This entirely new boom is an advanced and complex system that will have the advantage of offering the latest technology available and the most modern solutions at the time. Besides an advanced air refuelling boom main structure, it will have a fly-by-wire control with a larger refuelling envelope and controllability, including an automatic load alleviation system. In addition to the fuel transfer, it covers the control and command systems installed in the rear part of the aircraft and communicates with the entire avionics and communication system of the aircraft.
EADS CASA is currently in charge of design, testing, production and certification of the ARBS. A testing rig has been constructed, which will be used before and during the qualification flight tests, to carry out the entire functional tests and integration phase with a real boom. The first production series is reserved for the Australian Armed Forces, where an A330 MRTT (Multi Role Transport Tanker), combining both POD and ARBS, will be delivered.
The almost 18 metre-long boom has a larger refuelling envelope than the KC-135 and improves controllability with the roll & pitch joint. The nominal fuel flow is around 1200 US gal./min at 50 Psi with a maximum of 1500 US gal/min. The design is based on a fail-safe/fail operational concept and includes a release and retraction system with redundant hoist and lock, and independent disconnection capability. A boom operator (boomer), sitting at a Fuel Operator Station located in the cockpit, carries out the refuelling operation thanks to a 3D-vision system.
Three units have already been manufactured, one dedicated to the functional tests on rig, another for the entire ground qualification test process, while the third one is the flight unit, installed on the A310 platform, which will serve as a Demonstrator qualify the ARBS from the Getafe air base.
Other capabilities of the rig include simulation of a full air-refuelling operation on the ground from the pre-contact position to contact position. A receiver mock-up with a real F-16 receptacle covers the entire refuelling envelope (0-45º pitch, ± 30º roll). Before proceeding with the first transfer of fuel, all kinds of prior tests are carried out on the ground and in flight, to verify all the requirements and functional features. Among other tests, connections and disconnections are already being done, with and without fuel on ground, and in-flight tests will be carried out to verify the in-flight capacity of the new boom. The rig design simulates the Airbus Tail Cone and includes a hoist and lock system.
A vision system is installed on the rig in the same position as in the aircraft to give a 3D remote vision to a boomer located in the control room. A simulated Remote Aerial Refuelling Station to control and monitor the entire process is also located in the rig.
All camera state-of-the-art technologies have been tested to improve the boomer's perception of the scenario and to minimise the boomer's workload. The final design has had the key approval of boomers with experience of KC-135 or the remote refuelling system in the KDC-10.
