787 Design for Maintainability

Transcription

1 787 Design for Maintainability Justin Hale 787 Chief Mechanic Presented to: April 7, 2008

2 Agenda Role of maintenance in operating costs Measuring the value of a design Designing for maintainability

3 Direct operating costs (CAROC) ER US International Rules Airframe design plays a significant role in determining Fuel & Maintenance costs within an operation Cost Per Trip Fuel Flight Crew Maintenance Cabin Crew Landing Fees Control & Comm Ground Handling Overhead Ground Power

4 Direct operating costs (CAROC) Fuel Cost Maintenance Cost -20% (11% of CAROC) -30% (5% of CAROC) ER ER ER ER 787-8

5 Agenda Role of maintenance in operating costs Measuring the true value of a design Designing for maintainability

6 Measuring design performance Traditional design measures Life-Cycle Cost design approach Drag Weight Schedule reliability Certification risk Maintenance cost Training cost Cruise HP extraction Community / Cabin noise Development cost Build cost Safety Airplane availability Standard airplane impact Factory flow The 787 program uses these and more than 70 other performance measures to evaluate each design option

7 Agenda Role of maintenance in operating costs Measuring the value of a design Designing for maintainability

8 787 structures

9 Why composites? Lighter weight New design possibilities New manufacturing processes Better suited for many aircraft loads More durable Insensitive to fatigue No corrosion Reduced scheduled maintenance burden

10 Reduced scheduled maintenance 767 Aluminum Tail 777 Carbon Tail 787 Advanced Carbon Tail Tail Size Comparison Tail Size (wet area) Scheduled Labor Hours Scheduled Labor Hours Comparison % % 56%

11 Reduced non-routine maintenance Boeing in-service experience with carbon fiber floor structure in the 777 demonstrates the non-routine maintenance advantage The 777 fleet history reveals ZERO non-routine labor hours for the composite floor beams 787 Carbon Fiber Floor Beams Boeing has never sold a replacement composite floor beam for the 777

12 Why not 100% composite? 787 Aluminum Flight Deck sub-structure 787 Titanium Keel Beam Extensions 787 Titanium Frame & Fuselage Splice

13 787 Materials Overview Carbon laminate Carbon sandwich Other composites Aluminum Other Steel 5% 10% Titanium 15% Titanium Titanium/steel/aluminum Aluminum 20% Composites 50%

14 Structures maintenance intervals The 787 structure is optimized for reduced scheduled maintenance burden All routine inspections of structure are visual, with no NDI or special inspection equipment or skills required 767 current intervals 777 current intervals 787 intervals at EIS External (2C check) No inspection behind panels, no interior removal, etc. 36 months 48 months 72 months Internal (4C check) Typical D-check or heavy check - significant access required 6 yrs 8 yrs 12 yrs Landing Gear Restoration 9 yrs 10 yrs 12 yrs

15 Fuselage Construction Fuselage sections are produced as a single-piece barrel 787 design approach minimizes overall fuselage joints Eliminates all longitudinal lap-joints Reduces weight & drag Lowest structural maintenance burden The 787 fuselage is built of 5 barrel sections joined by circumferential splices

16 Scheduled maintenance Reduced inspection intensity 787 fuselage architecture enables non-invasive structural crown inspections without systems and insulation removal

17 Bonded & hybrid repair development Bonded and hybrid (bonded with bolted sub-structure) repairs are certified for all major areas of structure (fuselage, wing, tail, etc.)

18 Bolted repair development Bolted repair options are certified for all major areas of structure (fuselage, wing, tail, etc.)

19 Quick composite repair QCR is temporary composite repair which takes 1-hour to install and which can remain on the airplane for up to 24 months. Area Identified Coating Removed Patch Cut Adhesive 0:59 Installed Patch Surface Covering Finished Repair Time 35 Minutes Patch Applied Heat Pad Vacuum Tool Cure

20 787 Systems

21 Key 787 systems technologies Common Core Open Systems Architecture Advanced Flight Controls w/ Active Load Alleviation Dual-Redundant Fuel Quantity Indication System and Full Tank Inerting Advanced Flight Deck Power Electronics Liquid Cooling Systems Simplified Wing Trailing Edge Architecture w/ Variable Camber Technology Next Generation Engines Technology Electric Brakes Interior Enabling Architecture Advanced Onboard Maintenance Systems 5000 PSI Hydraulics No-Bleed / More Electric Systems Architecture

22 Electrical Power Generation Variable Frequency Starter/Generator (VFSG) VFSGs Installed On Engine No Constant Speed Drive No frequency conversion at engine Eliminates Pneumatic Start Motor Reliability improvement vs IDG

23 No-bleed/more electric architecture APU maintenance & reliability HS APS 5000 APU All pneumatic elements eliminated No Load Compressor No Inlet Guide Vane or IGV Actuator No Pneumatic Ducts or Sensors No Frequency Converter Improved MTBF Greater hours between overhaul Maintainability R&I Testing San Diego, CA

24 Line maintenance 787 Electric brakes

25 No-bleed/more electric architecture wing ice protection Slats 2, 3, 4 and 5 are protected on the LH wing Inboard & Outboard slats are not protected Ice protection is provided by electrically heated leading edge Heated portion of slat is line replaceable Aircraft is dispatchable into icing conditions with any two-zone LRU inoperative More reliable and more dispatchable than pneumatic anti-ice system Functional layout of each heated slat zone 1 zone 2 zone 3 zone 4 zone 5 zone 6 LRU 1 LRU 2 LRU 3

26 By-wire controls

27 Simplified trailing edge Simplified Trailing Edge reduces lubrication points by more than half 767 = = 82

28 Scheduled maintenance intervals 787 systems are optimized to reduce scheduled maintenance 767 current intervals 777 current intervals 787 intervals at EIS Line (A check) Light duty airframe and powerplant systems checks. 500 flight hours 650 flight hours 1000 flight hours Base (C check) Systems servicing and checks 18 months 37 months 36 months The 787 has no transit or daily maintenance tasks

29 Onboard maintenance systems

30 Onboard maintenance systems Expanded scope 777 Functions New for 787 Central Maint Computing Function EICAS Maint & Synoptic Page Viewer Flight Data Recorder Management DDG/MMEL & CDL Data Onboard Initiated Tests Circuit Breaker Indication & Control Flight Deck Security Door Interface Part Information Management (IPC Replacement) Onboard Configuration Management Cabin Services & Systems Fault Isolation & Maintenance Procedures Interactive Wiring Dgms & Systems Schematics Onboard Data Load IFE System Maintenance Electronic Logbook Interface Structural Repair Data

31 Onboard maintenance systems Expanded availability EFBs Maintenance Laptops (wired or wireless) Flight Deck MFDs

32 Onboard maintenance systems centralized, integrated & linked maintenance functions Dataload Circuit Breaker Control MAINT MENU CB BY ATA FLIGHT DECK CB CB BY BUS NON-NORMAL CB CB BY LOCATION RPDU M RECENT USED CB CB BY STATE CB SEARCH CB CUSTOM LIST Maintenance Procedure SLOT 1 EC CIRCUIT BREAKER NAME 1 CONTROL DETAILS EC CIRCUIT BREAKER NAME 2 CONTROL DETAILS EC CIRCUIT BREAKER NAME 3 CONTROL DETAILS EC CIRCUIT BREAKER NAME 4 TRIPPED CONTROL DETAILS EC CIRCUIT BREAKER NAME 5 CONTROL DETAILS 1 Airplane Systems Info EC CIRCUIT BREAKER NAME 6 EC CIRCUIT BREAKER NAME 7 CONTROL DETAILS CONTROL DETAILS FIM Procedure System Test Airplane Fault Data Pilot Report Maint. Log CLOSED

33 A guaranteed advantage Airframe maintenance costs 30% Years in service 29

34 Thank You!