Boeing 787 Dreamliner Long-Range, Mid-Size Airliner, USA

Boeing launched the new Boeing 7E7 Dreamliner passenger aircraft in 2003.

The launch order for 50 7E7 aircraft placed by All Nippon Airways (ANA) was announced in April 2004 and is the largest launch order for a Boeing commercial jet. The 50 7E7 aircraft deal has a list price value of $6bn. The aircraft was given its 787 designation in January 2005.

Firm orders have been received for 706 aircraft – 43 for the 787-3, 565 for the 787-8 and 153 for the 787-9.

Customers include: Air New Zealand (787-9, eight), British Airways (24), Qatar Airways (30 plus 30 options), First Choice Airways (12), Continental (25), Japan Airlines (787-3 13, 787-8 22), Vietnam Airlines (four), Chinese Airlines (60), Icelandair (four), Ethiopian Airlines (ten), Korean Airlines (ten plus ten options), Northwest Airlines (18 plus 50 options), Air Canada (37 plus 23 options), Air India (27), Royal Air Maroc (four), LOT (seven), China Southern (ten), ILFC (73 787-8, one 787-9), Qantas (45 plus 20 options), Kenya Airways (nine), Singapore Airlines (787-9, 20 plus 20 options), Air Pacific (787-9, five plus three options), Monarch Airlines (787-8, six plus four options), Virgin Atlantic (15 787-9 plus eight options) and Aeroflot (787-8, 22).

The 787 family of aircraft, in the 200 to 300-seat class, will carry passengers non-stop on routes between 6,500km and 16,000km at speeds up to Mach 0.85.

Aircraft assembly began in June 2006 with final assembly in May 2007. The first aircraft was rolled out in July 2007 and the first flight is scheduled for end of March 2008. The first delivery (of the 787-8) will be to All Nippon Airways and is scheduled for November 2008. The 787-3 and the 787-9 stretched variant are due to enter service in 2010.

The aircraft is highly fuel-efficient and offers lower cost of travel in terms of seat cost per mile as well as the ability to fly directly to smaller regional airports instead of to larger airports where passengers proceed to transfer flights to regional destinations.

In September 2007, BA announced an order for 24 Boeing 787s, to be delivered between 2010 and 2014. The group also has the option to buy a further 18 Dreamliners from Boeing.

BOEING 787 DREAMLINER VARIANTS

The Dreamliner aircraft is being designed in three versions, the baseline version, a short-range and a stretched version.

The baseline version, the 787-8, has a maximum take-off weight of 205,400kg. The aircraft typically accommodates 220 passengers in a three-class cabin configuration. The length is 56m. The wingspan is 58.8m and the height is 17.4m. The range is 15,700km (8,500nm).

The 787-3 short-range version is the same length and height as the 787 but has a shorter wingspan (51.5m). The maximum take-off weight is 136,075kg and the range is reduced to 6,500km. The aircraft will carry 296 passengers in two classes.

The stretched version, 787-9, has the same wingspan and height as the standard 787 but the length is increased by 6m to 62m. The aircraft carries typically 259 passengers in a three-class cabin layout. The range is increased to 15,370km and the maximum take-off weight is 223,000kg.

In October 2006, Boeing Business Jets launched a VIP version of the 787, with an order for four aircraft placed by undisclosed customers.

BOEING DREAMLINER DESIGN

The Boeing Dreamliner aircraft is of conventional design with low sweptback wings and two underwing pylon mounted engines. The design has replaced the Sonic Cruiser program and incorporates some of the advanced design features developed while examining the Sonic Cruiser concept. The design includes increased use of lightweight and high durability composites and advanced aluminium alloys.

The low sweptback wings have raked wingtips. Carbon fibre and epoxy composites and titanium graphite laminate will be used in the construction of the wings.

The major structural work is being shared by principal industrial partners in USA, Japan and Europe.

Boeing will be responsible for about 33% of the production with the flight deck and fuselage being manufactured at Wichita, the wings and the fuselage fairings at Winnipeg, Canada, the fin at Frederickson, and the moving leading and trailing edges of the wings at Tulsa and at Boeing Australia. Japan's Fuji Heavy Industries will manufacture the centre wing box and install the wells.

Kawasaki Heavy Industries is responsible for the manufacture of the mid forward section of the fuselage, the fixed section of the wings and the landing gear well. Mitsubishi Heavy Industries will manufacture the wing box. The all-composite nose section is being built by Spirit Aerosystems of Wichita.

A joint venture company, Global Aeronautica, set up by Vought Aircraft Industries and Alenia Aeronautica, is responsible for the manufacture of the mid section and rear section of the fuselage including the tailplane, representing a 26% share of production which will be based at Charleston, South Carolina. The French company Latecoere will supply the passenger doors. Goodrich will provide the nacelles and thrust reverser.

The fuselage cross section, 574cm, is compatible with standard LD3 containers. The cargo revenue capacity will increase by 40% to 60% compared with current airliners.

DREAMLINER FLIGHT DECK

Kaiser Electroprecision will provide the pilot controls, which will be similar in function to those of the Boeing 777.

Rockwell Collins has been selected to supply display, communication and situational awareness systems. There will be five 12in x 9.1in displays and dual flight dynamics head up displays. Thales will supply the integrated standby flight display.

Communication systems include advanced VHF and satellite communication radios. Situational awareness systems include terrain awareness warning systems, weather radar and Traffic Alert and Collision Avoidance Systems (TCAS) and an airport moving map for safer ground taxi operations.

Honeywell, of Phoenix, Arizona, has been selected to provide the flight control electronics, autopilot and the navigation package, which will include the flight management function, inertial reference system, air data system and a multi-mode receiver global positioning system. Honeywell will also supply the Crew Information System/Maintenance System (CIS/MS) which provides information on the general health of major aircraft systems.

The 787 avionics will be based on open systems architecture. Smiths Aerospace UK has been selected to supply the Common Core System (CCS). This will replace traditional dedicated signal wiring with remote data concentrators. The concentrators link sensors and effectors to a distributed computing resource through a dedicated communications network. This contributes significantly to the weight reduction.

Astronautics Corp. is to provide the dual Electronic Flight Bag (EFB), which will contain all the documentation required by the pilot in a digital format.

DREAMLINER CABIN

The aircraft cabin gives a very comfortable environment with higher humidity, wider aisles and seats and larger (48cm x 28cm) windows. The Boeing Interiors Responsibility Center will oversee development and suppliers for the 787 new concept interior.

The current configuration of the interior will feature repeated sweeping arches, dynamic lighting and electronic window shades whose transparency passengers can change during the flight. Diehl Luftfahrt Elektronik will provide the cabin lighting, which will include a 'simulated sky' ceiling effect produced by arrays of Light-Emitting Diodes (LEDs) which can change in colour and brightness.

The 787 will have larger centre-mounted overhead luggage bins that descend for easy loading and then pivot upward.

ENGINES

The aircraft is powered by high-bypass 10:1 ratio, extremely quiet engines. The fuel efficiency of the engines will contribute up to 8% of the increased efficiency of the aircraft.

Boeing has selected two engine types, the General Electric GENX and the Rolls-Royce Trent 1000, each type developing 55,000lb to 70,000lb thrust.

Each of the three planned 787 models will use the same engines. Both engines fit to a standard engine interface allowing interchangeability. The traditional bleed air heating and de-icing systems have been eliminated in favour of electrical systems.

The General Electric GENX (GE Next Generation) engine is a derivative of the GE90 engine and uses composite fan blades, a high-pressure ration compressor and a single annular combustor where the compressed air and fuel are mixed, to give very low level of emissions. Ishikawajima-Harima Heavy Industries (IHI) and Mitsubishi Heavy Industries (MHI) of Japan, Volvo-Aero of Sweden, Techspace Aero of Belgium and Avio of Italy will participate in the development. The GENX engine is scheduled for certification in September 2007.

The Rolls-Royce Trent 1000 is a new ultra high thrust variant of the Trent family and uses a three-shaft layout.

Goodrich of Charlotte NC has been chosen to provide the fuel-quantity indicating system and fuel management software.

Hamilton Sundstrand of Windsor Locks Connecticut will supply the primary power distribution system, auxiliary power unit, environmental control system, primary and remote power distribution system and the electrical power generating and start system.

DREAMLINER LANDING GEAR

Messier-Dowty of Velizy, France, has been selected to supply the main and nose landing gear. The company will be working with Boeing during the joint definition phase defining the landing gear and aircraft interface before the firm aircraft configuration is decided in 2005. Smiths Aerospace will provide the landing gear actuation systems.

The electric braking system, supplied by Goodrich and Messier-Bugatti, is comprised of the aircraft wheels, electro-mechanically actuated carbon brakes and electro-mechanical actuator controllers. The system provides advantages over hydraulic brakes of digital control and monitoring, reduced weight, high reliability. The absence of hydraulic brake fluid avoids the risk of leaks and possible fire hazards.

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