CASE STUDY Italy Aerospace Avio S.p.A. Vibroacoustic Testing of Aircraft Engines and Components PULSE™, Transducers

Avio was established in 1908, just five years after the Wright brothers historic first flight. Today, it is a global aerospace company, at the leading edge of propulsion technology.

In 2001, as part of its Six Sigma Cartesio Plus programme, Avio came to Brüel & Kjær for a solution to radically improve vibroacoustic testing productivity. A 30-channel PULSE system is used for all data collection and analysis while the procedure for automated data acquisition is controlled by PULSE WorkFlow Manager.

© 2004 Brüel & Kjær. All rights reserved.

Illustrations by kind permission of Avio S.p.A.

95 Years of Technological Innovation

Avio, originally a division of Fiat, was founded in 1908, only five years after the Wright brothers’ first flight at Kitty Hawk in their powered heavier-than-air craft. Fiat chose to diversify its business and to exploit its technological expertise in petrol combustion engine.

Today, Avio is a global company, at the forefront of aerospace propulsion technology. With its headquarters at Rivalta di Torino, near Turin in northern Italy, Avio has facilities in Italy, Poland, the USA, and French Guyana. Core Markets

Fig. 1 Avio focuses on four major markets: A slave gearbox from a Rolls-Royce EJ200 – two of Modules and Components for Civil these engines and Military Aircraft and Helicopter power the Propulsion Systems Eurofighter (Typhoon) In the commercial sector, Avio is a part- ner to the world’s major aircraft engine manufacturers, including General Elec- tric, Pratt & Whitney and Rolls-Royce.

Today, over 60% of the ‘wide body’ com- mercial aircraft in service are equipped with at least one component designed and manufactured by Avio.

Fig. 2 Avio is also a leader in the sector of hel- CH53 helicopter icopter engines, developing and produc- power transmission ing turbo-shafts and power transmission assembly gearboxes for main rotor and the tail ro- tors.

Avio is a participating partner in many European defence aerospace pro- grammes. With the EJ200 engine for in- stallation in the new AF2000 ‘Typhoon’, it is responsible for several of the en- gine’s key components, including the gearbox, low pressure turbine and after- burner.

Maintenance, Repair and Overhaul (MR&O) of Aircraft and Helicopter Propulsion Systems The activity in repair and overhaul, technical support and maintenance of aero engines is becoming an increasingly important part of Avio’s business. Its long expertise in the aircraft engine field enables Avio to support products over their total life cycle, thus guaranteeing its customers the benefits of quality, performance and contained costs.

Space and Tactical Propulsion Systems

Fig. 3 In 1996, Avio acquired BPD ‘Difesa e Ariane 5 before Spazio’, a leading European company in launching at the field of military and space propulsion. Kourou, French Guyana The experience and know-how with ex- plosives and propellants acquired by BPD since its foundation in 1913 has enabled Avio to develop solid, liquid and cryogen- ic propulsion products and systems. It is extensively involved with the Ariane launch vehicle.

2 Engines and Automation Systems for Naval and Industrial Applications Avio’s interest in marine activities dates back to the beginning of the last century, when the company began developing and producing marine engines. Today, Avio can meet the automation and propulsion requirements of highly sophisticated and efficient ves- sels.

Dedicated Test Cells

The new facility at Rivalta di Torino employs some 2000 people. It has recently been completely redesigned. The use of advanced technologies in dedicated cells enables the manufacturing process to be efficiently optimised and ensures that Avio’s products meet the highest quality standards. Avio designs, develops and manufactures a wide range of engine components and assemblies including fans, turbines and gearboxes for commercial and military aircraft (fixed wing and helicopters).

Reliability is essential as there are obvious catastrophic effects of failures during service. Avio extensively tests the performance and reliability of its products using traditional vibroacoustic test methods as well as coldflow and cascade coldflow tests, to evaluate performance under aerodynamic loading.

Avio has many test cells and the largest can accommodate the new 10 000 shaft horse power TP400-D6 turboprop engines that will power the EADS A400M military transport aircraft.

A Slow Process

The original test system relied on post-processing time data recorded onto 1-inch magnetic tape or DAT cassettes. This was a slow and laborious process involving a number of steps: ❍ Recording, labelling and transferring test data to the analysis station ❍ Actual analysis (one channel at a time) ❍ Reporting

All this for only a few minutes of valuable data such as during the transitory phases (run-up/down), the steady state conditions, or during rapid system transitions. The requirement for fourteen separate analysis results per channel in a two-page report was not unusual for such a measurement.

Cooperation

In 2001, as part of its Six Sigma Cartesio Plus initiative, Avio decided to upgrade its test facilities. Avio came to Brüel & Kjær looking for a solution that would radically improve its vibroacoustic testing productivity.

Based on his sixteen years of experience in R&D, testing and commissioning, Mario Plancher of Avio’s Experimental Dynamics Laboratory knew exactly what the new sys- tem had to do. Working closely with Carmine Salzano, Brüel & Kjær’s local sales engineer, they together provided Brüel & Kjær’s aerospace team with a clear understanding of Avio’s requirements.

3 Mario says. “Avio’s relationship with Brüel & Kjær dates back over thirty years. I have always worked with their products and they are the world leaders in sound and vibration technology. Coupling this with the superb local service and support we receive, it was natural for us to chose a Brüel & Kjær solution based on their PULSE hardware platform”.

State-of-the-art Solution

Fig. 4 The main functions of the system can be split into Mario Plancher of two: Avio’s Experimental Dynamics ❍ Test monitoring and data acquisition Laboratory has ❍ Off-line post-processing analysis worked for Avio since 1987. His Mario Plancher explains, “In the test monitoring and wide experience in data acquisition function, a PULSE data acquisition testing, R&D and system monitors vibration levels. If sustained levels commissioning was a key factor in above the trigger level are detected, a signal is sent choosing the right to the test cell PLC to shutdown, thus avoiding dam- solution age. There is also spectral based monitor using limit curves in PULSE, that when exceeded provide a visual notification as well as triggering a data (time history) recording or an RMS logger. Broadband RMS, spectral data and time history data can be recorded together with other test parameters such as temperatures and pressures”. The post analysis function involves taking the time histories recorded as part of the test and performing a number of different analyses including FFT, order, compressed time, crest factor as well as automatically generating slices at the frequencies or orders of peak magnitude. All information is then saved into a database where the engineer can add his comments and reports can be generated in the company format. Mario says, “The solution has a very flexible hardware setup so that a variety of different transducer types can be used with the same front-end. It is also necessary that the PULSE system can be stacked or split according to channel requirements. And the software has to be capable of performing the different types of analysis – from simple component testing to complete turbine and gearbox testing. Finally, quick and easy switching between different types of testing is essential”.

PULSE

Fig. 5 A 30-channel PULSE system is used The heart of the for all data collection and analysis data acquisition while the workflow for automated and analysis vibroacoustic test data acquisition is controlled by solution is a 30- PULSE WorkFlow Manager Type channel PULSE 7756. The system can be controlled front-end directly from the test cell or over the network using a PC in the control room. PULSE Data Manager Type 7767 en- ables the saved results to be viewed, compared and reported, away from the test cell.

4 awn(86 5275 ntdKndm(4)1 87900·UA(1 0 3 2040 332 800 7035 (+1) · USA 880 000 1 739 Local representatives and service 38 organisations (+41) worldwide Switzerland · 8600 14 449 (+44) Kingdom United · 8 7255 2502 (+46) ·Sweden 0820 2 659 Taiwan 4512 (+886) 91 377 53 · Spain · Singapore 0701 (+34) (+65) 4 443 11 47 25 21 56 · Portugal(+421) Republic (+351) Slovak 75 816 22 55 ·Poland (+48) 11 9290 77 55 66 0605 · NetherlandsNorway (+31)318 (+47) 3473 4083 807 2 1612 · Republic of Korea (+82) 1 5715 05 · Ireland (+353) 3 00 83 68061 · Japan (+81) 215 71 0257 Italy 1 (+39) 90 7486 · Hungary (+36) 69 2548 0 · Hong Kong 1 (+852) 87 (+33) ·France 950 9-755 17 1100 (+358) Finland · 421 6702 Germany (+49) 2 (+420) Republic Czech · 29906 680 10 695-8225 (+86) China 514 5188-8166 · Canada (+1) 00 · Brazil (+55)11 74 865 1 9889-8888 ·Austria (+43) 2 Australia (+61) 1405 · www.bksv.com · [email protected] 4580 ·+45 Fax: 0500 4580 Nærum · Denmark · Telephone: DK-2850 HEADQUARTERS: +45 PULSE configured by it is automatically standard format – in Avio’sreport, A typical test 6 Fig. Key Facts Great Time-saving made available to Avio'’ touch ofabutton,is immediatelyavailable on thelocal area network,can and beeasily 25 channels– means 150 pages! Test dataisinstantlyreported in Avio’s format, atthe A measurement on just one channel creates 2 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ also savesus concludes, “It He different setof controls for each testing function”. safety features all into one clear system. And and theuser gives interface a isvery It combines the vibroacoustic monitoring, recording, post-processing, reporting and Mario says, “The new solution is perfect and ❍ ❍ ❍ ❍ ❍ faster, andsetupofthemonitoring Manager Type 7756 stacked orsplit according to channel requirements” that the PULSE system can be “It is necessary types canbeusedwiththesamefront-end” setup so that a variety of different transducer flexible hardware“The solution hasavery platform” solution based ontheirPULSE hardware Kjær & “It wasnaturalfor usto choseaBrüel years”back over thirty Kjærdates & “Avio’s relationship withBrüel facilities In 2001, Avio decided toupgrade its test products meet the highest quality standards efficiently optimised and ensures thatAvio’s cells enables themanufacturing process tobe The use ofadvanced technologies in dedicated aircraft, spaceandmarine/industrial military Avioma focusesonfour French Guyana Italy,Avio in facilities and has USA, the Poland, of propulsion technology global aerospace company, atthe leading edge Avio wasestablished in 1908–today, itis a setup of the monitoring is “It also saves us a huge amount of time –data analysis is now five times faster, and “The new solution isperfect and greatly simplifies the measurement process” and reported PULSE Data Manager Type 7767 enables thesaved results to beviewed, compared The workflowfor A 30-channel PULSEsystem isused for all data collection and analysis automated dataacquisitionis development partners. developmentpartners. jor markets – civil and –civiland jor markets at leastthree timesquicker” ahugeamountoftime– data analysis isnow five times isatleastthree timesquicker”. greatly simplifies the measurement process. × 3 page3 reports (velocity/acceleration) controlled byPULSE WorkFlow

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