SAE T-115-2004 Aircraft Maintenance THE ART AND SCIENCE OF KEEPING AIRCRAFT SAFE (To Purchase Call 1-800-854-7179 USA Canada or 303-397-7956 Worldwide).pdf

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1、Aircraft Maintenance THE ART AND SCIENCE OF KEEPING AIRCRAFT SAFE Bruce R. AubinAircraft Maintenance The Art and Science of Keeping Aircraft Safe Bruce R. Aubin Warrendale, Pa.X Copyright 2004 Bruce R. Aubin eISBN: 978-0-7680-5583-2All rights reserved. No part of this publication may be reproduced,

2、stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. For permission and licensing requests, contact: SAE Permissions 400 Commonwealth Drive Warrendale, PA 15096-0001 USA

3、E-mail: permissionssae.org Tel: 724-772-4028 Fax: 724-772-4891 For multiple print copies, contact: SAE Customer Service E-mail: CustomerServicesae.org Tel: 877-606-7323 (inside USA and Canada) 724-776-4970 (outside USA) Fax: 724-776-1615 ISBN 0-7680-1242-2 Library of Congress Control Number: 2004101

4、717 Copyright 2004 Bruce R. Aubin Positions and opinions advanced in this book are those of the author(s) and not necessarily those of SAE. The author is solely responsible for the content of this book. SAE Order No. T-115 Printed in the United States of America.Other SAE titles of interest: What En

5、gineers and Managers Need to Know About Human Factors Richard F. Gabriel (Order No. R-331) Aircraft Accident Analysis James M. Walters and Robert L. Sumwalt III (Order No. B-824) Aerospace Standards Index 2004 (Order No. ASIN2004) Market Driven Trends in Reliability and Maintainability for Business

6、Aviation Propulsion Engines (Order No. SP-1731) For more information or to order a book, contact SAE at 400 Commonwealth Drive, Warrendale, PA 15096-0001; phone (724) 776-4970; fax (724) 776-0790; e-mail CustomerServicesae.org; website http:/store.sae.org.Contents Preface 7 Chapter One Background 9

7、Chapter Two Aircraft Maintenance Organization and Structure 15 Chapter Three Regulations 21 Chapter Four Planning 33 Chapter Five Scheduling. 39 Chapter Six Facilities 53 Chapter Seven Materiel 57 Chapter Eight Training 71 Chapter Nine Quality 75 Chapter Ten Engineering. 81 Chapter Eleven Economics

8、91 Chapter Twelve Maintenance Production 107 Chapter Thirteen Safety 123 Chapter Fourteen Associated Functions and Organizations 131 Chapter Fifteen Narrow-Body Aircraft 137 5Chapter Sixteen Wide-Body Aircraft 141 Chapter Seventeen Regional Carriers 145 Chapter Eighteen Environmental Effects on Main

9、tenance 147 Chapter Nineteen Maintenance in the Future 149 Chapter Twenty Conclusions 155 References 157 List of Acronyms 161 About the Author 165 6Preface F rom the original days of manned or unmanned flight, the individuals and their processes to repair, modify, maintain, and service the vehicles

10、that were used to rise above the ground have largely been unsung. This book is about the processes and the systems that they developed and used to ensure, on an ongoing basis, the quality, viability, and safety of the men and machines committed to flight. This book could not have been written withou

11、t the dedicated support of all the technical individuals from Trans Canada Airlines (currently Air Canada), USAir (currently US Airways), all those companies who are members of the Air Transport Association of America (ATA), the International Air Transport Association (IATA), the Society of Automoti

12、ve Engineers (SAE International), and many others who provided guidance, support, and knowledge to me over the last 50 years. I am also grateful to Jon Lynn and Nancy Govan-Aubin for their substantive efforts in creating the illustrations for the text. You will be taken from the earliest days and pr

13、inciples of aircraft maintenance to the high-level technologies currently in place to ensure the ongoing safety and reliability of airplanes in our commercial air transport system. It is also appropriate, having recently celebrated the 100th anniversary of manned powered flight, that acknowledgment

14、is made to the Wright brothers for their unique achievement because they were dedicated maintainers of their aircraft. 7Chapter One Background History Virtually every mechanism invented by man requires some type of surveil- lance and ongoing maintenance to ensure that it can continue to perform its

15、intended function. Airplanes are no different. In fact, because they operate in an environment generally considered to be at variance with mans normal existence, it is paramount that individuals are trained and that systems are developed to provide continuous inspection and repair. As implied in the

16、 Preface, the first aviators, commercial or otherwise, were often their own maintainers. However, as the airplane evolved from a novel experiment to a system for transporting people and cargo commercially, it became necessary to develop and train a professional cadre of individuals. To ensure that t

17、hese individuals possessed the skills and knowledge to perform their tasks appropriately, they were required to demonstrate their abilities to meet certain standards. Thus, government authorities established a legal requirement that individuals carrying out work on aircraft be certified profes- sion

18、al licensed mechanics. Although initially the standards for licensing varied widely because of the perceived requirements of individual governments, universality was gradu- ally established with regard to basic knowledge and skill to apply to all transport aircraft. In the United States, a mechanic

19、was licensed on a generic basis and carried the designation Aircraft and Engine Mechanic (A the most descriptive was probably the IEC (individual engine control). Each individual major component has its own failure characteristics (e.g., wear, stress). For instance, the compressor is affected by the

20、 rotational stresses, erosion from airborne particles, damage from failed blades or linings, and so forth. Turbines suffer from heat cycle distress, creep, burning, and similar factors. Therefore, each must have an individual maintenance system applied. In addition, because these individual componen

21、ts are transferable and interchangeable among engines, it was absolutely necessary that each have its own maintenance process and records system. 13The results of the IEC maintenance programs were that engines could be maintained on the wing without requiring removal, thereby reducing air- plane dow

22、ntime requirements and optimizing the overall life of the engine. There were additional benefits with the advent of the jet engine. The reduc- tion in vibration from power development had a significant effect on the remainder of the aircraft and its components. This allowed the establishment of true

23、 “condition-monitored“ “on-condition“ maintenance for all aircraft components, as well as significant life extension to those parts of the aircraft subject to fatigue-related stress. The airplane maintenance system subsequently evolved into a series of minor and major checks that verified the intern

24、al health of the structure, a system of auditing the various operating components, and an individual module con- trol system for the engines. Each maintenance system is developed by the individual airlines to ensure ongoing safety and reliability, not only in accordance with the specifications manda

25、ted by the regulatory authorities of the nations in which the airlines operate, but also in accordance with a complex set of operational variables, such as duration of flights, environmental and weather considerations, and passenger and cargo loading characteristics. 14Chapter Two Aircraft Maintenan

26、ce Organization and Structure P rior to developing any consideration of the various functions that are involved in the overall implementation and production of mainte- nance requirements for major airline, regional, and general aviation aircraft, a fundamental review of the systems and programs that

27、 support and form part of the operational segment of the organization and structure is necessary Aircraft Maintenance System The maintenance organization and structure are formed around various func- tions. These functions include organizational responsibilities that must be in place to accomplish t

28、he following: Achieve the work/production elements Ensure the availability of resources Permit achievement of aircraft operational requirements These are all influenced or affected by the operating plan, regulatory approval, and maintenance requirements for each specific aircraft, powerplant, and co

29、mponent, as well as the specific philosophies and strategies espoused by the individual corporations. The maintenance departments mandate is to develop objectives to support the objectives of the corporation (Figure 3). The systems required to provide these capabilities extend not only from the desi

30、gn concept but include the following: The initial maintenance program 15Figure 3. The maintenance systems and management must be suitable to accomplish the regulatory and functional requirements. 16 The dynamic and continuous review to achieve improvements to the program while considering the changi

31、ng physical aspects of the product due to age, environment, and operations The incorporation of the program into clear, concise, and appropriate manuals The transfer, in a straightforward manner, of these instructions to permit their correct accomplishment within the existing maintenance environment

32、 To be effective, each element of the foundation of the systems of mainte- nance must be accountable and responsible for its function. The aircraft manufacturer has the sole responsibility to design the aircraft and specify its maintenance requirements. The certifying and regulatory authorities must

33、 ensure that the design conforms with the airworthiness rules for its intended purpose, meeting all certification requirements, including those for fail-safe and redundant load paths, Code of Federal Regulations (CFR) Part 25-1309. The aircraft maintainer must implement the maintenance requirements

34、as defined by the manufacturer and be audited and monitored continuously by the regulatory authorities. Should either of the first two links be missing, the maintainer may be incapable of fulfilling its function. Work and Production Elements To produce serviceable aircraft, an integrated system is n

35、ecessary to establish what work is required, when it is required, where it will be performed, and the substantiation that the work has been done and done correctly. This involves the functions of planning, scheduling, production management, pro- grams/specifications/processes, and finally inspections/audits/records. Each of the functions necessary to ensure a safe and reliable product will be defined further in detail. 17