787 Technologies and the Evolution of Maintenance
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1 787 Technologies and the Evolution of Maintenance Ron Murray 787 Chief Mechanic April 13, 2011 BOEING is a trademark of Boeing Management Company. Copyright 2011 Boeing. All rights reserved. ROI# The statements contained herein are based on good faith assumptions and provided for general information purposes only. These statements do not constitute an offer, promise, warranty or guarantee of performance. Actual results may vary depending on certain events or conditions. This document should not be used or relied upon for any purpose other than that intended by Boeing.
2 Discussion Topics Chief Mechanics Office Maintenance Training New Technology Systems Common Core System Onboard Maintenance Systems More Electric Airplane Liquid Cooling Advanced Systems Monitoring Simplified Maintenance Structures Maintenance Programs
3 787 Chief Mechanics Office Harnessing in-service knowledge to influence aircraft design for optimal: Maintainability Dispatch reliability Operating cost Provide industry expertise of airline operational requirements
4 787 Maintenance Training 787 Training Philosophy Simulate the in-service troubleshooting environment Utilize actual support data available at the aircraft (not training data) Performance-based courses Categories Instructor-led training Student paced computer-based training Line maintenance-oriented scenarios
5 Common Core System Common Computing Resource module (CCR) Common computing service platform for hosted software applications Common Data Network (CDN) Common distribution service network for messages between aircraft system CDN Switch CCR RDC Remote Data Concentrators (RDC) Common analog and digital input/output services for aircraft systems
6 Fiber Optic Networks The 787 has 110 fiber links and more than 1.7 km of fiber optic cable Maintaining FO Networks End face inspection Light loss testing Handling Cleanliness COPYRIGHT THE BOEING COMPANY
7 Onboard Maintenance Systems Improvement Total faults managed in CMCF 18,000 45, % CMCF Maintenance Messages 12,700 20, % Parameters available to ACMF 120, , % ACMF report parameters available 4,000 6, % ACMF parameter acquisition rate 2,000/sec 4,200/sec +110% CMCF Central Maintenance Computing Function ACMF Airplane Condition Monitoring Function COPYRIGHT THE BOEING COMPANY
8 787 Maintenance Tools & Information Flight Deck Aircraft Maintenance Laptop CWLU - Crew Wireless LAN Network Ethernet Maintenance Laptop Ground Infrastructure TWLU - Terminal Wireless LAN Network Toolbox MyBoeingFleet Training BEDS IT and much more
9 More-Electric Systems Traditional Systems Power Architecture 787 No-bleed Power Architecture Engine Bleed Air Electric Power The 787 systems architecture eliminates the pneumatic bleed from the engines and powers those systems electrically Cabin pressurization Hydraulic demand pumps Wing anti-ice Engine start Nitrogen generating system Additional 787 systems powered electrically Wheel brakes Stabilizer trim Multiple spoilers
10 Liquid Cooled Systems Coolant Top-off Cart (CTOP) (line maintenance) Coolant servicing cart (CSC) (base maintenance) 1. Power equipment cooling 2. Galley chilling 3. Cargo air-conditioning New fluid spec New tooling New maintenance tasks Propylene-Glycol/Water DowFrost / BMS 3-42 ph Test Meter
11 Advanced Systems Monitoring
12 Simplified Trailing Edge Bar Linkage Bar Linkage 787 Single Hinge
13 Composite Material No fatigue tasks No CPCP tasks Enhanced zonal program eliminates many structural tasks Reduced scheduled maintenance burden
14 Fuselage Construction 787 fuselage sections are produced as a single part eliminating all longitudinal joints Traditional longitudinal lap and butt-joints are eliminated Seamless 787 skins eliminate the maintenance and weight of structural skin joints COPYRIGHT THE BOEING COMPANY
15 Ultrasonic Inspection Options 787 fuselage architecture enables non-invasive inspections of the internal fuselage structure, without removal of systems or insulation Optional NDI inspection technique reduces airplane disassembly, eases restoration functional test burden COPYRIGHT THE BOEING COMPANY
16 Instrumented Bolts i-bolt reader Instrumented bolts enable in-service torque checking tasks to be completed without large tools or time-consuming setup. COPYRIGHT THE BOEING COMPANY
17 FAA Approved Maintenance Program Line 700FH 1000FH 1,000FH Base 6,000 FH 18mo 12,000 FH 37mo 12,000 FH 36mo External Structure 6,000 FC 3yr 8,000 FC 4yr 12,000 FC 6yr Internal Structure 12,000 FC 6yr 16,000 FC 8yr 24,000 FC 12yr Landing Gear 18,000FC 10yr 20,000FC 10yr 24,000FC 12yr
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