MANUTENO

AERONUTICA

MANUTENO AERONUTICA

AREA DEPARTAMENTAL DE ENGENHARIA MECNICA

SECO DE ENG INDUSTRIAL E MANUTENO

Pedro Miguel Rodrigues da Costa

(email:[email protected])

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MANUTENO AERONUTICA????

Mestrado em Engenharia Mecnica (Perfil de Manuteno e Produo)

Manuteno Aeronutica ( 3 horas/5 ECTS)

1 Ano; 2 Semestre; Opo II

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A new airplane for a new world

BREAKTHROUGH BUSINESS
STRATEGIES for Airlines

A NEW ERA for Passengers

NEW LEADERSHIP
OPPORTUNITIES for the
Environment
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Partners across the globe are bringing the 787 together

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Structures progress

Boeing
Vought Latecoere FHI
Spirit Alenia KHI
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Fuselage & Interiors Progress

Section 41- Spirit

LU 2 in NDI
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Alenia Aeronautica:
First 787 fuselage sections delivered
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New technologies enable breakthrough business strategies

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Innovative systems technologies:A platform for the future

Advanced
Common Core Open Enabling Cabin Plug & Play IFE
Flight Controls
Systems Architecture Architecture

Enhanced
e-Enabled
Flight Deck
Systems

More Electric
Systems Architecture
Fuel Tank Integrated Health
Electric Brakes Inerting System Management
5,000 PSI Hydraulics
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787 more-electric architecture

provides greater operator value
Benefits:

3% fuel savings 35% less

engine power
2% airplane maintenance Pneumatic
extraction
required
& Electric
cost improvement

Lower airplane weight More

Electric
Improved reliability
Conventional 787
Improved monitoring
design
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No-bleed / more electric architecture

Starter / generator benefits
Variable Frequency -Starter Generator
-

No Constant Speed Drive

No Frequency Converter
No Pneumatic Start Motor
MTBF 30,000 FH
300% improvement vs. 767 IDG
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No-bleed architecture improves APU reliability

Typical Pneumatic APU Installation
Load Compressor

Inlet Guide Vanes

and Actuator

Surge Control Valve

Bleed Ducting
More Electric APU
Bleed Air Sensors
FWD
33% Reliability
Increase from 777

Eliminated on 787
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Longer scheduled maintenance intervals
The 787s use of advanced composites means longer intervals between
maintenance checks and less time in the hangar
A330 767
current current 787
intervals intervals intervals
A-Check interval 600 hours 500 hours 1,000 hours
36 months
C-Check interval 18 months 18 months
6,000 cycles
(elapsed time) (7 days) (7 days)
(5 days)

D-Check interval 5/6 years 6 years 12 years

24,000 cycles
(elapsed time) (22 days) (20 days) (15 days)
Note: Target for 787 systems tasks is 12,000 hrs. The tasks which will not make it to 36 months C-Check interval ( or if utilization
is > 4,000 Fhrs/Year) are designed to be accomplished during A-Check or overnight maintenance. This will ensure that the first
extended grounding does not occur earlier than 3 years and the airplane remains available for revenue service.
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New systems and materials enable fewer

days out of service for maintenance
20% reduction in scheduled content per maintenance check

60% fewer life-cycle scheduled maintenance hours

Metallic
787
airframe

Average out-of-service
days per year for 2.3 5.3 - 6.8
scheduled maintenance

60% reduction
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Designed for low maintenance costs Less maintenance.less often

Low airframe maintenance cost;Less time in the hangar
More time in the air
Less scheduled maintenance

Composite structure
Longer Check Intervals Fewer maintenance tasks
Resists fatigue; Resists corrosion
Twice as long as the 767 Less inspections with composite structures
30% Fewer tasks

Less unscheduled maintenance

More reliable systems ;Designed for low More durable structure: Health monitoring:
lifecycle costs;No pneumatic system
Less accidental damage; Easy to System monitoring; Engine monitoring
inspect; Quick repair techniques
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Combining the best in Airbus cockpit philosophy

Six large (15) identical & interchangeable displays

Future Ready for efficient navigation systems Page 19
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Global structure and systems testing pyramids for

maturity at Entry Into Service

More demonstrators and integration tests

Methods & tools validation
Develop manufacturing processes
Maturity at Entry into Service

Design for low cost Maintence

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A350 XWB suppliers selected All key partners on board
Aero-structure, systems, cabin equipment
ADAMS RITE: Cockpit Door Module MESSIER BUGATTI: Landing Gear System, Wheels & Brakes
AERNNOVA: HTP Box & Elevator MESSIER DOWTY: MLG
AEROLIA: S11-12 MONOGRAM: GAINs
ALESTIS: Section 19.1, Belly Fairing MOOG: Primary FC Actuators / Flap Actuation System
AOA/LGG: Water Waste / Heating System PACIFIC SCIENTIFIC: Cargo Fire Extinguisher
AMSAFE BRIDPORT: Cargo Nets PARKER: Hydraulics, Fuel & Inerting
ARIES: VTP Box PREMIUM AEROTEC: S13-14/S16-18 side shells
BELAIRBUS: LED RATIER FIGEAC: Side Stick
B/E AEROSPACE: Oxygen system / Galleys / Gains ROCKWELL COLLINS: AFDX, THSA, DRA/MMR, GWP
CCA: Pylon Panels Communication, NavAids, FSA-NG ASF, OWC
the
COMPOSITE INDUSTRIES: Cockpit Furnishing same processes, same tools and the RUAG: Wingtip
SABCA: Flap Support Structure
DAHER: Air Inlet Outer Surface
same way of working for all involved SAFT: Batteries
DIEHL AIR CABIN: Airducts, Core illumination,
SAGEM: FSA-NG gateway, CDAU/ACMS,
Floor2Floor, Crew Rest Compartments
partners
DIEHL AEROSPACE: Slat/Flap Control Computer / DSCS Throttle Control Assembly
SAINT GOBAIN SULLY: Cockpit Windows
EADS-SOCATA: MLGD
SIEMENS: Smoke Detection System
GE Aviation: Trailing Edge Details/Trailing
SIRIOPANEL: ICP, Cockpit Lighting
Edge Secondary Structure SOGERMA: MLGB, Cockpit Seats
GKN: FTE Assembly
SPIRIT: Section 15 Upper Shell & FLS, Fixed
GOODRICH: Probes, Ice Detectors, Wheels &
Leading Edge & Front Spar
Brakes, External Video Systems TAI: Ailerons
HAMILTON SUNDSTRAND: Electrical Power Generation, RAT
TELAIR: Cargo Loading System
HONEYWELL: Air Systems, APU, FMS, AESS
THALES: IMA / Inertial System, Cockpit Display
IPECO: GAINs
KAI: Midbox Ribs & Diaphragms System, HUD/OANS, Power Conversion, Remote
KID SYSTEM: Cabin Video and Cockpit Door Data Concentrator,
TRIUMPH: Cargo ISIS,
DoorFlight Control
Actuation Unit
System
Surveillance System VISION SYSTEMS: Sun Visors, Roller Blinds
LABINAL: Harnesses S11-15/21 & 16/19 ZODIAC - ECE: EPDS, Ext. Lights, Wipers
LATELEC: Racks 11-12 ZODIAC - INTERTECHNIQUE: Anti-ice Protection
L3COM: Digital Flight Data Recorders
System, Engine Interface Function
LIEBHERR: NLG, Slat Actuation System ZODIAC AIR CRUISERS: Evacuation Slides
MEGGITT: Fire Detection System ZODIAC C&D: Lavatories
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A350 XWB Extended Enterprise Partners

(2)

(1)

All A350XWB major partners

committed to Extended Enterprise
collaborative model
Harmonized planning
Harmonized Product Lifecycle Management

COMPOSITE INDUSTRIE
October 2010
S.A.
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A350 XWB Industrial set up

Broughton

Wing
Hamburg Aft Fuselage
Bremen & Stade
& VTP

Saint Nazaire / Nantes

Forward & Centre
Fuselage Toulouse
Getafe &
Illescas
Pylon & Nacelle

Horizontal Tail
Final Assembly Line
Plane (HTP)
(FAL)
A350 XWB sub-assembly & final assembly in Airbus sites
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A350 XWB Family Features Leading cabin comfort:

Intelligent airframe: -wide cross section
-extensive use of carbon composite -Wide windows Advanced engines:
and advanced material
-Provision for spacious overhead -fuel efficiency
-The right material at the right place flight and cabin crew rests
-Low maintenance cost
-Improved cabin atmosphere
-Low environmental
impact
Large Cargo Holds

Advanced wing design: Advanced Cockpit

-Advanced aerodynamics
-Adaptive high lift device Systems: A380 and beyond
-Structure optimized for each variant -2 hydraulic / 2 Electric flight
controls
Easy cabin configuration: -Integrated modular avionics
-optimized seat rails
-Quick fasteners
-Innovative modular customization
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A350 XWB Intelligent Airframe Wing

Empennage
Hybrid fuselage

Frames, ribs, floor beams, gear bays,..

Belly fairing
Landing gears, pylons, attachments

Misc.
A350-900 XWB Al/Al-Li
7%
Material Breakdown (%) 20%
Including Landing Gear

7% Steel

Composite
52% 14%
Titanium

A350 XWB puts the right material in the right place

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A350 Maintenance Philosophy

Airframe DMC per Trip
A380 advanced technology systems

Intelligent material selection A350-900 777-300ER

Datum

New maintenance programme -10%

Smart Cabin maintenance -20%

Air+: tailor-made maintenance -30%

by Airbus
-40%

-50% -45%
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A New Maintenance Concept

Line Visit every 4/6 months
Economy
Only technical servicing between Line Visits

Base Visit at 36 months

Flexibility Structures Visit at 12 years

No Maintenance before 10 days

Minimized task elapsed time

Minimized necessity of specific GSE

Minimized demand for highly qualified personnel

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A New Maintenance Concept

Efficiency & Remote access to On-Board Maintenance Functions

Efficient troubleshooting: one failure one message

Simplicity
Real-time monitoring of aircraft technical status with Airman evolution

The revolutionary
approach to availability
and cost efficiency
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A new maintenance concept

Economy
The revolutionary
approach to availability
Less maintenance, less time on ground, and cost efficiency
more time in revenue service
Flexibility

Timetable friendly maintenance,

supporting all customers operating
needs
Simplicity & efficiency
Less skills and less specific GSE

Designed for higher availability

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Maintenance Economy
No Maintenance below 10 days interval
Non Disruptive
Only technical servicing up to Line Visit
Maintenance
Line Visit every 4/6 months
Base Visit at 36 months
Structures Visit at 12 years

Line Visit
Base Visit
Structures Visit

EIS 3 YR 6 YR 9 YR 12 YR

Less time in the hangar, more time in service

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A380 technology and beyond

Structural for lower maintenance cost
health Integrated
monitoring* Modular
On-condition Avionics
maintenance Common hardware
Better monitoring Ethernet technology
and less downtime
Hydraulics Flexibility for
Electrical flight Only 2 circuits, 3000 psi
reconfiguration
actuation
Maintenance-free
Superior accumulators Brakes
redundancy Electrical
Increased actuation
operational
capability

Cabin systems Electrical system

Wireless cabin Variable frequency
maintenance Onboard Maintenance
E-Flight g New Interactive
Quick maintenance
re-configuration and cockpit server
E-Logbook,
digital circuit breakers
*Study item
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Maintenance Cost: A350-900 XWB

Maintenance Cost per Trip Maintenance Cost per Seat
Old A359 A359 XWB Old A359 A359 XWB
0% 0%
Datum Datum

-6.5%
-7.6%
-5% -5%

-10% -10%

A totally new design:

new cabin - new wing - new materials

new systems - new engines
Assumptions:
Study based on Lisbon - Sao Paulo route: 4,496 nm. 95 kg for all class pax. Max Volumetric
Old A350-900 - 2 class layout with 311 seats (36 B / 275 Y) with 15.6t of cargo: total Payload = 45.1t
A350-900 XWB - 2 class layout 8-abreast with 315 seats (36 B / 279 Y) and 18.5t of cargo: total Payload = 48.4t
TAP profile, Typical International, ISA +10. 85% annual winds.
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BREVE REVISO DE CONCEITOS GERAIS SOBRE MANUTENO

1 Gerao 2 Gerao 3 Gerao 4 Gerao

Protagonista: Operador Protagonista:

Protagonista: Engenherio de Protagonista: O Fabricante
Especialista de
Objectivo:Reparar a Manuteno
Manuteno Objectivo: Menos Manuteno
avaria Objectivo:Controlar o
Objectivo:Aumentar a Investimentos na Manuteno
equipamento
disponibilidade
Gesto Global
Monitorizao de condio
Equipas Multi tcnicas e grupos de
Design para fiabilidade e
trabalho
Manutibilidade
Benchmarking
Estudo de analise de risco
ndices de eficincia
Computadores pequenos e rpidos
Revises programadas
Segurana/Ambiente/Ecologia
Anlise dos modos e efeitos das
Sistemas de planeamento e
avarias Subcontratao
controlo dos trabalhos
Reparar
Equipas de trabalho polivalentes Outsorcing
quando Computadores grandes e
partir lentos Expert systems Sistemas de Manuteno Integrada
..1950 1960/1970 1980/1990 2000....
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BREVE REVISO DE CONCEITOS GERAIS SOBRE MANUTENO

Referncia :Condition Based Maintenance (CBM)/By- S.K.Sethiya/Secy.toCME/WCR/JBP

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BREVE REVISO DE CONCEITOS GERAIS SOBRE MANUTENO

DEFINIO DE MANUTENO:

NF X 60-010 - Conjunto de aces que permitem manter ou repor um bem num estado
especificado ou em condies de assegurar um servio determinado.

BS 3811 A - Combinao de aces realizadas para manter um bem ou rep-lo numa condio
aceitvel.

NP (EN) 13306 - Combinao de todas as aces tcnicas, administrativas e de gesto, durante o

ciclo de vida de um bem, destinadas a mant-lo ou rep-lo num estado em que ele pode
desempenhar a funo requerida.

Moubray (RCM II) - Those actions required for ensuring that physical assets continue to do what
their users want them to do.

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Typical Airline - Those actions required for restoring or maintaining an item in a serviceable
condition, including servicing, repair, modification, overhaul, inspection and determination of
condition.

FAA - Inspection, overhaul, repair, preservation, and replacement of parts.

Kinnison - Process of ensuring that a system continually performs its intended function at its
designed-in level of reliability and safety.

E porque no?... - Conjunto de aces que asseguram, durante o ciclo de vida de um dado
bem, que o mesmo desempenhe a funo requerida aos nveis de segurana e fiabilidade
incorporados no seu projecto ( Fiabilidade inerente, ou intrnseca, ou previsional, ou sada
da fbrica)

Notar a nfase na fiabilidade! Uma coisa manter a funo e outra manter a

funo com um dado grau de garantia de continuidade!

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CLASSIFICAO DA MANUTENO / MTODOS DE MANUTENO

MANUTENO

MANUTENO
MANUTENO MANUTENO

MTODOS DE
PREVENTIVA CORRECTIVA

CONDICIONAL
SISTEMTICA
OU PREDITIVA

PARMETROS QUE
AVARIA

OPERAES DE
MANUTENO
ORIGINAM AS
ESTADO DO AVARIA AVARIA
PRAZO
EQUIPAMENTO PARCIAL COMPLETA

OPERAES DE
MANUTENO
INSPECO REPARAO REPARAO
CONTROLO PROVISRIA OU DEFINITIVA OU
PALIATIVA OU CURATIVA
VISITA
DESEMPANAGEM

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CLASSIFICAO DA MANUTENO / MTODOS DE MANUTENO (cont.)

MTODO DE MANUTENO

NO MAINT.
PROGRAMADA NO-PROGRAMADA
PROGRAM!

PROACTIVA REACTIVA REACTIVA

PREVENTIVA CORRECTIVA CORRECTIVA

SISTEMTICA CONDICIONAL

FUNO DO FUNO DO FUNO DA FUNO DA

TEMPO ESTADO AVARIA AVARIA

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CLASSIFICAO DA MANUTENO / MTODOS DE MANUTENO (cont.)

MANUTENO DE MELHORIA, MTODO DE MANUTENO

MODIFICAO:
- Do Projecto (desenho,
PROGRAMADA NO-PROGRAMADA
material, tecnologia, )
- Do Progr. Manut. (tarefa,
intervalo, tecnologia, ) PROACTIVA REACTIVA REACTIVA

PREVENTIVA CORRECTIVA CORRECTIVA

SISTEMTICA CONDICIONAL

A Man. Melhoria, de especial relevncia na MAe, tem normalmente uma origem REACTIVA.
Aprende-se com a avaria ( => REACTIVA) e emenda-se para prevenir a avaria ( => PROACTIVA).
A Man. Correctiva pode ento, na Man. Melhoria, assumir o carcter PROACTIVO, e ser ainda
Programada, ou no, consoante o interesse (Segurana? Econmico?).
No caso de Modif., normalmente Programada, e para aplicao uma vez ( one time).

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CLASSIFICAO DA MANUTENO no mbito do TIPO DO MATERIAL DE VOO

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MANUTENO DE AVIO LINHA, BASE

A Manuteno de Linha engloba os trabalhos sobre a Aeronave que podem normalmente ser
executados ao ar livre (na Linha). Em caso de necessidade (muito frio, por exemplo) os
trabalhos podero ser executados dentro de um hangar.

Em Manuteno de Linha so
habitualmente realizados trabalhos
sobre a Aeronave do tipo:
Transit Check: T, T1, T2

Correco de Anomalias

Substituio de Unidades LRU

(Line Replaceable Units)

Troubleshooting (deteco e
caracterizao de avarias)

Etc.
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MANUTENO DE AVIO LINHA, BASE

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MANUTENO DE AVIO LINHA, BASE

A Manuteno de Base engloba os trabalhos sobre a Aeronave que necessitam normalmente
de docagem e que devem ser efectuados dentro de instalaes apropriadas (Hangar) de
modo a garantir as condies de segurana, qualidade e aeronavegabilidade adequadas.
Em Manuteno de Base so habitualmente
realizados trabalhos sobre a Aeronave do
tipo:-VTs: vrios trabalhos
A-Check

B-Check

C-Check

D-Check

Inspeco e Reparao Estrutural

Pintura

Modificaes

Substituio de Motores

Etc.
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MANUTENO DE AVIO LINHA, BASE

Para a realizao de Manuteno de Base (e tambm

Manuteno de Motores e de Componentes) so
habitualmente exigidos pelas Autoridades Aeronuticas s
MROs requisitos especficos alargados, tais como:
Instalaes adequadas

Equipamentos adequados

Ferramentas gerais

Ferramentas especiais para o trabalho a efectuar

Manuais de manuteno (documentao tcnica aprovada)

Recursos humanos formados e qualificado

Documentos de trabalho;

Normas e procedimentos escritos

Etc.
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MANUTENO DE AVIO LINHA, BASE

Exemplo de Base Maintenance

Oficina de Armazns Laboratrios

Material HANGAR
Limpeza Removido
Manuteno de
Oficina de Componentes
Estruturas Material Logstica Manuteno de
Oficina de em
e Gesto Motores
Inspeco
Compsitos de Rotveis
Oficina de
Mquinas Material
Fornecedores
Tratamentos til
Material Fabricantes Reparadores
Trmicos
Rejeitado Especializados
Tratamentos Interior de Clientes
Armazns
Electrolticos Cabines
Consignao
Oficina de Equipamento Oficina de
Para Abate
Pintura Emergncia Rodas Pooling
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MANUTENO DE AVIO LINHA, BASE

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New generation fuel efficient engines

93Klbs
84Klbs

Trent XWB 75 / 79Klbs

A350-800 A350-900 A350-1000

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-118 diameter fan selected as optimum performance / noise solution

Fan Compressor de Baixa

Veios (PVLs)

Cmara de Combusto

Compressor de Alta
Turbina de Alta

Turbina de Baixa

Fonte: GE, GEnx para A350

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Os Motores so dos sistemas mais complexos do avio.

Para um Motor de reaco de high-bypass, tpico de um avio wide body moderno:

O impulso de cada Motor em take-off pode exceder 50 toneladas.

A fora centrfuga em cada Fan Blade em take-off pode atingir 100

toneladas.

A temperatura do ar de descarga do Compressor de Alta Presso

pode atingir 680 C, temperatura suficientemente para fundir
Alumnio.

A presso mxima dentro do Motor atinge 30 atmosferas.

A temperatura mxima da chama na Cmara de Combusto pode

atingir 2300 C.

Cada p da Turbina de Alta Presso desenvolve uma potncia de

900 hp.

O preo de aquisio de um Motor novo pode exceder 10 milhes

de Euros.
Fonte: Rolls Royce
Uma shop visit pode exceder 1.5 milhes de Euros.
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MANUTENO OFICINAL (DE MOTORES)

A Manuteno de Motores engloba os trabalhos sobre o Motor aps a sua remoo da
Aeronave e habitualmente dentro de uma Oficina apropriada (Oficina de Motores). O Motor
pode sofrer graus de desmontagem de variada complexidade, dependendo do Workscope a
cumprir. Em Manuteno de Motores so
habitualmente realizados trabalhos sobre o
Motor do tipo:
Ensaio de Troubleshooting

Substituio de Unidades;Manuteno Modular

Substituio de PVLs (Peas de Vida Limitada)

Heavy Maintenance (HM)

Reparao

Overhaul

Ensaio de Aceitao

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Exemplo de Oficina de Motores

(Circuitos tpicos)
Sala de
Preparao e
Banco de
Expedio
Limpeza Ensaio
Tratamentos
Deteco de Plasma Spray
Shot Peening Trmicos
Desmontagem Fendas Soldadura Sala de
e Montagem Inspeco Rolamentos
de Motores Desmontagem Pintura
Inspeco de Reparao
Desmontagem Material
Compsitos
e Montagem
Overhaul de Accessory
de
Inspeco de QECs e Thrust
Subconjuntos Gearboxes
Recepo Reversers
Recepo de Recepo e Gesto de Electricidade
Preparao
Motores Expedio de Materiais e
Parts Pool Provisioning
Material Subcontratos
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Exemplo de Oficina de Motores

(Circuitos tpicos)
Manuteno de
Banco de Ensaio Componentes
Manuteno de
Tratamentos Sala de Preparao Avies
Laboratrios e
Trmicos
Armazns
Oficina de Mquinas Oficina de Motores
Reparadores
Tratamentos de
Especializados
Superfcie Fabricantes Armazns
Fornecedores Consignao
Clientes Pooling
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MANUTENO OFICINAL (DE MOTORES)

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MANUTENO OFICINAL (DE COMPONENTES)

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MANUTENO OFICINAL (DE COMPONENTES)

A Manuteno de Componentes engloba os trabalhos sobre os Componentes (Unidades,

Acessrios, Etc.) da Aeronave e do Motor aps a sua remoo e habitualmente dentro de
uma Oficina apropriada (Oficina de Componentes). dependendo do tipo de instalaes e da
Organizao o seu funcionamento, poder ser por especializao :
Componentes Mecnicos

Componentes Hidrulicos

Componentes Pneumticos

Componentes Elctricos

Componnetes Electrnicos (Avinicos)

Em Manuteno de Componentes so habitualmente

realizados tarefas de manuteno sobre componentes
designadas por :Inspeco Visual; Bench Check (teste)

Reparao;Overhaul, etc
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Exemplo de Oficina de Componentes

(Circuitos tpicos) Oficina de

Componentes Manuteno de

Mecnicos
Avies
Manuteno de
Hidrulicos
Oficina de Mquinas Motores
Pneumticos

Tratamentos de Elctricos
Laboratrios e

Superfcie Avinicos Armazns

Emergncia
Reparadores
Especializados
Fabricantes Armazns
Fornecedores Consignao
Clientes Pooling
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 MANUTENO
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Familiarizao a Manuteno Aeronutica

Visita virtual a uma

Organizao de Manuteno (OM), ou

Maintenance & Engineering (M&E), ou

Maintenance, Repair and Overhaul (MRO)

TAP Maintenance &

Engineering

SABENA TECHNICS

FL TECHNICS

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