The 787 DreamLiner

Photo by Y. Yasobara

Background
The September 11th, 2001 attacks on the United States had a large roll in the conception of the DreamLiner. As the airlines went into cost savings mode, especially in the area of fuel savings, Boeing realized that efficiency was a higher priority then ever. Consequently the Sonic Cruiser, Boeing’s high-speed project in the early stages of development prior to 9/11, was put on the back burner but a lot of the research that went into that project was used in the DreamLiner program.

The original “7″ series number assignment for the DreamLiner: 7E7. The “E” was thought by many to mean efficiency, energy saver, environmentally friendly, etc. In the end Boeing explained that the “E” simply was used as an initial for the letter “E” in the word Eight.

Interesting Difference in the Variants of the 787
Not all variants of the DreamLiner will have the raked wingtips. The 787-3’s wing will use large wing lets instead. This decreases the wingspan and the aircraft weight. Due to the decrease in weight, wing lets provide better efficiency over short distances than raked wingtips. The 787-3, being lighter at takeoff then the 8 variant, does not need the lift created by using the extension of raked wings, as having wings that provide more lift than needed also decreases efficiency, amazingly. The reduction in wing span also enables this variant of the 787 to use smaller gates.

Composites & Controversy
The 787 has an all composite fuselage, the first of it’s kind. Using research and information gained from the development of the Sonic Cruiser, Boeing was able to make a significantly refined product in it’s composite 787 fuselage. Airbus, widely known for it’s liberal use light weight composites, actually criticized Boeing’s use of all composites for the DreamLiner fuselage, calling it “rushed and ridiculous.”

The 777 contains 50% aluminium and 12% composites in it’s entire structure. By comparison, the 787 has 15% aluminum, 50% composites (mostly carbon fiber reinforced plastic) and 12% titanium all throughout. The composite design of the fuselage eliminates the need for 50,000 fasteners used in the building of a conventional airplane.

Increased Efficiency
Being 20% more fuel-efficient than current competing aircraft, 33% of that efficiency gain will come from the engines, another 33% from aerodynamic improvements and the increased use of carbon fiber in construction, and the final 33% from use of advanced systems.

Interchangeable Engines
Boeing has also created another first in commercial aviation: Plug and play engines. Both the GE or Rolls-Royce engines will have a standard interface with the aircraft mounting pods, allowing any 787 to be fitted with either a GE or Rolls-Royce engine at any time.

• This interface will allow airlines to change from one engine manufacturer to another, creating significant savings in cost, time, and resources..
• The launch engine is the Rolls-Royce Trent 1000.
• The engine market for the 787 is estimated at US$40 billion over the next 25 years.
• To allow quieter mixing of exhaust and outside air, resulting in overall reduction in noise levels, Boeing has redesigned the exhaust duct covers. The rims are tipped in a toothed pattern, and Boeing expects this will create significantly quieter conditions both inside and out.

No More Bleed Air
Speaking of efficiency, an electric architecture replaces bleed air and hydraulics with electrically powered compressors and pumps. And cabin air is provided by electrically driven compressors, not engine bleed air.

Passenger Comfort
So that passengers can see the horizon, and not feel the cramped and enclosed feelings brought on by standard windows, Boeing has designed larger windows in the DreamLiner than any other air transport aircraft of it’s kind. Additionally, these windows have electro-chromism based “auto-dimming” which reduces cabin glare while maintaining transparency.

Three color LED cabin lighting is used throughout the cabin instead of fluorescent bulbs, allowing the aircraft to have 128 different interior color combinations.

Composite fuselage construction allows for higher cabin humidity because composites do not corrode, and higher pressure levels (6000 feet instead of 8000 feet) because they can withstand higher stresses then aluminum.

The Cockpit
The cockpit comes standard with Captain’s and First Officer’s head up guidance systems (HUD’s). Additionally, future integration of forward-looking infrared (FLIR) systems are being considered which would use thermal sensing integrated into the HUD systems. This would allow pilots to see a black and white picture of the terrain ahead, right through the clouds. Pretty cool.

Production
Initially priced at $120 million dollars, the price for the 787-8 variant has been increased to $157-$167 million dollars.
The 787 is the fastest-selling wide body airliner ever before EIS (Entry Into Service).

• The tail fin is made in Frederickson, Washington
• The ailerons and flaps are made in Australia
• The fairings are made in Canada
• The wings are made in Japan
• The horizontal stabilizers are made in Italy
• The fuselage sections are made in South Carolina, Italy, Japan and Wichita, Kansas

Accordingly, the finishing time of a 787 on the final production line is expected to be in as little as 3 days.
By comparison, the 737 takes 11 days.

Japanese industrial participation is 35% of the total share.
Additionally, Japanese manufacturer Toray Industries announced a production agreement involving $6 billion worth of carbon fiber.

Boeing conducted an entirely computer based roll out of the 787 prior to it ever being close to a final roll out. This is intended to discover potential production problems prior to final assembly when they are cheaper to fix.

First Launch Customer Incentives
As is usual with the launch of any new design, the first half dozen aircraft or so will be slightly overweight and slightly miss expectations as Boeing optimizes it’s manufacturing process to meet initially stated goals. Subsequent aircraft are expected to be “optimized” aircraft and are expected to meet all projected goals.

In a common maneuver for launch customers, it is rumored that these initial half dozen aircraft are being discounted by 40–50% from the list price.

That’s all for now folks… Stay tuned for PM Episode #10!
~Capt’n Chris

Video
Click here…

Feeds:
Blog Feed
Podcast Feed

Filed under: Podcast | |