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FAST rarely has an editorial, but I felt that, in view of the dramatic happenings in our industry,
that this FAST would be a good vehicle to share some information with you.
Safety in the cockpit has been a major consideration since September 11th. Airbus’ engineers in
Design and Customer Services have been working on a responses to several demands.
The major challenge has been to design a door that meets many conflicting demands such as
the need to resist an attack and still behave correctly in case of depressurisation.
We are now finalising the design for the Phase 2 door, which has to meet both the existing and
new Airworthiness Authorities requirements for certification. Service Bulletins are being
prepared together with the associated kits with the aim to release them in the spring of 2002 to
meet the FAA’s probable embodiment deadlines. Our approach, for all our models, has been to
meet this demand via a minimum cost approach by absorbing the design costs and producing
the kits at a minimum price.
All of these modifications, which history imposes on us, will be competitively priced to minimise
their cost to you, the operator.
You have my assurance of Airbus’ will to help you through this period.
I wish you all, together with your families, a 2002 that is good for you personally.
Professionally, I also wish that it brings the signs of industrial recovery that we all need.
Sincerely,
Patrick GAVIN
Executive Vice President Customer Services
A I R B U S T E C H N I C A L D I G E S T
D E C E M B E R 2 0 0 1
AIRMAN® 2
Simplifying and optimising aircraft
maintenance
Christian Frémont
Christian Callay
FAST / NUMBER 29 1
®
On-ground data:
Shop data, logbook,
aircraft delays,
Technical Follow Up,
Technical notes...
By
Christian Fremont in collaboration with
Maintenance and Trouble Shooting Christian Callay
System Engineering Maintenance Software Development
Airbus Customer Services Airbus Customer Services
AIRMAN® concept: AIRMAN® provides the following:
◗ Real time aircraft technical follow up
Simplifying and optimising aircraft maintenance e-trouble shooting ◗ Preventive maintenance actions
(trend monitoring concept)
The Airbus aircraft technology opens maintenance since non-routine The Airbus fly-by-wire aircraft ◗ Analysed maintenance data avail-
are all equipped with data record- able for engineering to optimise
the door for innovation in the mainte- events are very penalising factors in ing features such as: aircraft technical follow up
nance area. Indeed, the A320 Family daily aircraft operation. ◗ Fault monitoring and diagnostics processes.
and long range A330/A340 fleet are Engine reports directly transmitted undertaken by the Built In Test These features further improve
all basically equipped with systems from the aircraft (down-linked) are Equipment (BITE) of each sys- aircraft dispatch, simplify aircraft
recording maintenance data to be already used by many airlines to tem. maintenance and cut down mainte-
used by maintenance personnel, monitor their engine parts. In the last ◗ ACMS (Aircraft Conditioning nance costs.
Monitoring System) reports.
such as ECAM warnings displayed to few years, to further improve their line
the crew, fault messages recorded maintenance and engineering effi-
All this data can be downloaded AIRMAN®
in real time via data-link (ATSU,
by the computers, engines and APU ciency, they have begun to down- ACARS) to the ground. Much of development
reports coming from the Data load ECAM warning and fault mes- the information related to mainte- process
Management Unit (digital recorder). sages. The trend is quite clear that, nance is also available on the
All this data can be transmitted in due to the advance of technology ground, such as:
◗ Aircraft documentation: Trouble Step by step approach
real time from the aircraft to a on board the aircraft, to further Shooting Manual, Aircraft The scope of AIRMAN® is large.
ground station. This data is consid- enhance the maintenance efficien- Maintenance Manual, etc…) The first step has been the develop-
ered as high value information relat- cy there is a need for an on-ground ◗ Airline technical notes ment of AIRMAN® 2000, which has
ed to aircraft maintenance. maintenance software aid. ◗ Logbook data been defined with Air France and
Use of new electronic data process- Airbus, in very close cooperation with ◗ Aircraft delays Sabena and tested and validated in
ing (EDP) tools, capable of analysing selected airline maintenance organi- ◗ Shop data the operational environment with
◗ Airbus information: Service these airlines and JetBlue.
this large volume of data coming sations, and using in-house mainte- Information Letter (SIL), The Airbus objective has been,
from entire fleets, helps the airlines to nance expertise, has developed its Technical Follow Up (TFU). and will be, to continuously
manage and anticipate unsched- own ground based maintenance By analysing and linking all involve the airlines in the definition
uled aircraft events. Their use has software aid: AIRMAN® (AIRcraft maintenance data related to of AIRMAN® modules. In this
raised high interest in aircraft line Maintenance ANalysis). unscheduled aircraft events, framework, the first "AIRMAN®
2 FAST / NUMBER 29 FAST / NUMBER 29 3
users club" workshop will be set up
during the first half of 2002. This
AIRMAN® 2000 Predictive maintenance
function
step-by-step approach allows the Features
airlines to take the benefit immedi- (Hangar maintenance)
ately of features offered by AIRMAN® 2000 provides the fol- Using algorithms based on statisti-
AIRMAN® 2000 and to define future lowing features based on the On- cal analysis, a selected fault mes-
modules to meet their needs. board Maintenance System (OMS) sage from the aircraft is recorded
Development of the complete set data analysis. in the job list and classified as "
of AIRMAN® applications has been Gate maintenance function new today", "still open" or "long
estimated to take four to five years. lasting" item.
Airbus will provide AIRMAN® cus- Whether the aircraft is at the gate, This feature allows the mainte-
tomers with yearly releases. Figure 1 on the runway or in flight, the AIR- nance operator to set up the appro-
shows an example of future AIR- MAN® 2000 software gives the priate trouble-shooting action
MAN® modules that could poten- operator direct access from a PC on before the failure message leads to
Figure 1 tially be connected to AIRMAN® the ground (see Figure 2), to infor- a malfunctioning of a system that
Standard interface to plug in Airbus 2000. mation on the Current Leg Report may be reported by the crew in the
or non Airbus modules or the Post Flight Report, at any logbook. By anticipating mainte-
time (see Figure 3). nance actions, pilot reports (Pireps)
AIRMAN® provides centralised are reduced and thus aircraft
access to information related to an delays. In addition, the mainte-
aircraft event (see Figure 4). Once a Figure 6
nance action can be planned Hangar maintenance
fault message has been analysed, according to the aircraft’s schedule “Scheduled maintenance actions"
the AIRMAN® 2000 system pro- (see Figure 6). related to unscheduled events
vides the line maintenance operator
with a direct link to the relevant Data analysis
troubleshooting task in the Trouble feature Figure 5
Shooting Manual(see Figure 5).
Furthermore, the operator gets AIRMAN® 2000 is able to process
access to the Airbus Technical the OMS data in order to support
Follow-Up (TFUs) and Service the maintenance teams. The results
Information Letter (SIL 00- come under the form of high value-
028/38/41) and also to any of the added information such as aircraft
airline selected documentation failure event concept and fault his-
such as Technical notes and tory tracking. With this feature, the
Engineering Bulletins. operator is able to take the most
appropriate action related to an air-
craft event, saving time and reduc-
ing the cost of “No Fault Found”
Figure 2
Fleet status
(NFF) by providing systematically
in real time "AIRMAN® post flight reports
(PFR)" to justify component
removals.
Figure 4
Figure 3
Hyperlink
with
necessary
aircraft
documentation
4 FAST / NUMBER 29 FAST / NUMBER 29 5
Engineering mation for the line maintenance, allow the reduction of a large mated (conservative calculation) to
the engineering and the Maintenance amount of data coming from approximately 4$US per flight
"transparency" Control Centre (MCC). entire fleets to the bare essentials. hour: 2$ coming form the gate
The generation of automatic The user package can be cus- The Client/Server architecture maintenance function and 2$ from
reports on analysed data and tomized according to the user pro- will move in the coming months to the predictive maintenance func-
records gives the airline’s engineer- files and needs. This allows AIR- a more open architecture based on tion. The following main areas of
ing department a clear picture of MAN® 2000 to be fully integrated web technology. Then, main func- benefit have been identified:
the technical status of the whole into the aircraft trouble shooting tions of AIRMAN® could be a new ◗ Gate maintenance function Operators who wish to have
fleet at any time (see Figure 7). The process in place in the airlines. service available through the - Direct access to technical docu- information on AIRMAN are
feedback, from the users to Airbus Whenever the aircraft fleet Airbus portal “Airbus On Line mentation (TSM, TFU, airline invited to contact
in an analysed form (AIRMAN® changes, the AIRMAN® 2000 pack- Services”. technical notes) Gérard Darteyre
2000 reports), accelerates the age can be electronically up-dated - Maintenance actions can be Marketing Director
process of continuous aircraft prod- quite easily. Savings from prepared on the ground while Airbus Customer Services
uct improvement such as monitor- the aircraft is still in flight; Phone number:
ing the upgrading of computers.
System architecture AIRMAN® 2000 - Failure confirmation based on +33 (0)5 61 93 11 39
AIRMAN® 2000 is a Client/Server A first estimation of savings AIRMAN® 2000 analysis. E-mail:
Figure 7 application. The software is divid- brought by the use of the current ◗ Predictive maintenance gerard.darteyre@airbus.fr
ed into three main parts: AIRMAN® 2000 release was con- - Cut down the number of air-
◗ The real time acquisition module ducted in 1998 with Air France. In craft delays; or
(AIRMAN® 2000 RTA).This mod- 1999, a second study using data - Reduction of pilot defect
ule acquires in real time OMS coming from Sabena was per- reports; David Grezes
data transmitted by the aircraft formed. Both investigations led to - Cut down line maintenance AIRMAN
through an on-ground service similar results. The gain was esti- actions. Marketing Manager
provider. Airbus Customer Services
◗ The database (Oracle®). The Phone number:
structure and content of the data Conclusion +33 (0)5 61 93 11 47
represent years of collective E-mail:
experience of aircraft mainte- AIRMAN® 2000 was officially presented in December 2000 to A320 david.grezes@airbus.fr
nance experts. In this database operators during the Airbus A320 Technical Symposium. During the
are stored data that are used by Le Bourget Air Show in June 2001, Air France, Finnair and JetBlue
the AIRMAN® 2000 core software. signed a contract to get AIRMAN® 2000. They have since been joined
Customized ◗ The core software (AIRMAN® by Austrian Airlines and Emirates. Discussions are currently run-
features/Fleet update 2000.exe). Algorithms based on ning with other airlines.The Airbus aircraft technology of today and
The AIRMAN® 2000 system con- advanced technology such as its evolution tomorrow, opens the door for AIRMAN® 2000.
tains a broad range of useful infor- "data mining" methodology, ◗ Simplifying and optimising aircraft maintenance,
◗ Reducing aircraft ground time,
◗ Launching preventive maintenance.
◗ Reducing the maintenance cost.■
Software requirements
A318
Maximum
Commonality
MTBUR
* 2000FH
Benefits for
1-D linear bar code
→ Technical logs,
airlines and Shop Finding Reports
IDG
The optimum oil level is at
... and comes back into the IDG. or near the top of the green band.
Airbus has produced a film that
illustrates in a user-friendly manner
how the oil system is filled during
flushed on the aircraft as solvent that drains oil during the servicing operation due to the aircraft pitch After the motoring the oil level the servicing. In addition to the
current Aircraft Maintenance
residue will be trapped in the to establish proper oil level. The top angle variations (e.g when the air- must be allowed to settle down for Manual (AMM) procedure, the film
cooler. of the overflow standpipe corre- craft is loaded or towed with the five minutes. Then the oil level provides an overview of the IDG oil
Expel air pockets sponds to the top of the green band nose gear lifted) leading to addi- sight glass must be checked again distribution and explains, using 3D
of the sight glass tional burdens for the maintenance to ensure that the oil level is at or animation, how the oil level is set
During servicing the oil is If there is too much oil in the IDG and flight crews. near the top of the green band. inside the IDG. The film is available
pumped through the IDG pressure the operating temperature increases. The oil level may be slightly on a CD-ROM with an interactive
fill port. It goes through the IDG This equipment is more affected by
Check the oil level above the top of the green band due mode, allowing easy navigation
filter and exits the IDG into the overfilling due to a high-speed gen- after servicing to thermal expansion. In this case inside the IDG servicing
external circuit, circulates into the presentation. It also contains a
erator rotating in the case. High When the servicing is complete the acceptable level is within the “Virtual Servicing“ section which
cooler, flows through the external temperatures are reached faster the engine must be dry motored or yellow band above the green one. allows the viewer to fully
circuit again and comes back into along with reduced IDG reliability run at idle for at least two minutes However the oil level may have understand what is happening
the IDG case. Once the oil level and potential IDG disconnection in to allow the oil to circulate through dropped due to the presence of air inside the IDG system during
exceeds the top of the overflow flight. the system and ensure that every in the system before the motoring. replenishment of the oil.
stand pipe it flows outside the IDG A low quantity of oil may be at cavity of the oil system is properly In this case the servicing should be
through the overflow drain port. the origin of low oil pressure and filled with oil. resumed. For procurement details
The servicing procedure is electrical frequency fluctuations. of the CD-Rom
designed to fill all the cavities of The use of the generator may be lost “IDG SERVICING”
the circuit with oil, expelling air in flight. Underfilling has other Ref 953.0616/01
pockets and thus setting the opti- refer to SIL 00-032.
effects such as accessory gear wear
mum oil level. and reduced IDG reliability.
Set up the optimum On the A330/A340 there is a sen- Conclusion
sor that monitors the IDG oil level
oil level thus avoiding the requirements of a The AMM procedure must be strictly followed to ensure proper servic-
The oil level is controlled via the regular oil level check. If the oil ing. This is a key factor in ensuring a smooth and long IDG operating life.
sight glass. The optimum oil level is level is near the bottom of the green It contributes to the operational reliability of the aircraft, removes unnec-
at or near the top of the green band. band, low oil level detection may be essary workload and reduces maintenance costs. ■
IDGs have an overflow stand pipe generated during aircraft ground
22 FAST / NUMBER 29 FAST / NUMBER 29 23
AUTOMATION allow the customer to order the lat-
est kit revision.
The full chain of the SB produc- In case a kit already delivered
tion process has been automated up experiences a revision, only the
to the dispatching to customers additional parts will be supplied
(with digital media), including on- through a supplemental kit .
line access. Actually, SB COMP Last but not least, Airbus is
provides digital services (SB under preparing the SBs for the future.
PDF and SGML formats) to AOLS Several technologies based on the
(Airbus on-line services) for Airbus use of photographs have been test-
customers. ed to introduce some improve-
Every year the application ments in a medium term (within
brought major improvements to the two years). The objectives of this
SB process. new SB will be to reduce text and
Some years ago, in FAST number 1993: SB writing automation on increase illustrations so as to give
the basis of SGML and an easier and more accurate Figure 1
13, an article presented a project of DTD standards. description of the part of the air- A340 SB on hydraulic systems
Service Bulletin (SB) digitalisation 1995: SB life-cycle follow-up in craft to be modified or inspected. A (SB A340-29-4054) “Modification of
the blue system pipework between FR44
a centralized database from prototype presented during the
By Annick Pedron with the introduction of SGML at the launching to dispatching. A320 Family Technical Sympo- and FR46”
Current illustration completed with a set
SB Method, Process and Quality SB author’s workstation. The inten- 1996: SB on-line consultation for sium in Seville in November 2000 of photos describing access, step by
all Airbus users involved in was well received by the audience
Group Manager tion at that time was to reduce the the process. (see figure 1).
step, to the area concerned by the
modification.
1997: Automation of paper and
production time, standardize the SB
and
floppy production. It was
format, further improve the quality the first time that digitized
SB were proposed by
and prepare for the future. Looking Airbus to its customers.
at past achievements, the SB 1998: SB validity (expressed in
MSN, also called “effectiv-
Jacques Pasdeloup
Computerisation (SB COMP) appli- ity”) computation, provid-
SB Department Manager cation, built “step by step”, has ing adequate follow-up of
validity changes and giv-
Airbus Customer Services allowed the implementation of ing the right information at
the right time. The number
more than just the initial basic of SB revisions for “effec-
objectives. It anticipated to a cer- tivity” changes has drasti-
cally decreased.
tain extent, the evolution of tech- 1999: Automatic interface imple-
nology. mented between SB
COMP and AOLS to pro-
vide SB as a digital product
and on-line access to the
customers.
2000: Automation of SB valida-
tion and approval within
Airbus. This module co-
ordinates actions by the
different participants in
this process, saving time
while improving the over-
all quality of this validation
and approval.
THE FUTURE
What will come next?
Very soon, Airbus will introduce
a kit revision indicator within the
kit part number reference. This
indicator will be quoted every-
where along with the kit reference,
within the SB document. This will
24 FAST / NUMBER 29 FAST / NUMBER 28
29 25
SB quality and technology is the Figure 5
subject of continuous improvement On screen digital view of a cleat at
within Airbus, in order to make stringer 32 (SB A320-53-1046)
them easy to understand and to use. with rivets to be installed
(Snap shot from a film)
The SBs dispatched during the
week are entered in AOLS the fol-
lowing Monday. Access to these
documents is through research cri-
teria such as: MSN, Program, ATA
chapter, text. AOLS also provides
the list of associated documents,
with the possibility to move back
and forth between them (see figures
left).
In future versions of AOLS,
hyperlinks with Vendor Service
Bulletins and other Tech Pub docu-
Figure 2 ments will be included in the SB.
AOLS – Performing a search to Having access to the document
retrieve Modification SB on ATA 27 for on-line, facilitates specific tasks,
aircraft type A340 with compliance such as job card preparation by
“mandatory”
allowing copying and pasting of
text and illustrations. It also gives
the possibility to download the file
into a portable PC and to use it
directly on the work site.
In the longer term, for the A380,
the digitalised computer aided
design (CAD) drawings will be
used in the next-generation multi-
media Service Bulletin. The digital
drawings will provide 3-D views of
the areas concerned by the modifi-
cation or the inspection (see figure 5).
Figure 3
Search results listing SBs
answering to selected criteria.
Conclusion
The continuous development of the Airbus SB system has come
from listening to customer comments and requests, and by making
use of technological benefits as they are developed. This is an on-
Figure 4 going process.■
Clicking on 27-4023 gives access to
related SB under HTML format
WORLDWIDE
USA/CANADA
CHINA
Following September 11th, Airbus set up a series of conferences on aircraft security. The objectives were to examine ways
to minimize risks related to the threat of terrorism in air transport and propose solutions to respond to these threats. Airbus
continues to identify and investigate solutions which could be implemented in the very short term.
The main improvements are:
- cockpit door reinforcement
- installation of a video camera (to make the cabin forward area visible to the pilots)
- installation of a specific emergency cockpit/cabin communication system
- a modification linked to the ATC transponder, allowing the pilot or co-pilot to transmit a 'hijacking mode' permanently
to the ground
During these conferences Airbus presented feasible technical proposals and evaluated operator's priorities. Technical def-
initions will be provided to meet the new FAA requirements linked to Aircraft Security enhancement. ■
32 FAST / NUMBER 29