Meeting Component Reliability Demands of the Aerospace Industry ...

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NPI process: Phase and Gate Process to achieve ReliabilityIdentify Product RequirementsCustomer Spec., Agency SpecsTranslate to to Technical Requirements& Flowdown to to ComponentsDesign Specification, QFD, Risk Assessment -> Key RequirementsFlowdown, Component Specifications, Validation PlansDesign Product, Assess AgainstTargets & Make TradesFMEA, PFMEA, Lessons Learned, Design Practices, DFSS,Maintainability AnalysisValidate Customer & AirworthinessRequirements are satisfiedDesign Review, Substantiation, Testing andManufacturing CapabilityFRACAS (Failure Reporting, Analysis and CorrectiveAction System)Problem Problem Tracking Trackingand and Resolution ResolutionAchieve Type Design Certificationand Production Readiness© Avio SpA - 2009Continued AirworthinessFailure, Malfunction & Defect Mangement,Engineering Change, Service BulletinMonitor Field Performance to to AssureCustomer Requirements are satisfiedObserved Reliability, Weibull, IFSD, MTBUROct. 6th, 2009 10
Gearbox Reliability Data and Maintenance ApproachGearbox Mean Time Between Unscheduled Removal(MTBUR) vs. Average Time On Wing (TOW)(Typical)MTBUR [per Million Flight Hours]2.01.51.00.5Corresponds to a singlePGB UnscheduledRemoval every more than200 years (yearly usagerate about 2000 hours)Turboprop PGB10Aeroengine AccessoryDrive Train20 30Gearbox TOW [per Thousands Flight Hours]Accessory Drive Train Reliability betterthan PGB for several reasons, e.g. lowertorque density, different usage spectrum,..Corresponds to a singleGearbox UnscheduledRemoval every more than1000 years (yearly usage rateabout 2000 hours)Typical Maintenance approach:• On Condition• Condition Monitoring:• Oil Content• Oil Debris Monitoring• Oil Filter Blockage• Oil Feed Pressure andTemperature• Higher failure rate components areallowed to be replaced On Wing (e.g.accessories, dynamic seals….)• Line Replaceable Units (LRUs)© Avio SpA - 2009Oct. 6th, 2009 11
Page 7 and 8: Latest Development - TP400 D6 Power
Page 12: Characteristics of Our GearboxesArc
Page 19 and 20: High Load Capacity Bearings - Integ
Page 21 and 22: Health Monitoring for Transmission
Page 23: Acronyms• Block Test or Type Test

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