Ground Support Equipment Supporting an Aircraft’s Mission on the Ground

Encompassing a wide range of equipment, ground support equipment (GSE) is the vital support found on airport aprons that keeps aircraft flying. From maintenance and refueling to passenger boarding between flights, GSE plays a crucial role in supporting the operations of aircraft while on the ground, maintaining safety and ensuring flights can depart and arrive on schedule.

GSE Impacts

With a diverse array of GSE to choose from — everything from simple machines like aircraft maintenance platforms to advanced hydraulic test stands — what factors impact GSE?

Michael Brandstoetter, head of sales and marketing at Dynell GmbH, Austria, explains that from a ground power unit (GPU) manufacturer’s perspective, “The primary factor is the size of the aircraft, as this determines power consumption requirements during light or heavy maintenance programs. Larger aircraft require higher power output, while smaller aircraft have more moderate needs. Efficient power delivery systems are crucial to meet these varying demands reliably.”

Obviously, safety standards are significant factors that impact GSE. When GSE is designed and manufactured in full compliance with prescribed safety regulations, Vesna Poznič, head of sales at TIPS GSE, Leskovec, Slovenia, explains, “The likelihood of errors, malfunctions and damage is significantly reduced or even eliminated. Conversely, equipment that does not adhere to these standards poses higher risks of operational failures and accidents. Additionally, factors such as the size and weight of aircraft, airport layout, and operational needs play a role in shaping GSE design and functionality. Strict adherence to safety requirements ensures not only the safe and efficient operation of GSE but also protects personnel, aircraft and airport infrastructure, making safety a critical priority in this domain.”

Different aircraft cockpit features share similarities but some aircraft have special requirements due to their specific aircraft system settings, such as under- and over-voltage protection relays. “Electrically-started aircraft do not require three-phase equipment to start their engines, unlike commercial aircraft which are pneumatically started,” says Eve Storm, president and CEO of START PAC, Las Vegas. “For maintenance purposes, onboard aircraft systems can be powered by 110V or 220V single-phased equipment that can provide from 25 to 400 amps of continuous power as most business aircraft, approximately 98% of them, will not require more than 400 amps continuous. Whether you are conducting engine starting or maintenance, using an external GPU has multiple benefits, including faster cooler engine starting that keeps turbine temperatures down to help extend turbine life and powering aircraft systems so that the onboard starting battery can be reserved for engine starting, thereby lengthening the ship’s battery life.”

David Dick, president of Wilcox GSE, Milton, Ontario, Canada, says that aircraft size impacts because GSE dimensions, such as maintenance stairs, must be compatible with aircraft heights and that adjustable GSE equipment can increase versatility. “[Also,] limited space at airports necessitates compact and maneuverable GSE to optimize valuable floor space. GSE equipment used outdoors must be robust and weather-resistant to withstand extreme temperatures, wind, rain and snow.”

Today’s GSE is more reliable, efficient, eco-friendly and safer than ever before. As the aircraft industry advances and innovates, the push for more efficient and state-of-the-art GSE has received more attention to align with sustainability and operational efficiency goals.

Dick explains that GSE electrification benefits reduce carbon footprint, lower noise pollution, improve air quality and reduce reliance on fossil fuels. Examples of this include electric tow tractors, GPUs and baggage handling systems. GSE sustainability benefits reduce environmental impact and improve resource efficiency. Examples of this include lightweight and durable materials like aluminum and composites, regenerative braking systems to recapture energy and efficient battery technologies for longer run times. Other GSE technology advancements are enhancing safety, improving efficiency and increasing operational accuracy. Examples of this include telematics, which are real-time tracking and diagnostics for predictive maintenance. Artificial intelligence, which optimizes routes, predicts equipment failures and improves operational efficiency. Advanced autonomous features include state-of-the art automated guidance systems for improved maneuverability and reduced risk of collisions. Enhanced safety systems include collision-avoidance systems (proximity sensors, cameras), improved operator visibility and ergonomics, and non-slip surfaces and anti-fatigue mats.

Dynell offers a range of ground power supply solutions tailored to modern maintenance requirements. These include advanced hangar setups such as pit systems paired with solid-state frequency converters for stationary operations. Additionally, “Dynell focuses on sustainable mobile products like battery-powered or hydrogen-powered GPUs, which provide an environmentally friendly alternative to traditional diesel units. Reliable power supply is essential for maintenance tasks, especially when testing systems under full load,” Brandstoetter says.

START PAC has aided ground support equipment technology by reportedly being the first company in the world to create safe lithium-ion portable starting units, which were released in 2007. “With more than 20,000 lithium units in more than 130 countries, their patented lithium products are lighter, smaller and have twice the battery-cycle life of older technology GPU equipment,” Storm says. “Carrying a lighter weight portable starting unit reduces the weight penalty so a bit more fuel can be carried and with twice the battery-cycle life of lead acid, users see up to 10 to 12 years of use before needing to change the GPU battery.”

One of TIPS GSE advancements is its advanced damage prevention system (ADPS). This onboard system combines sensors and actuators to coordinate the approach of GSE to an aircraft, controlling both speed and stopping procedures. “It helps by completely preventing any physical contact between the equipment and the aircraft, significantly enhancing safety and reducing the risk of damage,” explains Marjan Smole, technical sales engineer at TIPS GSE. “Additionally, ADPS features a multilayered safety redundancy, ensuring reliable operation even in case of technical challenges. Our GSE products are designed with energy efficiency in mind, supporting sustainable airport operations and aligning with industry goals for reducing emissions. Finally, TIPS systems are highly adaptable, making them compatible with a wide range of aircraft types and operational environments, ensuring maximum flexibility for our clients.”

Moving to All-Electric GSE

The transition to electric and hybrid-electric GSE environmentally friendly solutions presents both significant opportunities and challenges. Continued advancements in battery technology, charging infrastructure and vehicle design will be crucial for overcoming these challenges and realizing the full potential of electric GSE.

Dick explains there are weight optimization factors. “Minimizing vehicle weight is crucial for maximizing battery life and efficiency. Manufacturers like Wilcox GSE are redesigning equipment using lightweight materials (e.g., aluminum, composites) and optimizing component design to reduce overall mass.” There are powertrain integration factors. “Integrating electric motors and battery packs requires careful consideration of factors like power-to-weight ratios, torque curves, and cooling systems.”

There are charging infrastructure factors. “[With deployment], establishing a robust and reliable charging infrastructure at airports is a major challenge. This includes installing high-power charging stations, ensuring sufficient grid capacity, and optimizing charging schedules to minimize downtime,” Dick adds. There are interoperability factors. “Ensuring compatibility between different charging standards and equipment models is essential for seamless operation. Early adopters [of all-electric GSE] are primarily driven by sustainability goals and a desire to improve their environmental image. [There is growing acceptance] increasingly stringent environmental regulations and the availability of more advanced technologies are driving wider acceptance of electric GSE. Minimizing charging times is crucial for maintaining operational efficiency. Ensuring sufficient battery life to meet operational demands, especially during peak periods, is a key concern. Specialized training and maintenance procedures are required for electric and hybrid-electric GSE.”

Storm explains that transitioning from older technology fuel-driven GPUs to hybrid or all-electric models involves capital investment and employee training on new and unfamiliar equipment. “The flexibility in being able to use all-electric GPUs does offer several advantages such as zero fuel and noise emissions so that they can be operated in confined or closed spaces without jeopardizing employee health. Additional electric GPUs allow for a more relaxing and satisfying environment for onboard passengers or crew as these GPUs are silent running. Being emission-free, these GPUs, such as the START PAC GREEN Machine, are also a boon for the environment as all industries work towards more environmentally responsible operations.”

TIPS GSE has been producing electric products for over 30 years. “Electric GSE offers numerous advantages, such as significantly reduced maintenance costs due to fewer moving parts and less frequent servicing,” Poznič says. “It also improves working conditions for operators by minimizing noise and eliminating harmful emissions, while contributing to the industry’s broader sustainability goals.

“However, the transition to electric fleets requires addressing challenges like the need for robust charging infrastructure, battery-life limitations and initial investment costs. Despite these hurdles, the cyclical activity patterns of airports, with periods of downtime, make electric equipment particularly suitable as it allows for recharging during non-operational hours. Global adoption is steadily increasing, with more airports prioritizing the long-term benefits of electric GSE, including improved efficiency, cost savings and environmental impact.”

GSE and IoT

Telematics and IoT (Internet of Things) technologies are becoming increasingly important in GSE. Smart GSE, equipped with IoT technology, can communicate real-time data anticipating maintenance needs before a breakdown occurs. Autonomous operations are an exciting topic that occupies the majority of R&D departments among GSE manufacturers.

Brandstoetter explains that “Battery-powered GPUs benefit greatly from IoT-enabled remote monitoring, allowing real-time access to critical battery data for improved safety and performance optimization. These technologies also enable remote supervision and updates, which enhance service levels and reduce downtime. While autonomous GSE operations are still evolving, Dynell sees these advancements as a key part of the future, improving efficiency and reliability in maintenance operations.”

TIPS GSE is currently in the development phase and will begin testing the impacts of autonomous technologies for aircraft maintenance. “Telematics and IoT have already transformed ground support equipment by enabling real-time monitoring of equipment performance, predictive diagnostics and remote troubleshooting,” Smole says. “These capabilities optimize equipment utilization, reduce downtime and ensure timely maintenance, all of which are critical for aircraft maintenance. As we move closer to autonomous GSE operations, these technologies will further enhance precision, safety and operational efficiency. However, the adoption of autonomous systems also requires addressing challenges such as integration with existing airport operations and the need for robust safety protocols to ensure seamless and reliable performance.”

While remote-controlled ground support equipment is indeed starting to become more readily available, Storm contends, “We are still in the infancy stage of fully autonomous ground support equipment as any equipment will still require human operation of the remote as well as the connection to the aircraft. As AI continues to evolve and at an exponential rate, it will be fascinating to see how AI and autonomous equipment will be commingled to best serve the industry and its users.”