Bell 525 Relentless Program Presentation SFTE/SETP Southwest Flight Test Symposium October 25, 2014 James C Harris
The Bell 525 is designed in collaboration with an industry advisory group to meet all of the major market segments Corporate and VIP Firefighting Oil and Gas HEMS SAR and Parapublic
Relentless Focus On The Customer The Customer Advisory Panel (CAP) has told us that it is critical to have a new product in the market that can: Safely and repeatedly fly with zero exposure, raising the bar in the industry towards a new level of future helicopter safety. Provide the relevant technology that improves pilot awareness and enhances his/her ability to safely and effectively control the aircraft. Meet the demanding missions of the future, flying farther and carrying more payload in a comfortable and safe environment. Provide reduced maintenance and operating costs through state of the art vehicle health monitoring and design focus on life cycle cost and aircraft availability.
What is Productivity? We measure productivity in terms defined by our Customers: Economics = total operating cost per seat mile- best economics across all missions Performance = PC2E, ISA +20 with IFR reserves in a heavily configured aircraft Aircraft Availability = high component reliability with effective diagnostics, health monitoring and maintenance access. Fleet Integration = Executing on a transition of capability to the customer in terms of safety and operational capability. Designed for the Real World = Fit for Purpose
Bell 525 Product Overview Fly-by-wire flight controls Triply-redundant Non-depletable emergency power 5 Blades Canted tail rotor Excellent pilot visibility Garmin glass cockpit GE CT7-2F1 Twin engines LATD Large Best-in-class baggage bay with fire baggage suppression bay 16 Seats (OGP) with best-in-class comfort 20 seats in a high density configuration Large sliding doors every row an exit row Worldwide operational capability including flight Into known icing Customer value driven technology
Key Product Differentiators ITEM BENEFITS CAT A Performance FBW Augmentation GE Engines Corrosion Adverse Design Safety Safety Reliability, DOC DOC, RV 100% Kits Operational Reqmt 80%+ Kit provisions Multi-Role Capability, RV Modular/Integrated Kit Design Vibration Isolation BIC Payload Range Performance Fault Tolerant Design in Redundant Systems Latest integration of Digital Technology in Design and IVHM Multi-Role Capability, RV High Level of Comfort and Component Reliability Mission Requirements High Aircraft Availability Proactive Maintenance and High Aircraft Availability The 525 program has been focused on the best value equation from a total life cycle cost perspective as directed by our Customer Advisory Panel
Productivity Redefined Objective - Best-in-Class Productivity TECHNICAL SPECIFICATIONS SPEED 155 kts 287 kph RANGE 500 nm 926 km USEFUL LOAD 8000+ lbs 3,629+ kg Payload @ 250 nm (OGP Mission, PC2e, ISA +20C) Payload @ 500 nm (OGP Mission, PC2e, ISA +20C) 16+ pax (4,209 lbs) 16+ pax (1909 kg) 8+ pax (2,260 lbs) 8+ pax (1025 kg) Pax weight at 255lb, The specification data provided is presented as estimated/calculated
Bell 525 Interior Rugged Quiet Smooth ride Spacious/flexible Rapid ingress/egress Robust Environmental Control Best in Class Environment
Side View
Cockpit Seating
Where We re Going The future is here Intuitive pilot-vehicle interface with high level of situational awareness
Avionics and Electrical Garmin G5000H Integrated Avionics Suite Includes: Integrated Vehicle Health Management Cockpit Voice /Flight Data Recorder WIFI & Satellite Data Link Providing a simplistic, effective maintenance interface is crucial for Bell 525 success Includes: Displays GTC s Data Concentrators Signal Conditioners Nav/Com First Rotorcraft Touch Screen Avionics interface Conventional / Low Risk Power System Includes: DC Generators (AC kit) APU Starter Generator Solid State Circuit Breakers Distribution Panels FCS Permanent Magnet Generators Additional Systems: Interior/Exterior Lighting Active Vibration Control System Standby Flight Instrument Wiring Design
Cockpit Controls Best in class flight deck controls Improved crew comfort and pilot awareness Uncluttered, ergonomic integrated flight deck Interconnected side stick controllers with tactile cueing for enhanced situational awareness Excellent pilot field of view J-Track Pilot Seats Effective egress Reduces cockpit noise and aircraft weight Maximizes pilot viewing angles
Today s Safety Hazards 525 Hazard Intervention Strategy Fly-By-Wire, Enhanced Situational Awareness Loss of Control Most Common Causes of Rotorcraft Accidents Source: NASA report, IHST Symposium, September 2005 Improper Flight Control Engine Failures Low Rotor RPM Poor Pilot Judgment Inadequate Preflight Fault Tolerance Envelope Protection Enhanced Cat A Systems Training, IVHM Build hazard intervention strategies into aircraft design
Tomorrow s Solution: Bell 525 CAT A Legacy helicopters often operate with exposure Forced landings can be unsafe in hostile environments CAT A safety on par with Part 121 ops Fly-by-wire controls for precise, repeatable profiles Target of only one Cat A vertical profile The 525 Program has a target of only one Cat A vertical profile Simple, repeatable profiles aided by FBW
Low Vibes Vibration Treatment Pylon uses 4 LIVE mounts to cancel up to 95% of 5/rev vibration before it enters airframe. Up to 4 AVCS units mounted in airframe ensure smooth ride quality throughout flight regime and all rotor RPMs. LIVEs 429 Light Weight AVCS Active Vibration Control System
Airframe Integrated Maintenance Access Composite/metallic hybrid structure Reduced fastener count & number of joints to minimize corrosion Major primary structure metallic for flawtolerance and inspectability Carbon composites for corrosion prevention and weight reduction (i.e. boat hull, roof deck, and tail boom) Removable floor panels Titanium engine deck resists high temperatures Built-in Roof Access Full-length roof walkway Removable side panels
Designed for Support Built-in Work Platforms and Walk Strake Easy access means reduced downtime
Designed for Support Built-in Work Platforms and Walk Strake Easy access means reduced downtime
Flight Test Program
525 Flight Test Program 21 5 Test Aircraft ~1200 Flt Hrs ~83 Ship Months
Preparation for Flight: Instrumentation 22 Data Measurements 62001 4087 Channels* 62002 3443 Channels* 62003 4545 Channels* *Includes ~3100 bus channels per aircraft
Program Update
Relentless Advanced Systems Integration Lab (RASIL) Actuator Rig Room Location - Plant 6, Arlington, TX FCS Test Station Avionics Test Station Cockpit Rig RASIL provides the opportunity to fly the Vehicle Management System hardware one year in advance of aircraft First Flight
Test Progress 25 Certification Flotation Test Direct Effect Lightning Test Landing Gear Drop Test
Manufacturing Progress - Amarillo 26
Manufacturing Progress - Amarillo 27
Manufacturing Progress - DSC 28 Bull Gear 2 nd batch through Vacuum Carb TRGB Main Case after 2 nd machining operation IGB Main Case after 2 nd machining operation MRGB Main Case (Tape Try) Completed, ready for Case Set MRGB Top Case After 1 st post-liner machining
Manufacturing Progress - Rotors 29 All A/C #1 main rotor grips layed up and cured, parts 1-4 machined Next Step: Complete machining of parts 5,6 & bushing bond of A/C 1 parts Main rotor spar cell repairs complete Next Step: Build DT article 3 main rotor process verification blades bonded Next step: machining process verification Tail rotor bushing bond process verification Next step: Complete n/c machining of process verification blades
Thank You!!