waea single focus workshop – atlanta, february 17/18, 2000 a/c manufacturer initiative for...

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000

A/C manufacturer initiative for Seat/IFE Integration Improvement

AIRAIRCRAFT MANUFACTURERCRAFT MANUFACTURER INITIATIVE INITIATIVE FOR SEAT/IFE INTEGRATION FOR SEAT/IFE INTEGRATION IMPROVEMENTIMPROVEMENT

AIRAIRCRAFT MANUFACTURERCRAFT MANUFACTURER INITIATIVE INITIATIVE FOR SEAT/IFE INTEGRATION FOR SEAT/IFE INTEGRATION IMPROVEMENTIMPROVEMENT

WAEA Single Focus WAEA Single Focus WorkshopWorkshop

Atlanta, Atlanta, FebruaryFebruary 17/18, 2000 17/18, 2000

WAEA Single Focus WAEA Single Focus WorkshopWorkshop

Atlanta, Atlanta, FebruaryFebruary 17/18, 2000 17/18, 2000

Compiled by

Thorsten Steinlicht Roland L. SchaferDaimlerChrysler Aerospace Airbus The Boeing Company



CONTENTS:

• Introduction• Current Status of Seat/IFE Integration• OEM Actions for Integration Improvements • Requirements for Electrical Installation Drawings• General Installation Requirements• Cable Installation and Protection Means• Required Actions for A/C manufacturers to improve Electrical Installations• Required Actions for Seat Vendors to improve Electrical Installations• Required Actions for IFE Vendors to improve Electrical Installations• Required Actions for Airlines to improve Electrical Installations



Introduction

Due to the steadily increasing amount of electrical equipment to be integratedinto passenger seats, the OEMs started initiatives to help the Seat Suppliersto understand their specific requirements.

Looking at the high number of queries raised at First Article Inspections,Final Assembly Lines and In-Service, it has to be concluded that the industrialrequirements for electrical installations, given in the existing documents, arenot detailed enough and that the Seat Suppliers should have more supportof the OEMs.

Therefore the OEMs appreciate and fully support the intention of this WAEAWorkshop. We hope to achieve a better understanding of the Seat/IFE Integration „challenges“ in order to transform them into „tasks“ and later into„solutions“.



Yesterday


–


Global multimediacommunication Internet

Direct

TV

PC power/Modem Video/…on demand VCC

Gaming/Gambling

Passenger Services

Music/…on demand

Seat electronics

In-seat telephone

Reservations

Shopping

Today



Current Status of Seat/IFE Integration

• Unclear definition of how to integrate electrical components into seats due to a lack of specific industry guidelines

• Electrical installations are not sufficiently taken into account during basic seat design

• Incomplete electrical installation drawings

• LRUs are difficult to remove

Resulting from an intensified cooperation between A/C manufacturers andSeat/IFE Vendors in 1999, the following main items have been identified asregular points of discussion:

• Excessive cable length, coiled up inside the seat, leading to cable failure

• Covers and shrouds are often not adequate

• Testing of IFE equipment sometimes not performed prior to shipping



OEM Actions for Integration Improvement

Improvement of the Requirement Documentation for Electrical Installations

Establishment of a „Single Point Of Contact“ for Seat and IFE Vendors

Workshops and Fora with Seat- and IFE-Vendors

Intensified Cooperation with other OEMs, ARINC and WAEA

Increased Personnel Capacity for Seat Integration Tasks



What are the first results of the improvement initiative?

There is a growing awareness about the importance of electrical installations

The IFE vendors released installation guides for their equipment

OEM‘s and IFE vendor‘s documents were reviewed and streamlined

Contribution to ARINC 628 Part 5 with general installation requirements for seats

Establishment of a catalogue of recommended standard cable installation parts

Introduction of a new type of open, textile conduit for cable protection

Process of continuous discussion and knowledge exchange has started



Requirements for Electrical Installation Drawings

•No systematic installation principle can be realized

•Cables are arbitrary attached to the structure just by a tie strap

•Inadequate protection means on wires and bundles

•Different cable installation on same seat models

•Installation quality depending on capability of worker only

•Trouble after delivery with regard to certification and documentation

If electrical equipment is installed in a seat without a detailed drawing,following consequences are usually stated:

Detailed Electrical Installation Drawings are required to achieve repeatabilityof seat build and an equal level of quality throughout the complete shipset.In addition, the seat suppliers should establish Process Specifications toassure application and verification of their drawings.



Electrical Installation Drawings should contain the following:

Position of all electrical in-seat components

Partnumber list of all electrical in-seat components

Front and side view of seat leg including cable routing and dimensions for STS-cable interface points

Position of all seat installation/protection accessories for electrical in-seat components (spacers, tie straps, cable ducts, conduits, clamps etc.)

List of all in-seat cables including both cable connection points

Views and designation of in-seat cable routing

Principle wiring diagram of all harnesses and boxes which are designed and manufactured under seat vendor responsibility



General Installation Requirements

• Installation of electrical units and boxes

– Mounting Requirements

Cable access

Connector access

Thermal performance

Seat mounting brackets– Cover

• Installation of electrical wiring and connectors

– Wiring

Clearances

Bend radius

Slack in wiring

Drip loops

Protection of wiring

– Fixing of cables and wire bundles

Cable ducts, clamps, supports, brackets

Fixing of coaxial cable

Tie-up of cable bundles

Wire bundle separation

Plastic tie straps

Rework and modification

• Terminations and connectors

– Bending of terminals– Connector installation and stowage

• Protection against magnetic fields

In order to help seat suppliers to meet design requirements of A/C manufacturers,Vendors and ARINC, all specifications and guides should agree on following items:



In order to achieve a safe cable routing, two basic requirements have to be respected:

– Cable bundles shall never be fixed directly to the structure. The use of cable ducts, clamps and brackets is recommended. When using tie straps, a spacer shall be mounted between structure and cable.

– Appropriate protection means are to be applied on the bundles in hazardous areas of movement, vibration, contamination etc.

Following page shows examples of how to attach cables to the seat structure. These figures have now been incorporated into ARINC 628 Part 5.



Cable Installation and Protection Means

The OEMs have commonly established a catalogue of protection sleeves,conduits, brackets, rub strips etc.

These means are approved with regard to fireworthiness and other requirements and shall allow the seat supplier to standardize electrical installations independantly from the A/C type.

The catalogue is now incorporated in the latest revision of ARINC 628 Part 5.

Any other parts deemed useful by Seat/IFE vendors for installation or protection of cables are appreciated and should be presented to the OEMs.If no objections with regard to specific requirements exist, the proposedpart will be added to the catalogue.



Required actions for A/C manufacturers to improve electrical installations

Encourage seat suppliers to develop mechanical provisions for cable routing

Attend ARINC andWAEA Meetings

Encourage IFE-equipmentstandardization

Accelerate process of seat-to-seat cable length definition

Monitor electrical installation definition process more closely

Attend and support Design Reviews

Support the Seat Suppliers during first installation for a new project and FAI

Check and comment test reportsand drawings prior to FAI

RequiredMandatory

Train and support Seat/OEMSuppliers

to understand airworthiness requirements

Successful First Article Inspection !



Required actions for Seat Suppliers to improve electrical installations

Take electrical installations into consideration before designing a new seat

Employ or educate specialistsfor electrical installations

Standardize IFE-equipm. provisions

Install mechanical provisions for cable routing inside the seats (cable ducts, clamping points etc.)

Establish detailed Electrical Installation Drawings and Process Specifications

Prepare efficient Design Reviews according to engineering requirements

Install electrical equipment according to your Drawings,OEM Specification and IFE Vendor Installation Guides

Minimize cable overlength (or its effects if unavoidable)

RequiredMandatory


Provide a fully representative prototypeseat for first installation and testing

Perform a cycle test for video armsincl. cabling (40.000 cycles minimum)

Recommended




Required actions for IFE Suppliers to improve electrical installations

Provide a full set of equipment drawings at the ITCM or soon after


Standardize IFE-equipment

Establish common definition exchange forms to ease the transfer of techical data

Help the Seat Vendors to define the in-seat cable lengths - come together early

Prepare efficient Design Reviews according to engineering requirements


Provide a seat tester allowing completetesting without equipment removal

RequiredMandatory

Train and support the Seat Suppliersto understand your requirements

Recommended




Required actions for Airlines to improve electrical installations

Purchase seats with new contracts that require the new standards to be met


Encourage IFE-equipmentstandardization

Inform OEM and Seat/IFE vendors about definition changes early

Attend and support Design Reviews


RequiredMandatory

Inform Seat/IFE/OEMSuppliersabout systematic in-service quality

deficiencies


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