Mark IV Antiskid Brake Control System Upgrade Randy Williams Crane Aerospace & Electronics 818-288-7620 randy.williams@craneae.com
Purpose Provide an overview of Hydro-Aire TM Mark IV Antiskid Brake Control System
Overview Crane Aerospace Introduction Brake Control Experience & Technology Evolution Mark IV as part of USAF WBSI program C-130 Antiskid Configurations System Components and Installation Mark IV Background & Benefits Aero Precision Distribution Partner
Who is Crane? A Diversified Manufacturer of Engineered Products Founded 1855 11,000 employees Over 120 locations in 25 countries Headquarters Stamford, CT, USA $2.6B sales (2012) Fluid Handling $1,196M Merchandising Systems $372M Controls $94M Aerospace & Electronics $701M Engineered Materials $217M 4
Crane Aerospace & Electronics 2,800 employees globally 12 Manufacturing sites in 8 countries Global product support Seven core solutions focused on niche technologies 2012 $701M Sales 5
Crane Aerospace & Electronics Heritage Brands Hydro-Aire - legacy supplier of all C-130 brake control systems Lear Romec ELDEC Interpoint Signal Technology Keltec P.L. Porter 6 Merrimac Industries
Segment Solutions AEROSPACE Cabin Systems ELECTRONICS Power 7 Fluid Management Landing Systems Sensing & Utility Systems Microwave Microelectronics
Landing Systems Solutions Brands: Hydro-Aire, Eldec Locations: Burbank CA, Lynnwood WA Brake control In-axle functionality Remote data concentrators and integrated modular avionics packaging Landing gear indication and control systems 8
Crane Brake Control Experience Crane is the undisputed leader in aircraft brake control systems 60+ years experience 65% market share commercial programs 80% market share military programs Over 15,000 systems delivered and in service Most experienced engineering staff in the industry Crane All Others 9 Crane can work with any wheel & brake manufacturer and provide an independent perspective on brake system architecture
Crane Innovation in Brake Control Mk1 Crane introduces first antiskid in 1947 Mk2 Mk3 First wheel speed transducer First adaptive control Electronics to drive rate sensing & linear four-way pressure control valves Higher response hydraulic control valves; Improved brake control, smoothness and efficiency Mk4 First microprocessor based digital system Mk5 10 Complete brake-by-wire system Improved control algorithms; efficiencies >95% ; Unigain antiskid valve; Improved system performance under variable pilot pedal input Very high performance digital brake control; used on B787 (electric brake)
USAF WBSI Program Overview USAF Wheel and Brake System Improvement WBSI Reliability and performance improvement program Major Components of System Upgrade 3000 psi Brake Metering Valve (Eaton) Mark IV Antiskid Brake Control System (Crane) Wheels and Carbon Brakes (UTC Aerospace Systems) 11
12 USAF Antiskid Upgrade Drivers Mark II brake control system limitations Older analog technology with obsolete components Low braking efficiency by today s standards Control limitations prevent efficient control of carbon brakes to allow inherent operational and life improvement characteristics Similar J model antiskid configuration and performance characteristics Provides Fault Isolation 2011 Crane Aerospace & Electronics
Mark IV System Upgrade Provides Digital Brake Control Velocity Control / High Efficiency braking Proven Technology Military: C-130J, C-17 Civil: 737, 747, 757, 767, 777, 717, most business and regional jets Enables maximum braking performance 20% efficiency gain on wet or icy runways 8% efficiency gain on dry runways 13 2011 Crane Aerospace & Electronics
Mark IV Antiskid Upgrade Timeline Qualified.July 2010 Production Contract awarded..august 2010 Functional Fit Check.September 2010 Flight Test. June 2011 to August 2011 Deliveries.October 2010 to November 2012 USAF TCTO.. October 2012 USAF Legacy Fleet Retrofit Underway 14
USAF WBSI TCTOs 1. Brake Metering Valve 1C-130-2096 replaces 2030 psi with 3000 psi 2. Mark IV Antiskid Brake Control System 1C-130-2095 replaces Mark II system 3. Wheels and Carbon Brakes 1C-130-2098 replaces wheels and steel brakes 15
Antiskid Configurations C-130 Brake Control Configurations Application Brake Brake Key Performance Control Material Factor C-130A/B Mark I Steel Rate detection C-130E/H Mark II Steel Electronic 16 C-130J Mark IV Steel C-130 E/H WBSI upgrade Mark IV Carbon Digital Velocity Control Maximum Brake Performance: Life, Torque, Wear
Mark IV Upgrade Components 17
Mark IV Upgrade Components Digital Antiskid Control Unit (DACU) One per ship set P/N 142-151 Fault Display Unit (FDU) One per ship set P/N 140-15520 18
Mark IV Upgrade Components Dual Brake Control Valves (BCV) Two per ship set Includes Park Brake Function P/N 39-941 Wheel Speed Transducers (WST) Four per ship set P/N 140-325 19
Mark IV Upgrade Components Cable Assembly Adaptor Connects Aircraft Electrical Plugs, DACU and FDU One per ship set P/N 142-15512 20
Mark IV Upgrade Components Mounting Plate Assembly Mounts DACU and FDU onto overhead hog trough channel One per ship set P/N 142-16110 (flat) or P/N 142-15530 (shelf) 21
Mark IV Installation 3000 psi Brake Metering Valve Prerequisite TCTO 1C-130-2096 One to one replacement Components Wheel Speed Transducers Brake Control Valves Digital Antiskid Control Unit 22 Additional Components Fault Display Unit Cable Assembly Adaptor Mounting Bracket
Mark IV Installation Remove Mark II Press Test Console (Cockpit) Cap and Stow wiring Install Blank Faceplate Installation takes approximately 24 hours USAF Standards 23
Mark IV Background & Benefits 24
Background World's first microprocessor based digital antiskid systems New methods for implementing software to generate improved antiskid control algorithms improving adaptability and allowing very high efficiencies on all runway conditions Digital systems offer faster response, faster skid recovery and better control. Tuning optimization is easier and faster due to the great flexibility software adjustments allow Improved Built-in-Test with fault isolation to the LRU Level
Steel Brakes C-130J Airplanes With Hydro-Aire MK IV Antiskid Systems Carbon Brakes C-130H C-17 757 717 767 737 737 757 C-17 767 747-8, 747-400 Cessna Citation 777 Gulfstream V Proven Benefits in antiskid systems with either steel or carbon brakes
Evolution of Antiskid Technology ~15% Efficiency Improvement
Skid Control Performance Mark II Mark IV
Why is performance important? A wheel lock-up for 300 ms will scrub through 28 plies and blow the tire If the tire is operated past the peak of the mu-slip curve, tire heating, ablation, and scrubbing forces can destroy the tire The tire-runway interface and brake torque are not constants MKIV is extremely adaptive to these dynamic varying conditions MK IV will stop shorter, optimize tire wear and brake life 29
Digital vs Analog Features Digital MK IV Analog MK II Component Technology Accuracy and Consistency High speed Microprocessor Fully adaptive - not affected by environment Transistors/Operational Amplifiers - Obsolete Technology Dependent on stability and accuracy of components Control Functions Resident in processor memory Dependent on physical circuit configuration Performance Easily accomplished Hardware component optimization and through software flexibility selection and values must physically change Built-In-Test Continuous BIT w/fault Crude Brake Release
Analog Obsolescence Crane no longer supports Mark II Decreased demand Diminishing sources of supply Increased manufacturing costs 31
Improved Maintenance Features Built-In-Test Continuous monitoring capable of detecting antiskid system failures Provides an Antiskid INOP indication of antiskid system failure Verifies system operational integrity Collects and evaluates data for correctness Failures detected result in activating the INOP indicator in the flight deck 32
Improved Maintenance Features Fault Isolation Isolation to the Component LRU Level Remote Maintenance Fault Display Unit identifies the failed LRU Failures within the Digital Antiskid Control Unit Short or Open detected within the wiring of the Antiskid Valves Short or Open detected within the wiring of the Wheelspeed Transducers 33
Reduced troubleshooting Mark II: Mark IV w/fdu: Field Level Tester Required Single Cockpit Light activated Perform Press Test cockpit control panel Perform Continuity Checks: Pull each hubcap to check wheel speed transducer Antiskid Control Unit access hog trough Check Brake Control Valves pull panels Replace faulty part Single Cockpit Light activated Visually check FDU flags Go directly to source of fault(s) Replace faulty part cockpit indicator light automatically resets.
Why upgrade? Improved performance & safety Improved Brake Control Efficiency Improved Wet and Icy Performance Shorter Stopping Distances/Improved Tire & Brake Wear Eliminate Obsolescence Improved maintenance with BIT Fault isolation Eliminates need for field level tester Reduce Operational and Maintenance Cost 35
Sales and Distribution Favorable pricing and payment terms Dedicated Sales Representatives Available stock Timely delivery Installation and integration support 36
Points of Contact Stop It! Noreen Kabra International Business Development Director 30 Lindbergh Avenue Livermore, CA 94551 Office: +1 925-579-8037 Mobile: +1 925-519-1393 nkabra@aeroprecision.com 37 Randy Williams Regional Business Mgr. 5962 Zebulon Road, Suite 328 Macon, GA 31210 com Office: +1 478-477-6684 Mobile: +1 818-288-7620 randy.williams@craneae.
38 STOP IT! with Mark IV Antiskid Brake Control System