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A new makeover to the flat/ slap unit for one of the leading 65 Aerospace suppliers

A new makeover to the flat/ slap unit for one of the leading 65 Aerospace suppliers

The client is among the largest global suppliers of technologically advanced aerospace and industrial products. The company designs and manufactures aerospace systems for commercial, regional, corporate and military aircraft, and is a major supplier for international space programs. Industrial products manufactured by the company serve industries ranging from hydrocarbon, chemical and food processing to construction and mining.

Unreliable slat flap result in flight risks

Critically advanced development in aerospace engineering has enabled pilots to takeoff and land safely even in emergency situations. The Slat Flap Control Units (SFCUs) in an aircraft are the critical enablers for safety and efficient landing in any situation. They control the airflow and speed of the wing, and allow for higher lifts during take-off and also reduce the stalling speed by altering the air flow over the wing.

The client was facing reliability issues with its flap/ slat control units, and certain components were outdated. The SFCU had another problem – it was using an analog card, which would sometimes lead to false alarms or auto switch off.

On diagnosis, several requirements were identified that needed a strategic solution, that ranged from a complete board re-designing of the SFCUs and replacement of the outdated components to redesigning the layout to improve productivity.

Decoding the problems

The re-designing of microprocessors was a major challenge. The challenge included identification and replacement of the obsolete parts and verification and validation software development. After thorough diagnosis of the problem, a step-by-step procedure was evaluated and designed to address the challenges.

The uniqueness of the problem demanded an in-depth discussion with the relevant teams, to understand the expectations and craft a focused solution. An execution cycle was planned using a dual structure, which was a balanced mix of onshore and offshore teams. The initial phase was more focused on the offshore execution and gradually the work started moving offshore to gain operating and cost efficiencies.

During the entire duration of the project execution, there was a constant support and coordination between the teams from both companies for review, fabrication and integrated testing. HCL had an onsite coordinator while the client had employed a technical program coordinator for the entire project duration. The client’s technical specialist would visit the offshore locations and review the technicalities of the detailed design phase. A web portal was developed to facilitate faster and secure information exchange.

Aircraft goes out of the hangar

The A2 board was tested under the SRC conditions at board level, box level and system level at full wing stand. Additionally, it was also suggested that the components be placed on the same side of the board as compared to its earlier position on the opposite side of the board. The result was a delight for everyone involved, and it was surely a refreshening makeover of one of the most important systems of this leading aerospace supplier.

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