Cowlings : Global aspect
Task 1.9: Airworthiness and compliance substantiation of the Ejector
2. Scope of work Tasks
Ref. No. Title Description Due Date
T1 Product Description
The main objective of this task is to review the Topic leader specification, to give the description of the products to be designed, manufactured, qualified and provided to the leader for bench testing, to specify the requirement for test method elaboration.
Equipment interfaces need will also be analysed.
This activity will be closed by a review: Product Description Review.
T0 + 3 months
T2 Ageing study and Test method Definition
The main objective of this activity is to validate the ageing key phenomenon which occur on connectors, wires and insulation means and to determine the key parameters for qualification
This activity will be closed by a review: Test Method Review.
T0 + 9months
T3 Installation rules based on architecture hypothesis
The main objective of this activity is to define the harness installation means, protection and insulation means, rules, and qualification tests. Installation rules shall be conservative taking into account non compliances to standard practices e.g. chafing, excessive wire bend, compression by clamps, …
Definition of sample receiving environment shall be representative to aircraft structure (edges, rivet tails, fluid and heat aggression)
Two configurations will have to be taken into account, one with severe constraints and one in standard golden rules (EN3197).
This activity will be closed by a review: Installation rules and QTP1 Review.
CfP03 Call Text 155 Tasks
Ref. No. Title Description Due Date
T4 Design
The main objective of this activity is to check that components preliminary design is consistent with requirement of robustness, performance, safety requirement, sizing, interface definition, drawings, prior to launch components manufacturing.
Substantiation of design choice will have to be done, taking into account the T2 & T3 assumptions.
The Qualification Test Plan including sampling will also be defined. This activity will be closed by a review: First Design Review (DR1).
T0 + 15 months
T5 P1 Samples manufacturing
The main objective of this activity consists of manufacturing the prototypes for tests (P1 samples are identical models in fit, form and function with the specified components defined in T4).
This activity will be closed by a Sample review and by samples delivery for customer evaluation.
T0 + 18 months
T6 P1 Samples tests
This activity consists of performing the QTP on the P1 samples installed according T3 assumptions.
This activity will be completed by a QTR analysis.
This activity will be closed by QTR (Qualification test report) validation and a FSQ (File Synthesis of Qualification).
T0 + 21 months
T7 Loop on Design, needed in case of T6 failure
The objective of this activity is to define design correction after QTR assessment and topic leader evaluation in order to prepare P2 samples manufacturing (P2 samples are identical models in fit, form and function with the specified components at latest design that will be qualified for flight test clearance).
This activity will be closed by a Second Design Review (DR2)
T0 + 24 months
T8 P2 Samples manufacturing (if needed)
The applicant will have to manufacture P2 samples according to design file validated in DR2.
This activity will be closed by a samples review and delivery for customer evaluation.
T0 + 27 months
CfP03 Call Text 156 Tasks
Ref. No. Title Description Due Date
T9 P2 Samples tests (if needed)
This activity consists of performing the QTP on the P2 samples to demonstrate that P2 samples are flight cleared.
This activity will be completed by a new QTR analysis.
This activity will be closed by a QTR validation and a FSQ (File Synthesis of Qualification).
T0 + 30 months
T10 Harness Samples tests
This activity is to make harness samples installed on a mock-up as per installation rules defined in T3 and to perform the QTP1
T0 + 30 months
General requirements:
Weight: The target is to reach the lowest weight possible for the proposed components compliant with technical requirements and compatible with a serial aeronautical production and to define installation rules minimising the weight.
For the Installation rules and QTP1 review, the partner shall provide a detail weight impact of the proposed installation rules and demonstrates that these rules will minimise the weight. Trade-off between weight reduction and cost optimisation has to be presented.
For the Design review(s), the Partner shall provide a detailed weight analysis of the components in accordance with the requirements agreed with the topic manager. Trade-off between weight reduction and cost optimisation has to be presented.
At QTR, an update of the weight analysis has to be presented with a substantiation of the difference with Design review version.
Recurring cost estimation: The target is to obtain the optimum between the compliance with specification, minimum weight and recurring cost.
It is applicable for Installation rules and the Component’s.
Recurring cost assessment (for a serial production) has to be presented for the Design review(s) and updated at QTR.
Eco-design: The Partner shall monitor the use of hazardous substances regarding REACh regulation and select materials which are exempt of- or contain acceptable substitutes to hazardous substances, as far as possible.CfP03 Call Text 157
3. Major deliverables/ Milestones and schedule (estimate)
Deliverables
Ref. No. Title – Description Type Due Date
D1.T1 Product Description with requirements tracking
(Deliverable 1 task 1) Document T0 + 3 months
D1.T2 Ageing study report
(Deliverable 1 task 2) Document T0 + 9 months
D2.T2 HVDC Ageing Test Method Document T0 + 9 months
D1.T3 Qualification Test Program for harnesses (QTP1) Document T0 + 9 months D1.T4 Detailed design file & drawings:
-
Detailed design description with weightDocument T0 + 15 months
D2.T4 Substantiation file including :
-
Insulation material choiceDocument T0 + 15 months D3.T4 Safety and reliability assessment (FMEA) Document T0 + 15 months
D4.T4 Qualification Test Plan Document T0 + 15 months
D5.T4 Sampling definition Document T0 + 15 months
D1.T5 Sample review + samples delivery to customer Components
+ Document T0 + 18 months D1.T6 Qualification Test Report + validation Document T0 + 21 months D1.T7 Updated Design documentation after loop (if needed) Document T0 + 24 months D1.T8 Updated sample review + sample delivery to customer Document T0 + 21 months D1.T9 Updated Qualification Test Report if needed Document T0 + 30 months D2.T9 FSQ (File Synthesis of Qualification).
(Extrapolation to serial product) Document T0 + 30 months D1.T10 Qualification Test Report for Harnesses (QTR1) Document T0 + 30 months
Milestones (when appropriate)
Ref. No. Title Description Type Due Date
M0 Kick off Meeting Review T0 + 1 month
M1.T1 Product Description Review Review T0 + 3 months
M1.T2 HVDC Ageing Test Method Delivery T0 + 9 months
M1.T3 Installation Rules Review Review &
Delivery T0 + 9 months
M1.T4 Design Review 1 (DR1) Review T0 + 15 months
M1.T5 P1 Samples manufacturing Delivery T0 + 18 months
M1.T6 Qualification Test Report Delivery T0 + 21 months
CfP03 Call Text 158 Milestones (when appropriate)
Ref. No. Title Description Type Due Date
M1.T8 P2 Samples manufacturing Delivery T0 + 27 months
M1.T9 Qualification Test Report
FSQ (File Synthesis of Qualification). (Extrapolation to serial product)
Delivery T0 + 30 months
M1.T10 Qualification Test Report for Harnesses (QTR1) Delivery T0 + 30 months M2.T10 Electrical components available for program delivery Delivery T0 + 30 months
4. Special skills, Capabilities, Certification expected from the Applicant(s)
Skill 1: Cable conception and manufacturing for aeronautic use
Skill 2: Connectors and contacts conception and manufacturing for aeronautic use Skill 3: electrical insulation and harness protection in aerospace environment Skill 4: Harness installation (rules and means) in aerospace environment Skill 5 : Aeronautic knowledge and experience
Skill 6 : High Voltage expertise and experience Skill 7 : High Voltage and ageing laboratory means
Skill 8 : Project management between cable manufacturer, connector manufacturer and customer
Skill 9 : Eco-design, Capacity to monitor and decrease the use of hazardous substances regarding REACH regulation.
Skill 10: Capacity to design low weight components within an optimised recurring cost Process
CfP03 Call Text 159 4.