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Abstract This study underscores the benefits of refining the intralogistics process for small- to medium-sized manufacturing businesses (SMEs) in the engineer-to-order (ETO) sector, which relies heavily on manual tasks. Based on industrial visits and primary data from six SMEs, a new intralogistics concept and process was formulated. This approach enhances the value-added time of manufacturing workers while also facilitating complete digital integration as well as improving transparency and traceability. A practical application of this method in a company lead to cutting its lead time by roughly 11.3%. Additionally, improved oversight pinpointed excess inventory, resulting in advantages such as reduced capital needs and storage requirements. Anticipated future enhancements include better efficiency from more experienced warehouse staff and streamlined picking methods. Further, digital advancements hold promise for cost reductions in administrative and supportive roles.

To many, a digital twin offers “functionality,” or the ability to virtually rerun events that have happened on the real system and the ability to simulate future performance. However, this requires models based on the physics of the system to be built into the digital twin, links to data from sensors on the real live system, and sophisticated algorithms incorporating artificial intelligence (AI) and machine learning (ML). All of this can be used for integrated vehicle health management (IVHM) decisions, such as determining future failure, root cause analysis, and optimized energy performance. All of these can be used to make decisions to optimize the operation of an aircraft—these may even extend into safety-based decisions.

AIR5317 establishes the foundation for developing a successful APU health management capability for any commercial or military operator, flying fixed wing aircraft or rotorcraft. This AIR provides guidance for demonstrating business value through improved dispatch reliability, fewer service interruptions, and lower maintenance costs and for satisfying Extended Operations (ETOPS) availability and compliance requirements.

Success in metal additive manufacturing (AM) relies on the optimization of a large set of process parameters to achieve materials whose properties and performance meet design and safety requirements. Despite continuous improvements in the process over the years, the quality of AM parts remains a major concern for manufacturers. Today, researchers are starting to move from discrete geometry-dependent build parameters to continuously variable or dynamically changing parameters that are geometry- and scan-path aware. This approach has become known as “feedforward control.” Process Control for Defect Mitigation in Laser Powder Bed Fusion Additive Manufacturing discusses the origins of feedforward control, its early implementations in AM, the current state of the art, and a path forward to its broader adoption. Click here to access the full SAE EDGETM Research Report portfolio.

Engineering Events staff at SAE International in Warrendale, Pennsylvania, have extended the call for abstracts through September 21 for the organization’s AeroTech aerospace and defense technology conference, which will take place at the Fort Worth Convention Center in Fort Worth, Texas, March 14-16, 2023. Visit the AeroTech call for abstracts page for more information and to get started.

Abstract The demand for contactless, rapid manufacturing has increased over the years, especially during the COVID-19 pandemic. Additive manufacturing (AM), a type of rapid manufacturing, is a computer-based system that precisely manufactures products. It proves to be a faster, cheaper, and more efficient production system when integrated with cloud-based manufacturing (CBM). Similarly, the need for semiconductors has grown exponentially over the last five years. Several companies could not keep up with the increasing demand for many reasons. One of the main reasons is the lack of a workforce due to the COVID-19 protocols. This article proposes a novel technique to manufacture semiconductor chips in a fast-paced manner. An algorithm is integrated with cloud, machine vision, sensors, and email access to monitor with live feedback and correct the manufacturing in case of an anomaly.

The aerospace industry is facing immense challenges due to increased design complexity and higher levels of integration, particularly in the electrification of aircraft. These challenges can easily impact program cost and product time to market. System electrification and electromagnetic compatibility (EMC) have become critical issues today. In the context of 3D electromagnetics, EMC electromagnetic compatibility ensures the original equipment manufacturer (OEM) that radiated emissions from various electronic devices, such as avionics or the entire aircraft for that matter, do not interfere with other electronic products onboard the aircraft.

This recommended practice has been developed for use in any EEE system used in the AADHP industries. RPA is especially important to AADHP systems, which are often safety critical applications that must operate for long times in rugged environments. These EEE systems often use EEE components that were originally designed and produced for more benign consumer applications. Although the focus of this recommended practice is on AADHP applications, the process described herein is not limited to AADHP and may be used for EEE systems and components in any industry.

Quality management professionals across the global aerospace and defense community are convening for one hour – Wednesday, October 27th, starting at 10 am Pacific Daylight Time (PDT) – to discuss the AS9100 international standard. Register to take part in the free AeroTech webinar, hosted by SAE International and Tektronix, designed to help manufacturers, contractors, and subcontractors throughout the global aviation, space, and defense supply chain keep pace with and meet the requirements of AS9100 international quality management system standard.

SAE International is inviting global participation in its AeroTech® aerospace and defense technology conference and exhibition, which is for the first time co-located with ASM International’s AeroMat, at the Pasadena Convention Center in Pasadena, California, March 15 through 17, 2022.

Thermal Management Techniques in Avionics Cooling Curing the Porosity Problem in Additive Manufacturing Space-Qualified Crystal Oscillators Reimagining Automated Test During a Pandemic EW: New Challenges, Technologies, and Requirements Software Enables New-Age, Flexible Test Solution for Analog and Digital Radios Formal Process Modeling to Improve Human-Decision-Making During Test and Evaluation Range Control Using the Innoslate software tool to formally model the process of conducting test range events can expose previously overlooked ambiguities and identify high-value decision points? Test and Evaluation of Autonomy for Air Platforms Tools, approaches, and insights to confidently approach the safe, secure, effective, and efficient testing of autonomy on air platforms.

Abstract Presently, 270 V direct current (DC) systems replace older 28 V DC voltage systems in both the civil and military aviation industry due to the requirement for more electrical power needs on board. Therefore, the existing avionics require retrofitting. The conversion from 270 V to 28 V appears to be quite promising for both old and new systems. This study aims to design an interleaved synchronous modular buck converter topology as a candidate for these requirements. Calculations for the converter design are conducted considering aviation standards. Switching with pulse-width modulation (PWM) is used to control the power converter. A double-loop feedback control system based on voltage and current feedback is designed. Therefore, the buck converter circuit with 1145 W power output is proposed, which supplies a 28 V and 41 A DC output from a 270 V DC input. The concept is verified using simulations and hardware-in-the-loop (HIL) experimental results.

The “holy grail” for prognostics and health management (PHM) professionals in the aviation sector is to have integrated vehicle health management (IVHM) systems incorporated into standard aircraft maintenance policies. Such a change from current aerospace industry practices would lend credibility to this field by validating its claims of reducing repair and maintenance costs and, hence, the overall cost of ownership of the asset. Ultimately, more widespread use of advanced PHM techniques will have a positive impact on safety and, for some cases, might even allow aircraft designers to reduce the weight of components because the uncertainty associated with estimating their predicted useful life can be reduced. We will discuss how standard maintenance procedures are developed, who the various stakeholders are, and – based on this understanding - outline how new PHM systems can gain the required approval to be included in these standard practices.

Game-changing opportunities abound for the application of vehicle health management (VHM) across multiple transportation-related sectors, but key unresolved issues continue to impede progress. VHM technology is based upon the broader field of advanced analytics. Much of traditional analytics efforts to date have been largely descriptive in nature and offer somewhat limited value for large-scale enterprises. Analytics technology becomes increasingly valuable when it offers predictive results or, even better, prescriptive results, which can be used to identify specific courses of action. It is this focus on action which takes analytics to a higher level of impact, and which imbues it with the potential to materially impact the success of the enterprise. Artificial intelligence (AI), specifically machine learning technology, shows future promise in the VHM space, but it is not currently adequate by itself for high-accuracy analytics.

This SAE Aerospace Information Report (AIR) is prepared for stakeholders seeking information about the evolution, integration, and approval of SHM technologies for military aircraft systems. The report provides this information in the form of (a) two military organizations’ perspectives on requirements, and (b) general SHM challenges and industry perspectives. The report only provides information to generate awarness of prespectives for military aircraft and, hence, assists those who are involved in developing SHM systems understanding the broad range of regulations, requirements, and standards published by military organizations that are available in the public domain from the military organizations.

This SAE Aerospace Standard (AS) establishes guidelines for the use of IEEE-1394-2008 Beta (formerly IEEE-1394b) as a data bus network in military and aerospace vehicles. It encompasses the data bus cable and its interface electronics for a system utilizing S400 over copper medium over extended lengths. This document contains extensions/restrictions to “off-the-shelf” IEEE-1394 standards, and assumes that the reader already has a working knowledge of IEEE-1394. This document does not identify specific environmental requirements (electromagnetic compatibility, temperature, vibration, etc.); such requirements will be vehicle-specific and even LRU-specific. However, the hardware requirements and examples contained herein do address many of the environmental conditions that military and aerospace vehicles may experience. One should refer to the appropriate sections of MIL-STD-461E for their particular LRU, and utilize handbooks such as MIL-HDBK-454A and MIL-HDBK-5400 for guidance.

Why should the supply chain be concerned if their buyers or subcontractors are purchasing counterfeit electronic parts or if their products contain counterfeit electronic parts? If these parts end up in items that are safety critical and security-risk sensitive such as aviation, space, and defense products, whole secure systems can be comprised. As organizations have become aware of counterfeit parts, one of their responses may be to test upon acceptance or prior to receipt. But testing alone may not detect all counterfeits. Possible sources of counterfeits include products that did not meet quality control requirements and were not destroyed, overruns sold into the market place, unauthorized production shifts, theft, and e-waste. The counterfeited electronic part ends up in the supply chain when ordered by an unsuspecting buyer, who does not confirm the originating source of the part.