Flugzeugelektrik als technologische und industrielle ... · Airbus will be be in a position to fully master and control this key technology and process in order to be able to qualify

Christoph Zammert

Flugzeugelektrik als technologische und

industrielle Herausforderung am Beispiel des A 380

____________________________________________________________________ Christoph Zammert Head of Improvement & Performance, Centre of Excellence Electrics, Airbus SAS

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Feb 2006

Aircraft Electrics A technological and industrial challenge

13. Kolloquium Luftverkehr – TU Darmstadt

TLA

Presented by

Christoph ZammertHead of Performance & Improvement, Centre of Excellence Electrics

Agenda

A little bit of history

The A380 industrial system

The A380 – an innovative aircraft

Aircraft electrics and the Centre of Excellence

New challenges for aircraft electrics

The next programmes – A350 and A400M

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Development of Aerospace Industry in Europe

Restructuring efforts over more than 50 years have led to a consolidation of theEuropean aerospace industry.

Bae BAe Systems

EADS

DASA

Aerospatiale

British AircraftCorpHawker SiddeleyDynamicsScottish Aviation

Air FougaMorane-SaulnierOuest-AviationSud-AviationNord-AviationArsenal AEA

Weser-FlugFocke-WulfHeinkelHFBMesserschmittBölkowJunkersDornier

CASAHASA

bis 1950 1960 1970 1980 1990 2000

BreguetMarcel Dassault

Dassault Aviation

Fairchild -Dornier

MTU München

Marconi Electronic

MTU München

VFW MBB

The Structure of Airbus (SAS)Before July 2005

CEO

Operations Finance Programs Customer Affairs Human Resources

General Manager Airbus France

General Manager Airbus

Deutschland

General Manager Airbus España

General Manager Airbus UK

Product Safety

Govt. Relations & Communications

Military Programs

General CounselComp. Secretary

Procurement

Independent national entities

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The Structure of Airbus (SAS)After July 2005

Operations

General Manager Airbus France

General Manager Airbus

Deutschland

General Manager Airbus España

General Manager Airbus UK

Engineering Quality Centres of Excellence

Information Systems

CoE Forward and Aft Fuselage

DCoE Wing

UK

CoE Nose and Center Fuselage

F

CoE Horizontal Taiplane

E

CoE Pylons & Nacelles

F

CoE Vertical Tailplane

D

CoE ElectricsF,D, E, UK

Locally empowered Centres of Excellence

Manufacturing – Centers of Excellence

Final Assembly Lines

Airbus Transport

Fuselage (fwd & aft)Hamburg, Bremen, Nordenham, Varel

Fuselage (nose & center)Nantes, Saint Nazaire, Méaulte

Cabin & Cargo CustomizationLaupheimBuxtehude

WingBroughton, Filton

StadeVertical Tailplane

Pylon, NacelleToulouse (Saint Eloi)

Centers of Excellence

Horizontal TailplaneGetafe, Illescas, Puerto Real

Hamburg, Toulouse

Final Assembly LineA318 / A319 / A321

Final Assembly LineA300 / A310 & A330 / A320 / A340

Toulouse

Final Assembly LineA380

Seven Centers of Excellence send their production direct to the Airbus final assembly lines in Hamburg & Toulouse.

•Cabin & Cargo Customization•Installation of cabin systems

•Painting•Delivery to

customers from theNear East and

Europe

•Wing assembly•Engine installation•Installation of flight

systems•Delivery to

customers in America and Asia

HamburgToulouse

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Agenda







AIRBUS FRANCEAIRBUS DEUTSCHLANDAIRBUS UNITED KINGDOMBelairbusAIRBUS ESPANARolls Royce or Engine Alliance

The A380 Building on Airbus Centers of ExcellenceA380 Workshare

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Broughton (UK)

Getafe /Puerto Real (Spain)

Hamburg (Germany)

Hamburg(Germany)

Stade (Germany)St. Nazaire / Nantes (France)

St. Nazaire /Meaulte (France)

Toulouse (France)

Bremen (Germany)

Puerto Real(Spain)

Hamburg(Germany)

A380 Airframe ProductionMajor Component Assemblies

KAI (outer bottom panel)

FACC (flap/fairings)

Alenia

Jamco(CFRP crossbeams)

Eurocopter (all doors)

Finavitec(spoilers)

HdH (wing tip)

Hurel Hispano

Latecoere(lower shell)

Sonaca(upper shell)

Belairbus(slats)

Fokker (J nose)Glare panels/

Nippi(HTP Tip)

FHI (leading, trailing edge & tip)

Saab(mid & outer front spar)

GKN (shroud box, access panels)

A380 Industrial Partners

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S 11/12

MCA in St. NazaireComponents from Meaulte and Industrial Partners.

MCA in St. NazaireDelivery to FAL.

MCA in HamburgFuselage Shells from Nordenham. Parts, Components from Bremen, Varel, and Industrial Partners.

S 11/12

S 13

Fwd Fuselage MCA

S 13

A380 Aircraft Build ProcessFront Fuselage MCA

Aft Fuselage MCA

++

MCA in HamburgShells from Nordenham. Components, Parts from Getafe, Stade, Varel, Bremen, and Industrial Partners.

A380 Aircraft Build ProcessAft Fuselage MCA

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A380 Components delivered to FAL

Station 31/30Structural Completion /Equipment Installation /

System-Testing

Station 45Wing Equipping

Station 41/40Structural Assembly

Station 18Outside

Tests

TLS

HAM

A380 Aircraft Build Process The Final Assembly Line - Toulouse

Station 15Station 15Production Production

FlightsFlights

Station 37HTP Equipping

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Agenda







A380 – New Technologies

Engines:reduced noiseemission and fuel consumption

Engines:reduced noiseemission and fuel consumption

(based on 3-D design)Wing aerodynamics

New production processes(e.g. LASER beam welding)New production processes(e.g. LASER beam welding)

CFRP tailplaneCFRP tailplaneExamples:Examples: CFRP pressure bulkheadCFRP pressure bulkhead

New materials(e.g. GLARE)New materials(e.g. GLARE)

Completely newcabin conceptwith the most advancedcommunication and entertainment systems

Optimizedmechanical, hydraulic andelectrical systems

Optimizedmechanical, hydraulic andelectrical systems

(optimized man-machineinterface)

Cockpit

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More opportunities than ever before

to define and reinforce brand

First Class

Ceilings

Forward stairs

Rear stairs

Huge scope for customisation

A380 Upper Deck, Economy Class - white light

Lighting customisation

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The Cabin – an important differentiator

A340A340--600:600:Upper Class BarUpper Class Bar

A340A340--500:500:First classFirst class

A340A340--500:500:Executive Eco. BarExecutive Eco. Bar

A380 mockA380 mock--up:up:First ClassFirst Class

A380 mockA380 mock--up:up:First Class BarFirst Class Bar

A380 mockA380 mock--up:up:Premium Class BarPremium Class Bar

A380 – An All New Cockpit

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Specific A380 challenges

Completely new design (i.e. not a variant like e.g. from the A340-300 to the A340-500/600)

Completely new cabin and cockpit features (high impact on system definition)

A380 enables airlines to differentiate themselves from the competition (i.e. very high level of customisation per customer, sometimes several variants)

New risk share partners and suppliers on board

High pressure to deliver an aircraft “mature at entry into service”

Tough lead time challenge to meet certification schedule and customer delivery dates

Agenda







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Electrics - Key Elements of the ProcessSYSTEM DEFINITION

PD

ELECTRICALPRE-DESIGN

ELECTRICAL DESIGN WD

ELECTRICAL INSTALLATION DESIGN

3D DMU

WIRESDATABASE

HARNESSDATABASE

CONFIGURATION MANAGEMENT

ManufacturingS/C management

Installation

HTPFAF

VTPWingFALCCCFlt

Test

CCC FDE CA FuelPCS LGS PRO

APUFAF

Flight Test

NCFPylon

ELECTRIC PROCESS THE HINGE BETWEEN TWO WORLDS

The Specific Role of Electrics

Non-specific design work

Specific design work

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Some General Figures on A380 Electrics

400 kmTotal Harness Length

1200Number of Harnesses

4800Wiring Diagrams

3000Principle Diagrams

107,000Links(connections)

Electrical harnesses A380 nose section

Systems

&

CabinCOE

Elec

COE

Sec.

COE

Sec.

COE

Sec.

COE

Sec.FAL

The COE Electricscreated to steer the global electric processPositioning the CoE in the organisation

• Configuration Control for Electrics

• Consolidated electrics planning

• Process and too harmonisation

Synchronisation & Harmonisation:

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• The data flow from definition to harness installation is ensured by the CoE Electrics

• Pull / Push Principle

COE SectionCOE SectionCOE Section

DMUPD

WD DB

SWRD

Section COEs

COE L

SYSTEMS

Referentiel

CABIN SYSTEMS

FAL

929 Manuf. Inst.

CoE Electrics PerimeterOrganisation follows the electrical process

TL – Activity Overview

Toulouse

Madrid

HamburgFilton

Filton – 150 FTE• Harness Manufacturing (SA)

• Design Office(all programmes)

Getafe – 35 FTE• Installation Focal Point

• HTP harness manufacturing

Hamburg – 300 FTE• Design Office

(SA, LR, A380)

• Harness manufacturing

• Programme management(SA)

Toulouse – 500 FTE• Central Functions

• Design Office (all programmes)

• Programme management(LR, WB, A380, A400M)

• Harness manufacturing (all programmes)

• Cockpit panels, avionic racks, power centres

BremenBremen – 90 FTE• Design office

(A400M)

• LR harness manufacturing

Status: 12/2005 – only Airbus internal FTE (functional and operational reporting)

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Electrical Harnesses

Power Centres

Avionic Racks

Cockpit Panels

Main Deliverables

Key figures on TL deliverables

• 75-80% of the activity(engineering + manufacturing) isoutsourced

• RC cost of shipset is from0.6 to 2.9 M$

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Immediate Measures Implemented On The A380

Deployment of a specific organisation

Creation of the “FAF Plateau” at the Harburg Channel (approx. 1000 FTE) allowing the co-location of electrics and installation design for better reactivity and efficiency

Integrated planning and tracking on deliverable level

Implementation of a robust configuration management tool

Quick hits introducing harmonisation and standardisation

2005 160M$ 2008 280M$

Total Harnesses

Total VUs

Latelec

Labinal

Fokker Elmo

Other

Single Aisle

Long Range

A380

Wide Body

2005 2008

Supply Chain Developments And Trends

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Next Steps

Standardisation and harmonisation towards “ one way of doing electrics” – one process, one tool

Implement the appropriate make or buy and industrial policy to be able to control the entire electrics process, both internally and of the extended enterprise

Prepare the future for more electric, more composite aircraft

Review subcontracting arrangements in order to reduce number of interfaces per aircraft and have a well balanced market stimulating competition

Prepare for new industrial partnerships and offset or collaboration obligations

Agenda







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787 Dreamliner

787 Dreamliner

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787 Dreamliner

TLE Boeing

•RSP resources•Airframer + Capacity Subcontractors

airframer

airframer

airframer

airframer

airframer

airframer

airframer

Boeing

Pre Functional

design

Harness Inst

Drwg Set928

Harness Dwg. Set

929

Pre3D

design

WDDrawings

Harness Manuf.

Detailed3D

design

Supplier A

airframer

Boeing

Boeing On The 787 – A Radical New Approach

Leader ship

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More Industrial Flexibility and Modularity

More Electronic A/C

More Composite A/C

More Electrical A/C

New concepts for basic electrical functions and protections:

• GFI (differential circuit breaker)

• Electrical bus bar for current return

• Improved electrical shielding & bonding devices

New components

• More electronic on power circuits

• High voltage capabilities

New installation concepts

• Customised electronic bays & panels

• Standard harnesses ( eg flat cables,…)

• Advanced pre-sizing assessment

New Trends in Aircraft Electrics

New technologies require new processes and skillsMetallic Overbraiding (Example)

Increased use of composite materials in aircraft structures requires metallic overbraiding for electromagnetic protection of electrical harnesses

Airbus will be be in a position to fully master and control this key technology and process in order to be able to qualify and control subcontractors

Big implications on late changes at FAL-level and modifications / repairs and for development aircraft

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Agenda






Our next programmes – A350 and A400M

A350 – The Airbus answer to the 787

All new cabinAll new cabin

Full titanium pylonFull titanium pylon Centre wing box in CFRPCentre wing box in CFRP

CFRP outer wing boxCFRP outer wing box Optimised fuselage Optimised fuselage design (Aldesign (Al--Li)Li)

Rear fuselageRear fuselageAlAl--LiLi

New HTPNew HTPPassive and active Passive and active

load alleviationload alleviation

New high bypass New high bypass enginesengines

Wing drag Wing drag improvementsimprovements

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A400M• Length 42.2 m; wing span 42.4 m• Max. take-off weight 130 t• Speed Mach 0.68-0.72

A400M

The A400M largely profits from the accumulated Airbus knowhow!

Centralizedmaintenance data system

Aerodynamic design, optimized for different mission criteria

Large cargo compartmentwith robust and self-containedloading system

Modern turboprop enginefor high airspeeds

Advanced but provenmaterials technology

Flight control in “fly-by-wire“technology; based on Airbusexperience

Navigation system for ground-independent all-weather/ night and day missions

Proven system and componentsof high reliability

Wings and tailplanesmanufactured from CFRP

A400M – New Technologies

The A400M largely profits from the accumulated Airbus knowhow!

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A400MSame complexity as A380 on less space

A400M

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© AIRBUS S.A.S. All rights reserved. Confidential and proprietarydocument.

This document and all information contained herein is the sole property of AIRBUS S.A.S.. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to athird party without the express written consent of AIRBUS S.A.S.This document and its content shall not be used for any purpose other than that for which it is supplied.

The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are notshown, AIRBUS S.A.S. will be pleased to explain the basis thereof.

AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.

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Flugzeugelektrik als technologische und industrielle ... · Airbus will be be in a position to fully master and control this key technology and process in order to be able to qualify