CFM56-7 Overall HMU Reliability

航空发表于 2011-4-12 08:35:09

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CFM56-7 Overall HMU Reliability CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 2 CFM56-7 P07 HMU Removals / MTBUR 0 5 10 15 20 25 30 35 40 45 50 Jan-01 Feb-01 Mar-01 Apr-01 May-01 Jun-01 Jul-01 Aug-01 Sep-01 Oct-01 Nov-01 Dec-01 Removals 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 MTBUR HMU Removals 6-Month MTBUR 12-Month MTBUR CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 3 Removal Cause Last 12 Months 116 95 46 43 42 40 33 16 16 9 8 0 20 40 60 80 100 120 140 Chafing / Wrap Fault FMV F/B HPSOV Switch Unknown / Misc Engine Control Light DMD/FDBK BSV Leak Precautionary No Start No Shutdown CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 4 • HMU reliability remains flat - Current 12 Month MTBUR is 12,000 Hr’s - Average removals, 32 per month over the last year • Corrective Actions for top removal causes - Chaffing/Wrap Fault is leading cause for removal - Wire bracket Intro production 5/01, SB issued 9/14 - HPSOV Switch Latching on Starts • Investigations - Refer to separate presentations - FMV Feedback Fault - MSV / BSV position faults - Fault accommodation introduced in EEC S/W version 7.B.N - June 2002 Reliability Summary CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 5 CFM56-7B HPSOV Indication System • Background - HPSOV switch leading cause of HMU removals and D&C’s - Joint CFMI/Boeing/Honeywell team have studied design alternatives to increase reliability to acceptable level - SPST switch eliminates predominant failure mode via run reed deletion - New HMU P/N (P08) creates one-way engine/aircraft interchangeability NC NO Arm NC NO Arm Current Double Throw Proposed Single Throw Run contact eliminated Proposed Switch Configuration CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 6 CFM56-7B HPSOV Field Plan • Qualification Testing Status - Completed test program that addressed potential field failure modes - Endurance testing for both run and shutdown modes - Bounce testing completed at 1.25X engine “g” levels with Boeing P5-2 card - Completed 4000 cycle endurance test on prototype switch installed on development engine CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 7 CFM56-7B HPSOV Field Plan • Boeing Production - Introduce new P5-2 panel circuit cards line # 1047 (Complete) - Introduce new SPST HMU (P08) line # 1077 (Complete) • Field retrofit of P5-2 circuit cards - 60 cards per week available for field retrofit (2 cards per aircraft) - P5-2 Circuit Cards available for entire fleet in approximately 10 months - Boeing logistics focal identified and will work with CFM/HW - Customers “No Charge” Purchase Orders will be required • Customer Contacts: - Bill Swearengin - Boeing - Francois Boitelet - CFM SA - Don Thurnquist - CFM Inc - Bob Chojnacki - Honeywell CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 8 Interim HMU plan until P5-2 cards attain fleet penetration •Aircraft must be compatible with new SPST switch - Aircraft must have new P5-2 circuit - If new card is not available: - Convert P08 to P07 (CFM SB 73-068; HW SB CHT1 - 73-0015) - Shop return HMUs to remain P07 until Aug 2002 - Airlines can elect to note on repair PO to upgrade to P08 (SPST) - HMU switch kits available “Free Of Charge” for airlines that wish to upgrade proactively CFM56-7B HPSOV Field Plan CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 9 Interim HMU plan until P5-2 cards attain fleet penetration • Honeywell will continue to replace current switches at “No Charge” - 48 hours notice is required - Can be accomplished on-wing - P08 to P07 conversion if required (CFM SB 73-068; HW SB CHT1 - 73-0015) CFM56-7B HPSOV Field Plan CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 10 Retrofit Strategy • Hardware will be maintained for unscheduled use - Honeywell will have both switch configurations available - Boeing will have aircraft cards available at Spares Dist. Center - Boeing AOG system will support urgent orders • Spare engines will be delivered with P08 HMUs – Can be changed to P07 at customer request by Honeywell • CFM lease pool engines will remain equipped with P07 – Converted later in the program to allow for flexibility CFM56-7B HPSOV Field Plan CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 11 Summary • P5-2 circuit card will be FOC to customer • New switches/installation will be FOC to the customer • Logistics focal point identified and contact information to be published •AOG scenarios addressed • Your CFM ATPMs and CSMs will be thoroughly engaged with customer specific field programs CFM56-7B HPSOV Field Plan CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 12 Service Bulletin Summary CFM56-7B HPSOV Field Plan SB Intent Boeing SB CFM SB H/W SB On-wing sw N/A 73-037R2 CHT1 73-008R2 replacement On-wing rev K N/A 73-061R1 CHT1 73-011 sw replacement with wire support bracket Rework P5-2 737-28-1179 N/A N/A 233A3202-28-02 Introduce P08 N/A 73-067 CHT1 73-0014 P08 to P07 N/A 73-068 CHT1 73-0015 Conversion CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 13 FMV Related Faults • FMV faults have become leading cause of D&Cs in -7B fleet - Fault codes 73-x034y, 73-x035y (x=Channel, y=Engine position) - Faults result in Engine Control Light indication in cockpit - Driving 10 HMU removals per month - No operational events • Extensive root cause investigation on-going - Analysis, component, systems rig testing • Design and manufacturing process changes are being incorporated to address identified failure modes • Additional changes for improved reliability being defined, evaluated and tested - Design, manufacturing, software logic CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 14 • HMU and resolver analytical efforts - Tolerance studies, loads, modal, thermal effects including finite element analysis • HMU Testing at Burbank - Run-as-received, electrical checks, inspections (wires, binding, wobble) • Resolver Module Testing at Kearfott - Room temperature electrical tests and thermal cycling (all) - “Shake & bake” testing (10 units) - no failures observed - Wire disassembly of unconfirmed units (7) - 2 rubbed rotors observed FMV Root Cause Investigation - Scope CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 15 • Systems level testing on CFM systems rig - Focus on unconfirmed units - Allows monitoring of individual windings and EEC faults • HMU / Resolver module testing at Honeywell - South Bend - Cell 8 rig test temperature and FMV cycling - 11 units - Vibe testing for intermittent opens / shorts - 26 units - Thermal and moisture tests of resolvers to check for shorts - 13 units - Load testing for channel disagree faults - 2 units FMV Root Cause Investigation - Scope CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 16 FMV Root Cause Investigation - Findings • Fault confirmation rate currently 42% - 74% resolver, 26% HMU-related • Fault tree analysis used to identify 70 possible failure contributors - 65 of these have been investigated • Design and process improvements incorporated for 11 of 12 failure modes identified to date - Implemented in new production and field return units following introducPteirocenntage 42% 58% 74% 26% Unconfirmed Confirmed Resolver HMU CFM56 Operators Conference – May 21 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 17 FMV Root Cause Investigation - Findings • Majority of resolver failures related to wiring issues - Quality and position adjustment lessor contributors • “Rotor winding open” to be addressed 2Q’02 - Improved strain relief at termination - Wire gauge increase from 43 to 42 …currently being tested 0 2 4 6 8 10 12 14 16 Rotor Winging Open Lamination Damage/Binding Stator Termination Failure Sator Winding Open Insulation Resistance Rotor Termination Failure Resolver Position Adjusted Wire Chafing High Eng Play Bent Connector Pin Mis-pinned Connector FMV Extension Wobble End Play Stator Termination Rotor Opens in Winding and Near Termination Stator Winding Open Low Insulation Resistance Resolver Schematic Resolver Failure Pareto Corrective Action in Process Corrective Action In Place No Corrective Action Defined

979199501 发表于 2011-4-12 14:27:20

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CFM56-7 Starter Reliability

kinran 发表于 2011-6-4 23:33:03

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bocome 发表于 2011-7-31 04:27:08

CFM56-7 Overall HMU Reliability

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CFM56-7 Overall HMU Reliability

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