Category: PRs

Bally Ribbon Mills Offers Prototype Development and Testing for Woven Webbings

Bally Ribbon Mills (BRM) is offering prototype development and testing critical for ensuring that a fabric can perform for a particular purpose and in specific environmental conditions.
At BRM, all projects are prototyped and tested for the application – whether BRM has off the shelf fabrics or develops a new fabric. Every inquiry goes through a process that includes a regimented data creation method. Extensive sampling is performed on everything woven, dyed, and finished. All information is entered into a vast database of test data linked to all manufacturing processes. Application experts draw from this information during the product development stage to pair products with customer needs.

The process begins with communication between the customer and BRM to understand the application. The customer may show drawings and BRM shares relevant test report information. Following the information gathering stage, BRM application experts begin by searching the company’s exhaustive materials database to determine if the customer can incorporate an existing off the shelf fabric into their development process. BRM sends customers several possible materials options, which the customer tests for actual application performance with regard to thickness, tensile strength, and the effects of UV or saltwater.

When the project cannot use an off the shelf item, BRM uses a rigorous regulated project planning control process for developing a new solution to meet the requirements. Weaving experts review all the specifications to gain a deep understanding of the environment the fabric will be used in, and the chemistry required. They then enter into a product development agreement for a particular application, which includes producing prototypes for detailed customer testing. In most cases, customers want prototypes to blow apart and model through observation rather than benchtop studies.

All applications are unique. They rarely fit into a neat box and it is simply not possible to predict the performance of any particular woven material for all applications. The BRM prototyping process is ideal for match up application performance requirements to a solution that meets established fiber performance and chemistry criteria.

JPB Système’s Smart Washer Technology Improves Efficiencies Across Helicopter Maintenance Operations

Airbus Helicopters is testing innovative and disruptive technology across its maintenance operations, leading to quantifiable efficiency gains. In some cases, this can lead to time reductions for certain activities from two days to just two hours.

The company is trialing JPB Système’s proof-of-concept Smart Washer solution, which is designed to improve efficiencies within maintenance, repair and operations by enabling touchless and wireless measurement of bolt axial load. Instead of the need to manually check the tightening torque level of traditional bolts within the helicopter, Smart Washer allows engineers to directly measure bolt tension in just a few seconds with no need for intervention on the bolted assembly.

According to Georges Devilliers, senior expert for Helicopter Maintenance at Airbus Helicopters, since trialling Smart Washer over several months, the company has identified the potential for significant efficiency improvements across helicopter maintenance activities. This is underscored by a more hassle-free process on the company’s helicopters.

An example is the periodic check of the tightening torque on the main gearbox suspension bar attachment – a procedure that first requires removal of the two engines, as well as the helicopter’s interior trim, before maintenance engineers can gain access and check the bolts. Once checked, the engine needs to be re-installed and a ground-run undertaken to ensure correct installation of the engines.

“Basically, this is a heavy maintenance operation that takes around two days and requires two engineers to check about 12 bolts,” explains Devilliers. “By comparison, using Smart Washer, the same task can be performed by just one engineer in about two hours; we don’t need to physically access the bolts to perform the checks, so there’s nothing to dismantle.”

Via its tests of Smart Washer, Airbus Helicopters believes that the device could monitor more accurately the tension in the bolted assemblies.

“To check proper tension of the bolts, we currently measure the tightening torque; this is very difficult and also very imprecise,” continues Devilliers. “Difficult, because you need access to the assembly, loosen it and then re-tighten it, which can introduce room for error in so far as the dismantling of parts to access the bolts, as well as the subsequent re-assembly. The issue of imprecision arises because of the dispersion of coefficient of friction between the nut and the bolt.”

As a result, when it comes to servicing, a substantial amount of time is required to undertake such checks, which for helicopters, can sometimes represent as much as 10% of the overall scheduled maintenance time.

For Airbus Helicopters’ customers, the speed at which such checks can be performed also helps to minimize helicopter immobilization, which drives further efficiencies. In such instances, Smart Washer technology has the potential to facilitate much easier, shorter and less costly procedures.

Big Data for a wider vision

For Airbus Helicopters, the attributes of Smart Washer have more far-reaching potential. Since the device can register tension, date, location, temperature as well as other parameters this data could feasibly be used to alert customers to the need to perform other maintenance procedures – be it immediate or just according to schedule.

“We’ll continue to work closely with JPB Système as they develop Smart Washer to see how it could be integrated with Airbus Helicopters and, perhaps even within the group as a whole,” continues Devilliers. “Importantly, it addresses our fundamental challenges insofar as the need to make maintenance operations safer, easier and less time-consuming, so for us, it’s definitely a box-ticker.”

Airbus Helicopters provides efficient civil and military helicopter solutions to customers in around 150 countries. From its head office and main facility in Marignane, near Marseille, in France, the company’s operations span an array of activities, including design, assembly, training, test flights and delivery.

Burnishing Process to Improve Fatigue Life of Metallic Components Reaches Production Milestone, Establishing itself as Validated Design and Repair Solution

One million critical components used in everything from aircraft engines and power turbines to nuclear waste containers and medical implants are safer and will last longer because of the metal burnishing process dreamt up by Lambda Technologies Group CEO and co-founder, Paul Prevéy during a family trip to Disney World more than 25 years ago.

Low Plasticity Burnishing, or LPB, is a patented mechanical process that applies pressure to the surface of metallic components using a custom-designed hydrostatic burnishing tool – a wheel or ball tool that rolls across the surface of a material to apply compressive stress. Prevéy came up with the idea after a happenstance look across the World Showcase Lagoon in which the Epcot ball appeared to be hovering atop the surface of the water.

In engineering, compressive stress (or residual compression) increases the fatigue strength and extends the life of components by mitigating crack propagation. Lambda developed LPB to impart a layer of deep, stable compression with an extremely high level of control.

The high level of control allows the beneficial compression to be applied in a single pass with no overlapping paths using conventional CNC machine tools. This high level of control is particularly important for the compression to remain stable in high temperatures, like jet engine blade applications. The single-cycle application also provides faster production times and lower operational costs.

LPB can sculpt designed levels of compression onto a component surface ranging from a few thousandths of an inch to over a full centimeter. Critical components processed by LPB, both at the company’s Cincinnati, Ohio manufacturing plant and in the field, include:

· Military and commercial aircraft components: fan blades, disks, vanes, IBRs/blisks, landing gear, structures, etc.

· Helicopter components

· Large and small armaments

· Fitness equipment

· Bicycles

· Large and small automotive components

· Medical implants

· Nuclear power components & waste containers

· Power turbine components

· Train components

· Mining equipment

· Oil drilling components surface/down hole

The increase in fatigue life combined with the reduction in out-of-service and inspection times from component failures have saved customers millions of dollars in operations and maintenance costs. LPB has received numerous certifications and accreditations over the years, and Lambda Technologies Group is an approved supplier for NAVAIR, Pratt & Whitney, Delta TechOps, and GE Aviation.

ASM Rebranding as JANA Engineering

JANA, Inc., an engineering and technical documentation services company, has announced the rebranding of Aircraft Systems and Manufacturing, Inc. (ASM) to JANA Engineering.

Ean Niland, president of JANA, Inc., states that the move is the last piece of the transition plan that began when JANA purchased ASM in 2017. “We are undertaking this rebranding effort to reflect the reality that ASM has grown to become an integral part of the JANA family, and its inclusion is an important step toward achieving the overall company goals that were established when JANA purchased ASM nearly five years ago.”

Under the new name, JANA Engineering will continue to serve the Aerospace industry as a whole, with emphasis on operators and commercial carriers, component OEMs, airframe OEMs, and MROs. As the world leader in advanced avionics integration, JANA Engineering is able to offer FAA Organization Designation Authorization (ODA) services, STC certifications, design and engineering for avionics integration, fabrication/assembly and kitting capabilities, and 24/7 AOG support.

As part of the transition, the company name, logo, and website will adopt the present JANA branding. The content from ASM’s website has been incorporated into the existing JANA site and can be found at janacorp.com/engineering. The company says these changes will not affect JANA Engineering’s ability to deliver top-notch customer service and solutions to clients and that their primary focus continues to be ensuring that all projects receive the highest level of attention and follow-through.

Air Industries Group Announces $7.4 Million Release for Commercial Jet Engine Components

Air Industries Group an integrated manufacturer of precision assemblies and components for leading aerospace and defense prime contractors, announced that it has received a $7.4 Million order for “Thrust Struts,” a critical component of the Geared Turbofan (“GTF”) Jet Engine. This release is part of a previously announced Long-Term Agreement (LTA).

“Military aviation products dominate Air Industries’ business. In terms of revenue, the Thrust Strut is our largest commercial aviation product,” said Lou Melluzzo, CEO of Air Industries. “The pandemic’s impact on air travel, and on the commercial aviation business, reduced demand for this product in 2020. This new release supports our sense that a rebound in commercial aviation is occurring sooner than expected. As a component of the Geared Turbofan Engine, our product is used on smaller airliners including the Embraer E2 and, most notably, the Airbus A-220, which has become increasingly popular with the Airline Operators.”

Bally Ribbon Mills Introduces New Series of Advanced Textile Products for Electronic Transmission Data

Bally Ribbon Mills announced its newest line of advanced textile products to increase part functionality and utility. As companies demand higher durability and product differentiation, BRM has developed  its E-WEBBINGS and TPCM thermoplastic materials. Both products offer multiple features, including lighter weight, specific strength, durability, stability, abrasion resistance, and sustainability.

BRM’s advanced textile products are ideal for electronic transmission data, energy storage, and manufacturing automation. Working with companies that include NASA, Tier 1 Defense suppliers, as well as directly with the Department of Defense (Army, Air Force), BRM has developed advanced textiles used in parachutes, safety harnesses, personal protective equipment, and chemically resistant webbing. BRM is in accordance with safety standards, specifications and certifications, including ISO9001, AS9100, ISO13485, ISO14000, NFPA, ASTM, ANSI, *UL, and CSA.

E-WEBBINGS are narrow-fabrics that are conductive, enabling the electronic transmission of data sensations (light, noise, vibrations, heat), and power that can be stored or used to actuate/transform objects. Unique conductive fibers can be woven in conjunction with other fibers and can be used in embedded sensors in both wearable and integral technology, including the Internet of Things.

TPCM thermoplastic composite materials are 2-D or 3D-woven, thermoplastic structures for incorporation into composite parts produced within varied, continually-evolving molding processes. The woven structural shapes are used in hybrid composite structures used in numerous industries, including aerospace/aviation, automotive/transportation, defense, architecture/infrastructure, marine and sports/recreation.

BRM customizes weave designs to modify performance properties, offering expert capabilities for custom options and configurations to optimize designs. BRM’s laboratories consider application details, width, tensile strength, elongation, color, quantity, and other special requirement with customized advanced textile products.

 

PWI Offers LED Replacement Variable Dimming Control System

PWI now offers an LED Variable Dimming Control System for the cockpit map light of all King Air models of aircraft.

“LEDs can be extremely powerful which is good on cloudy days and around dusk, but for night flying it can be too much light,” says Robi Lorik, President and CEO of PWI. “Most pilots prefer fully adjustable, variable dimming LEDs for their map lights. So, our Dimming Control System will give owners and pilots more options.”  

The PWI LED Variable Dimming Control System includes two PMA certified LEDs for the overhead map lights, as well as a STC/PMA approved Variable Dimming Controller. PWI also offers just the Variable Dimming Controller for those King Air owners who have already purchased PWI LED map lights.

“The installation of the PWI Variable Dimming Control System is adaptable to owner preferences,” says Lorik.  “The aircraft owner can decide whether to replace the existing LED light controls or add the new Variable Dimming System on to the current cockpit instrumentation.”

The system can be ordered with either the 303, 1495 or the 1308/1309 LED reading lights. Installing PWI LEDs give King Air owners more than 30,000 hours of light as well as being energy efficient. LEDs are less expensive over the life of the aircraft, saving owners from repeated bulb purchases. The Variable Dimming Controller is compact in size and ultra-light weight, yet sturdy. The LED Variable Dimming System is easy to install and both the LEDs and the Dimmer Controller are certified by the FAA.

“This Variable Dimming Control System checks a lot of boxes for us and we think it will be really popular with our King Air customers,” says Lorik. The LED lights have a three-year warranty and the Controller has a one-year limited warranty. PWI is the OEM for most King Air interior lighting.

AMADA WELD TECH Introduces Compacting Unit for Modular Resistance Welding of Stranded Wire and Cables

AMADA WELD TECH has introduced a redesigned wire compacting unit for its line of modular resistance welders. Ideally suited for stranded wires, the plug and play, ready-to-install modular compacting unit provides precise, fast, and reproducible adjustment after electrode exchange.

This new product replaces the previous open C-frame box type unit, with a unique closed box design that provides maximum rigidity; eliminating any flexing of the unit due to lateral forces. Ball bushes offer precise guidance of the ceramic slide and a new cross roller guide facilitates adjustment of the electrode position.

Featuring fast, precise, and reproducible adjustment of the ceramic and electrode position, using a micrometer screw, operators can now lock the ceramic and electrode position without affecting adjustment. As a result, the adjustment time has been reduced from thirty minutes down to five.

The redesigned unit can be used for numerous process variants, including single compacting, double compacting, single compacting welding, and double compacting welding. It accommodates several unit options, including single closing right or left and double closing. The compacting unit also accommodates such special wire industry requirements as inline feeding, top loading, and front-loading.

The newly redesigned New Horizon modular resistance welder delivers consistent and accurate compacting, thus ensuring part quality, minimal variation, and increased production stability in automotive and electronics applications.

Resistance welding is a thermo-electrical process that uses the principles of Joule’s first law, known as Joule heating. Resistance welding-based compactors use the generated heat and a constantly-applied mechanical force to form the strands into the desired shape. As a result, when compared to the competing ultrasonic methods, the surface of a resistance welded stranded wire is even and not curled. This ensures superior part quality throughout the production process.

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About AMADA WELD TECH
AMADA WELD TECH is a leading manufacturer of equipment and systems for Laser Welding, Laser Marking, Laser Cutting, Resistance Welding, Hermetic Sealing and Hot Bar Reflow Soldering & Bonding. We customize our products around specific micro-joining applications for all our customers around the globe. AMADA WELD TECH product markets include medical devices, battery, automotive, solar industry, electronic components and aerospace. We are an ISO9001 certified company. Contact AMADA WELD TECH at infode@amadaweldtech.eu. Find out more about the company’s products and services at http://www.amadaweldtech.eu.

Pinnacle Solutions Delivers First UH-60M Virtual Maintenance Trainer to United Arab Emirates

Pinnacle Solutions, Inc. delivered the Block 1 Upgrade to its first UH-60M Virtual Maintenance Trainer (VMT) to Global Aerospace Logistics, LLC (GAL) in the United Arab Emirates (UAE). In late February 2021, a team from Pinnacle visited the customer site for the second time to install the UH-60 VMT software upgrade offering additional work packages to expand the maintenance trainer software installed last year to more aircraft systems.

The full classroom suite (Block 0) was delivered to GAL, a leading regional provider of integrated aircraft sustainment solutions for military and civilian customers in Abu Dhabi, on 15 March 2020 to assist the UAE with training Black Hawk maintainers. A total package delivery included on-site testing, Train-the-Trainer course of instruction, an initial 12-month warranty followed by optional long-term maintenance support for both software and hardware.

Furthermore, a Pinnacle Subject Matter Expert participated in the International Defence Exhibition and Conference (IDEX 2021) in Abu Dhabi, UAE, where show visitors and exhibitors viewed demonstrations of the UH-60 and CH-47 VMTs.

About the product

The UH-60 VMT, developed by Pinnacle as an Internal Research & Development (IR&D) project, is a powerful and sophisticated computer-based training platform for Black Hawk maintainers spanning all skill levels. The VMT may be used for aircraft systems, subsystems, and component familiarization as well as fault isolation and troubleshooting. The Pinnacle VMT software is installed on off-the-shelf hardware allowing for accelerated deliveries around the world.

Pinnacle says their VXT family of products, of which VMT is a part, can be tailored to best meet specific customer requirements. For this particular UH-60M VMT delivery, the first block of maintenance work packages included the delivery of the base Instructor Operator Station (IOS) package, which provides the instructor with the ability to monitor and control the training scenario, check system status, and track student progress in real-time. The subsequent block of maintenance work packages provided an IOS system capable of scoring students’ performance and providing a “Pass” or “Fail” grade.

The delivered work packages strictly follow approved maintenance manuals and offer three levels of interaction – beginner level tasks provide step-by-step instruction and guide students through the completion of a maintenance task. Intermediate level tasks allow the students to perform a task while referencing the appropriate maintenance manual. Advanced level tasks challenge the students’ troubleshooting abilities. At this level, the VMT can be used for recurrent training to reinforce and refresh knowledge or procedures and skills that are not applied on a regular basis.

C&L Aviation Group in Final Stage of STC Development for ERJ 135/145 FMS Upgrade

C&L Aviation Group is in the final stages of STC development which solves obsolesce issues with the Universal UNS-1K FMS (Flight Management System). The solution upgrades Embraer ERJ 135/145 aircraft currently utilizing the aging UNS-1K to single or dual UNS-1Lw. This STC also provides a pathway to LPV capabilities such as WAAS (Wide Area Augmentation System).

“There are currently no other solutions in the marketplace, making this an incredibly useful program for operators,” said Charlie Carroll, avionics sales manager for C&L Aviation Group. “We’re excited to offer this solution to our customers, furthering our commitment to their needs and the ERJ 135/145 aircraft.”

The STC will be FAA/EASA validated and C&L expect to begin installations on June 1st. 

In 2020 C&L hosted a webinar addressing issues related to, and upgrade solutions available for operators who will be affected by Universal’s announcement which outlined they would be discontinuing repair on UNS 1C, 1C+, 1Csp, 1Csp+, 1D, 1D+, 1K, and 1K+ Flight Management Systems due to parts obsolescence. This STC is the next step in providing solutions for operators concerned about the obsolescence, and associated costs. 

“This STC is the beginning of a more comprehensive upgrade package that we have planned for this platform.” said Carroll. “We continue to be a one-stop solution for Embraer operators for heavy maintenance, parts, interior modifications and upgrades, paint, and major avionics upgrades like this.”