Flugzeugelektrik als technologische und. industrielle Herausforderung am Beispiel des A 380

Transcription

1 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

2 246 TLA Feb 2006 Presented by Christoph Zammert Head of Performance & Improvement, Centre of Excellence Electrics Aircraft Electrics A technological and industrial challenge 13. Kolloquium Luftverkehr TU Darmstadt 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

3 247 Development of Aerospace Industry in Europe British Aircraft Corp Hawker Siddeley Dynamics Scottish Aviation Weser-Flug Focke-Wulf Heinkel HFB Messerschmitt Bölkow Junkers Dornier Air Fouga Morane-Saulnier Ouest-Aviation Sud-Aviation Nord-Aviation Arsenal AEA Breguet Marcel Dassault bis Marconi Electronic Bae BAe Systems MTU München Fairchild -Dornier VFW MBB MTU München DASA Aerospatiale Dassault Aviation EADS CASA HASA Restructuring efforts over more than 50 years have led to a consolidation of the European aerospace industry. The Structure of Airbus (SAS) Before July 2005 CEO General Counsel Comp. Secretary Govt. Relations & Communications Product Safety Operations Finance Programs Procurement Customer Affairs Human Resources Military Programs General Manager Airbus France General Manager Airbus Deutschland General Manager Airbus España General Manager Airbus UK Independent national entities

4 248 The Structure of Airbus (SAS) After July 2005 Operations Engineering Quality Information Systems Centres of Excellence CoE Electrics F,D, E, UK CoE Vertical Tailplane D CoE Pylons & Nacelles F CoE Forward and Aft Fuselage D CoE Wing UK CoE Nose and Center Fuselage F CoE Horizontal Taiplane E General Manager Airbus France General Manager Airbus Deutschland General Manager Airbus España General Manager Airbus UK Locally empowered Centres of Excellence Manufacturing Centers of Excellence Centers of Excellence Fuselage (fwd & aft) Hamburg, Bremen, Nordenham, Varel Fuselage (nose & center) Nantes, Saint Nazaire, Méaulte Wing Broughton, Filton Pylon, Nacelle Toulouse (Saint Eloi) Horizontal Tailplane Getafe, Illescas, Puerto Real Vertical Tailplane Stade Cabin & Cargo Customization Laupheim Buxtehude Airbus Transport Seven Centers of Excellence send their production direct to the Airbus final assembly lines in Hamburg & Toulouse. Final Assembly Lines Final Assembly Line A318 / A319 / A321 Hamburg, Toulouse Final Assembly Line A300 / A310 & A330 / A320 / A340 Toulouse Final Assembly Line A380 Toulouse Wing assembly Engine installation Installation of flight systems Delivery to customers in America and Asia Hamburg Cabin & Cargo Customization Installation of cabin systems Painting Delivery to customers from the Near East and Europe

5 249 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 The A380 A380 Workshare Building on Airbus Centers of Excellence AIRBUS FRANCE AIRBUS DEUTSCHLAND AIRBUS UNITED KINGDOM Belairbus AIRBUS ESPANA Rolls Royce or Engine Alliance

6 250 A380 Airframe Production Major Component Assemblies Broughton (UK) St. Nazaire / Meaulte (France) Hamburg (Germany) St. Nazaire / Nantes (France) Stade (Germany) Getafe / Puerto Real (Spain) Hamburg (Germany) Hamburg (Germany) Bremen (Germany) Puerto Real (Spain) Toulouse (France) A380 Industrial Partners Belairbus (slats) KAI (outer bottom panel) Nippi (HTP Tip) FHI (leading, trailing edge & tip) Fokker (J nose) Glare panels/ FACC (flap/fairings) Alenia Jamco (CFRP crossbeams) Eurocopter (all doors) GKN (shroud box, access panels) Sonaca (upper shell) Latecoere (lower shell) Finavitec (spoilers) HdH (wing tip) Saab (mid & outer front spar) Hurel Hispano

7 251 A380 Aircraft Build Process Front Fuselage MCA S 11/12 S 13 MCA in St. Nazaire Components from Meaulte and Industrial Partners. S 11/12 S 13 MCA in Hamburg Fuselage Shells from Nordenham. Parts, Components from Bremen, Varel, and Industrial Partners. Fwd Fuselage MCA MCA in St. Nazaire Delivery to FAL. A380 Aircraft Build Process Aft Fuselage MCA + Aft Fuselage MCA MCA in Hamburg Shells from Nordenham. Components, Parts from Getafe, Stade, Varel, Bremen, and Industrial Partners.

8 252 A380 Components delivered to FAL A380 Aircraft Build Process The Final Assembly Line - Toulouse Station 37 HTP Equipping Station 41/40 Structural Assembly Station 45 Wing Equipping Station 31/30 Structural Completion / Equipment Installation / System-Testing Station 18 Outside Tests Station 15 Production Flights TLS HAM

9 253 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 A380 New Technologies Examples: Completely new cabin concept CFRP tailplane CFRP pressure bulkhead with the most advanced communication and entertainment systems New materials (e.g. GLARE) Wing aerodynamics (based on 3-D design) Engines: reduced noise emission and fuel consumption Optimized mechanical, hydraulic and electrical systems New production processes (e.g. LASER beam welding) Cockpit (optimized man-machine interface)

10 254 Huge scope for customisation More opportunities than ever before to define and reinforce brand First Class Ceilings Forward stairs Rear stairs Lighting customisation A380 Upper Deck, Economy Class - white light

11 255 The Cabin an important differentiator A : Upper Class Bar A380 mock-up: First Class Bar A : First class A380 mock-up: First Class A : Executive Eco. Bar A380 mock-up: Premium Class Bar A380 An All New Cockpit

12 256 Specific A380 challenges Completely new design (i.e. not a variant like e.g. from the A to the A /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 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

13 257 Electrics - Key Elements of the Process SYSTEM DEFINITION PD ELECTRICAL PRE-DESIGN ELECTRICAL DESIGN WD CONFIGURATION MANAGEMENT ELECTRICAL INSTALLATION DESIGN 3D DMU WIRES DATABASE HARNESS DATABASE Manufacturing S/C management Installation The Specific Role of Electrics Non-specific design work CCC FDE CA Fuel PCS LGS PRO APU FAF Flight Test ELECTRIC PROCESS THE HINGE BETWEEN TWO WORLDS Flt Test CCC FAL NCF Pylon FAF Wing HTP VTP Specific design work

14 258 Some General Figures on A380 Electrics Links (connections) Principle Diagrams Wiring Diagrams Number of Harnesses Total Harness Length 107, km Electrical harnesses A380 nose section The Positioning COE Electrics the CoE in the organisation created to steer the global electric process COE Sec. COE Systems & Cabin COE Elec Sec. COE Sec. Synchronisation & Harmonisation: Configuration Control for Electrics Consolidated electrics planning FAL COE Sec. Process and too harmonisation

15 259 CoE Electrics Perimeter Organisation follows the electrical process The data flow from definition to harness installation is ensured by the CoE Electrics Pull / Push Principle CABIN SYSTEMS SYSTEMS COE Section COE Section COE Section Section COEs SWRD PD DMU 929 Manuf. Inst. Referentiel FAL COE L WD DB TL Activity Overview Hamburg 300 FTE Filton 150 FTE Design Office (SA, LR, A380) Harness Manufacturing (SA) Harness manufacturing Design Office (all programmes) Programme management (SA) Bremen 90 FTE Filton Bremen Hamburg Design office (A400M) LR harness manufacturing Toulouse Toulouse 500 FTE Central Functions Getafe 35 FTE Installation Focal Point HTP harness manufacturing Madrid Status: 12/2005 only Airbus internal FTE (functional and operational reporting) Design Office (all programmes) Programme management (LR, WB, A380, A400M) Harness manufacturing (all programmes) Cockpit panels, avionic racks, power centres

16 260 Main Deliverables Electrical Harnesses Power Centres Avionic Racks Cockpit Panels Key figures on TL deliverables 75-80% of the activity (engineering + manufacturing) is outsourced RC cost of shipset is from 0.6 to 2.9 M$

17 261 Immediate Measures Implemented On The A380 Deployment of a specific organisation Creation of the FAF Plateau at the Harburg Channel (approx 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 Supply Chain Developments And Trends M$ M$ Total Harnesses Total VUs Latelec Labinal Fokker Elmo Other Single Aisle Long Range A380 Wide Body

18 262 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 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

19 Dreamliner 787 Dreamliner

20 Dreamliner Boeing On The 787 A Radical New Approach Pre Functional design WD Drawings Pre 3D design Detailed 3D design Harness Inst Drwg Set 928 Harness Dwg. Set 929 Harness Manuf. Leader ship Boeing airframer TLE airframer airframer airframer airframer airframer Boeing Boeing Supplier A airframer airframer Airframer + Capacity Subcontractors RSP resources

21 265 New Trends in Aircraft Electrics More Electrical A/C More Composite 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 More Industrial Flexibility and Modularity New installation concepts Customised electronic bays & panels Standard harnesses ( eg flat cables, ) Advanced pre-sizing assessment More Electronic A/C New components More electronic on power circuits High voltage capabilities New technologies require new processes and skills Metallic 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

22 266 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 Our next programmes A350 and A400M A350 The Airbus answer to the 787 All new cabin New high bypass engines Passive and active load alleviation New HTP Wing drag improvements Rear fuselage Al-Li CFRP outer wing box Full titanium pylon Centre wing box in CFRP Optimised fuselage design (Al-Li)

23 267 A400M A400M Length 42.2 m; wing span 42.4 m Max. take-off weight 130 t Speed Mach The A400M largely profits from the accumulated Airbus knowhow! A400M New Technologies Centralized maintenance data system Aerodynamic design, optimized for different mission criteria Advanced but proven materials technology Wings and tailplanes manufactured from CFRP Flight control in fly-by-wire technology; based on Airbus experience Navigation system for groundindependent all-weather/ night and day missions Large cargo compartment with robust and self-contained loading system Modern turboprop engine for high airspeeds Proven system and components of high reliability The A400M largely profits from the accumulated Airbus knowhow!

24 268 A400M Same complexity as A380 on less space A400M

25 269 AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. 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 a third 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 not shown, 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.