Technology Update

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January/February 2002
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Sikorsky S-92 enters production

The Sikorsky S-92 Aircraft 4 production prototype made its first flight in October.

Formal FAA certification flight testing has begun for the Sikorsky S-92, and the cabin for the first production aircraft is nearing completion as the program gathers momentum toward 2002 certification and 2003 first deliveries.

Aircraft 4 and Aircraft 5 are engaged in busy flight test schedules at Sikorsky's Development Flight Center in West Palm Beach, FL. Aircraft 4 is performing handling qualities flight testing to develop data for the Flight Safety Inc. pilot training simulator. It was the last S-92 prototype to be completed and the first that incorporated customer-suggested design changes along with a Rockwell Collins glass cockpit. In response to the requests for additional cabin space and a larger main cabin door, Sikorsky has increased the aircraft's cabin length by 16 in., reduced the height of the tail pylon, and relocated the horizontal stabilizer by setting it lower and moving it from the left to the right. An extension added to the forward part of the cabin will permit the installation of a 50 in. wide door to improve hoisting capabilities and accommodate a Stokes litter during search and rescue operations. Reducing the tail pylon by approximately 40 in. will largely offset the additional weight from the cabin extension. This combination of changes will allow the S-92 to maintain current payload and range.

The new Rockwell Collins cockpit provides good field of view and is equipped with a highly integrated avionics package. The Avionics Management System (AMS) provides the display and integrated management of primary flight data for the S-92. The system also provides flight management data, a digital map, weather radar, terrain information, and engine instrument caution and advisory system processing and display.

At the center of the AMS are four 6 x 8-in. high-resolution, color, active-matrix liquid-crystal multifunction displays, with a fifth display to be offered as an option. The displays are sunlight and cross-cockpit readable, and are also compatible with night-vision goggle operations.

In addition to the displays, the AMS consists of data concentrator units (DCU) and a maintenance data computer (MDC). The DCUs provide the interface between the S-92 aircraft systems and the multifunction displays, while the MDC provides the single-point collection for maintenance and performance data of the aircraft systems. Rockwell Collins will also provide the radio and navigation equipment to be certified for delivery to initial civil customers of the S-92.

Meanwhile, Aircraft 5 is completing performance flight testing to generate the information on speed, lift, and engine operating characteristics needed for FAA certification.

As work continues in flight testing, the company has begun to move forward with S-92 production. Mitsubishi Heavy Industries Inc. of Japan is nearing completion of the cabin section for Aircraft 6, the first production aircraft. Long-lead-time components have been ordered for production aircraft scheduled for delivery through 2004. Sikorsky is also developing the lean tooling and manufacturing methods to increase delivery flow and decrease costs.

The S-92 program accumulated a total of 845 h of flight test through early December. Aircraft 2 has flown in excess of 380 h. Aircraft 3 has undergone military mission applications. Aircraft 5, which validated the longer cabin and lower tail, joined the flight program in early 2001 and has logged more than 220 h in the air. Aircraft 4 has 25 flight hours. The Ground Test Vehicle, Aircraft 1, completed the 200-h FAA endurance test to certify the entire drive system.

The Sikorsky S-92 evolved from the S-70 Black Hawk and Seahawk aircraft and incorporates more than 50 years of Sikorsky civil and military multi-mission experience. Available in a 19-passenger commercial, a 22-troop utility, and a multitude of mission-specific configurations, the design offers standup cabin flexibility, rapid convertibility, operational suitability, and a full cabin-width rear ramp.

Honeywell to improve Falcon 50 performance

Honeywell's TFE731-40 engine retrofit has received U.S. and European certification for use on board the Falcon 50 aircraft.

Honeywell has completed its first TFE731-40 engine retrofit for the Falcon 50 business aircraft. The aircraft was recently delivered to aircraft owner Anheuser-Busch.

"The TFE731-40 engine retrofit will give Anheuser-Busch's Falcon 50 faster time-to-climb and cruise speeds, improved engine reliability, durability, and reduced cost of ownership," said Jim Bonadio, Program Director, Honeywell Engines, Systems & Services. "With our TFE731-40 engines on the Falcon 50, operators who fly the North Atlantic track will be able to reach their cruising altitudes in under 23 minutes, eliminating step-climb requirements and maximizing fuel endurance for enhanced aircraft mission performance."

Operators of TFE731-40 retrofitted Falcon 50 aircraft can climb to 41,000 ft in approximately 16 min less than the present model's climb performance of 39 min to 39,000 ft. At altitude, TFE731-40 engines may deliver as much as a 24% increase in cruise thrust over TFE731-3 engines and nearly a 10% reduction in thrust specific fuel consumption.

Each TFE731-40 will give Falcon 50 operators flat-rated, hot-day (86°F) performance of 3700 lb of takeoff thrust at sea level, improved fuel economy at altitude, and extended engine inspection intervals. The engine has a thrust rating of 1010 lb at 40,000 ft and Mach 0.8 cruise.

The 731-40 engine carries maintenance intervals of 2500 h for major periodic inspections and 5000 h for compressor zone inspections, a 16% improvement over existing engines. The engine includes a digital electronic engine control allowing automatic takeoff, climb, and cruise thrust settings; newly designed ceramic seals; a new oil pump; enhanced turbine cooling; an improved combustor; and improved compressor durability.

In another announcement, Honeywell said it has been selected to supply the pneumatic system for the Rolls-Royce Trent 900 engine, chosen to power the Airbus A380 jetliner. With thrust range capable of growth to 84,000 lb, the Trent 900 is the latest offering in Rolls-Royce's successful Trent family of large turbofan engines. For each engine, Honeywell will provide a pneumatic system composed of bleed valves, thermal anti-ice valves, turbine case cooling valves, an air-turbine starter, and the starter valve. The value of the award is estimated to be nearly $1 billion over the life of the A380 program.

- Frank Bokulich

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