, these circumstances can lead to unsuccessful contact with the receiver aircraft, aircraft damage or even mission cancellations. It also adds more work and stress to the pilot’s plate.
Given the high stakes, improving drogue stabilization became a key priority for our engineers. During the initial phase of the product development lifecycle, we embraced a model-based systems engineering approach, utilizing digital twin modelling and virtual reality simulation to evaluate options and enhance the hose and drogue system.
By combining these two methods, Eaton’s engineers analyzed hose and drogue system performance, capturing data that influenced design iterations in real time without wasting valuable materials or flight test time and resources.
Following product enhancements and virtual simulations, our solution—the actively stabilized drogue—was tested during a joint flight demonstration with Naval Air Systems Command (NAVAIR) and Calspan Aerospace Test Services. We attached the drogue to the hose end of an aerial refueling store installed on a Gulfstream III testbed aircraft, assessing its stability across various in-flight conditions, including turbulence and maneuvers. The demonstration highlighted how our drogue independently counteracted perturbations through the automated actuation of its control surfaces.
When wind gusts or other atmospheric disturbances occur during a refueling mission, the drogue’s active stabilization holds a steady position relative to the tanker aircraft. The pilots and aircrew on both the receiver and tanker platforms do not need to intervene which, in turn, reduces stress, workload and refueling cycle time. Enabling pilots to complete these missions more quickly and confidently is reason enough to invest in automation solutions.
Although more testing and evaluation lie ahead, it’s evident that the actively stabilized drogue is a viable solution that will have a substantial impact on the operational efficiency and effectiveness of refueling missions. Ultimately, the most significant advantage is pilot safety.
The future of aerial refueling is being shaped today. Automation is more than an emerging trend. It is a vital capability needed for legacy and next-generation systems and platforms.
With unparalleled aerial refueling experience and best-in-class engineering tools, our team is ready to help you navigate and achieve your automation goals.
