Crossing limits is part of her daily life

Lufthansa Technik AG and Politecnico di Torino, the polytechnic university of Turin, Italy, recently developed an automated, non-invasive diagnostic procedure for the initial examination of primary hydraulic flight control actuators. The aim of the Hydraulic Diagnostics (HyDiag) project, which will run to the end of 2020, is to make diagnoses for these safety-critical components much more precise, to speed up maintenance and to significantly extend their service life. 

Since they are constantly in motion during flight, primary fly-by-wire flight control actuators in particular are subject to a very high load. If an error message occurs, they are checked for wear and tear at Lufthansa Technik's component workshops in Hamburg and are readjusted. For this purpose, the actuator in question is first extended and retracted in the test bench following an extensive sequence of individual patterns of movement, while a highly sensitive measurement system records its behavior during this input. Repairs are made wherever the results exceed the tolerances prescribed by the Component Maintenance Manual. 

Up to now, this initial test was performed by a mechanic, but owing to human limitations in recognizing errors and making accurate adjustments, this person could only "work by feel" finding individual areas of damage. Many areas of incipient damage remained undiscovered with this approach because they were still within the tolerance limits, but just a short time later, these areas could also trigger a repeated exchange of the actuator. As a result, the actuator's time-on-wing dropped continually with every visit to the workshop. 

To prevent this, the automated HyDiag procedure follows a strictly data-centric approach. In the process, the actuator is stimulated during initial examination with an extensive oscillation pattern developed especially for this process. In a fashion similar to a stress ECG, during the procedure the test bench records all the component-specific reactions to this stimulation. The data gained this way is so informative that conclusions can be drawn about the wear and tear of nearly all individual components. As a result, the mechanic obtains a much more comprehensive diagnosis of the wear and tear on the entire actuator system as early as the initial examination, and can focus afterwards on preventing future wear and tear as well. The service life of the component is prolonged significantly as a result. The procedures for stimulating the actuator and for analyzing and interpreting the test results were created in close cooperation with the polytechnic university of Turin, Italy. 

As a second core component aside from the measuring system, HyDiag uses an industrial robot whose software was developed by the Component Services division especially for this task. The robot can carry out all the necessary adjustments during initial examination completely automatically, and in contrast to a human mechanic it does not require special protection when working in the danger zone of a pressurized actuator. Using the data that is recorded, the robot also always "knows" where the optimum for each of the settings lies, and it delivers additional measurement data that has historically not been available for analysis. As a result, the final adjustment of the actuator – the certification test – is also much more precise than it previously was when completed by hand. 

All the adjustment tools for the robot were manufactured using 3D printing at Lufthansa Technik's Additive Manufacturing Center. In addition, when producing its findings the new data-based procedure uses all the existing service life data of the actuator in question – with up to 16 gigabytes of data generated by every initial examination. The result is a much more extensive and detailed analysis of the status of the actuator, which permits wear and tear to be recognized and treated very early.  

"The automated work process means that devices can be tested faster, more data can be generated, and new diagnostic procedures can be used. That enables us to undertake much more extensive troubleshooting than we ever could before," said Michael Burke, who heads up the HyDiag project for Lufthansa Technik. 

"The HyDiag project has a highly innovative content leading to a technological breakthrough in the maintenance of aircraft equipment. Our work together with Lufthansa Technik has advanced the field of Prognostics and Health Management and resulted in multiple papers acknowledged by the community for their quality and scientific relevance," said Professor Giovanni Jacazio, who supervises the activities of Politecnico di Torino on HyDiag. 

Collins Aerospace Systems, a unit of United Technologies Corp. (NYSE: UTX), and Lufthansa Technik AG today announced a first-of-its-kind licensing and asset agreement for Airbus A380 main landing gear Maintenance Repair and Overhaul (MRO) services. Under the agreement, which spans the life of the A380 program, Lufthansa Technik will be able to provide A380 main landing gear MRO services and access to assets supporting customer layover schedules.  

To help Lufthansa Technik develop MRO capabilities for the A380 main landing gear, Collins Aerospace will provide training, parts and proprietary repair procedures, including access to technical publications required to perform A380 main landing gear MRO services.  Lufthansa Technik will offer asset management services through access to a collaboratively managed main landing gears pool of Collins Aerospace. 
 
"This agreement will provide A380 operators with more options for their main landing gear MRO services from high-quality repair centers," said Ajay Mahajan, president of Landing Systems at Collins Aerospace. "Lufthansa Technik and Collins Aerospace have enjoyed a longstanding, collaborative relationship and we look forward to continuing to work together to better meet the MRO needs of our customers moving forward." 
 
Sandra Eckstein, Vice President of Aircraft Systems at Lufthansa Technik said: "This agreement will enable us to support customers comprehensively, not only for planned repair events but also in the case of non-routine work. Our landing gear experts in London will be ready for A380 services in 2020. Especially for customers in the EMEA region this capability will save time and costs. And the next step to further expand our intensive partnership with Collins Aerospace in this area is already planned as we intend to develop new repair methods for the A380 landing gear which are OEM approved."  

About Collins Aerospace 
 
Collins Aerospace Systems, a unit of United Technologies Corp. (NYSE: UTX), is a leader in technologically advanced and intelligent solutions for the global aerospace and defense industry. Created in 2018 by bringing together UTC Aerospace Systems and Rockwell Collins, Collins Aerospace has the capabilities, comprehensive portfolio and expertise to solve customers' toughest challenges and to meet the demands of a rapidly evolving global market. For more information, visit CollinsAerospace.com.  
 
About United Technologies Corporation 
 
United Technologies Corp., based in Farmington, Connecticut, provides high-technology systems and services to the building and aerospace industries. By combining a passion for science with precision engineering, the company is creating smart, sustainable solutions the world needs. For more information about the company, visit utc.com or follow on Twitter: @UTC 

With the continued customer-focused expansion of the independent digital platform AVIATAR, Lufthansa Technik has further integrated the possibilities of digitalization with proven maintenance, repair and overhaul (MRO) services. A growing number of new digital solutions and automated processes allows airline customers to benefit from lower cost, more efficient operations and higher aircraft reliability.

Lufthansa Technik is rigorously developing AVIATAR further into the Digital Operations Suite, which is set to contain all of the company's digital solutions. A number of these are currently being renamed to make the purpose and customer benefits of individual digital services more transparent to users. Airlines using AVIATAR will thus find it even easier to obtain not only a comprehensive real-time view of the status of their fleets, but also fast and efficient solutions to problems which arise during operations.

This week, Lufthansa Technik has further increased its market presence for connectivity modifications in Asia, the world's most rapidly developing market for inflight internet solutions. As the most recent customer for these services, Lufthansa Technik welcomed Chinese service provider Air Esurfing Information Technology Co., Ltd., which it will help in providing aircraft with the first ever inflight connectivity solution for the Chinese market. Further contract partners include Honeywell (antenna hardware provider) and China Satcom (satellite provider). 

According to a new 5-year agreement, Lufthansa Technik will design and certify Ka-band-based connectivity retrofit packages for both the Airbus A320ceo and A320neo aircraft families as well as the Boeing 737NG and 737MAX. The company will also work with Air Esurfing Information Technology Co., Ltd. to provide the respective CAAC validated EASA Supplemental Type Certificate (VSTC) to support Chinese airlines. Moreover, Lufthansa Technik will take care of material supply and material handling services for the installation of the packages, that can be tailored to each of Air Esurfing's airline customers and their specific requirements.  

"As an in-flight solution provider on connectivity, the Company's strategic cooperation with Lufthansa Technik signals a new chapter in our history, as we take a big step forward empowering Chinese airlines with high-speed in-flight Internet services," said Herman Guo, Chief Executive Officer of AirNet, Air Esurfing's parent company. 

"The partnership with Air Esurfing is a significant step in Lufthansa Technik's global focus to meet a promising market demand in China," said Gerald Steinhoff, Vice President Corporate Sales Asia Pacific of Lufthansa Technik. "As a joint force, we shall exploit the full potentials of the Chinese market."

Lufthansa Technik Malta has started to carry out technical services on the Airbus A350. A first aircraft, an Airbus A350-1000 from an undisclosed customer, received a cabin modification in September.

The first A350-900 is expected to arrive in the next weeks for a C-check. So far, three international carriers, amongst them Air Mauritius, have signed MRO (maintenance, repair & overhaul) contracts for the A350 family with Lufthansa Technik Malta.

The start of modification and overhaul services at Lufthansa Technik Malta further strengthens Lufthansa Technik's position as the leading MRO services provider for this aircraft type in Europe, but also in Asia. More than 100 airplanes from different customers already receive comprehensive technical support for components, auxiliary power units, airframe related components, engines and other parts of the aircraft.

Marcus Motschenbacher, Chief Executive Officer of Lufthansa Technik Malta, said: "Our intensive preparations for the arrival of the A350 have been very successful. The first aircraft was re-delivered as planned. We are now looking forward to execute the first C-checks for this aircraft type and feel very well positioned to provide long-term technical support for the entire A350 family. Our facility has become the latest member of the global Lufthansa Technik A350 services network, adding new capabilities for this aircraft type to the whole group."

Lufthansa Technik Malta has undertaken thorough preparations in infrastructure investment and staff qualification to be able to carry out overhaul work on the A350 family. The German Federal Aviation Office (LBA) certification for the A350-1000 was achieved in August 2019. This certification complements the approval for overhaul work on the Airbus A350-900, attained in 2018. Lufthansa Technik Malta is among the first providers of this sort of MRO work anywhere in the world.

On the 30th of September 2019, XEOS, the new aircraft engine service centre located in Środa Śląska near Wrocław, has celebrated its official opening. The company is a joint venture of Lufthansa Technik (51%) and GE Aviation (49%) and is a service centre for GEnx-2B and GE9X engines. It was built in a record time of 16 months. The first commercial engine was accepted for repair in April 2019. In 2019, a total of about 20 engines will have been inducted for service here. After reaching its maturity in 2023 the plant will repair more than 200 engines per year. 

The grand opening ceremony was attended by representatives of the Chancellery of the President of the Republic of Poland and the Polish government as well as Ambassador of the Federal Republic of Germany Rolf Nikel and Christian Cardona, Political and Economic Consul of the US General Consulate. Carsten Spohr, CEO and Chairman of the Executive Board of Deutsche Lufthansa, Dr. Johannes Bussmann, CEO of Lufthansa Technik, David Joyce, Vice Chair, GE and President & CEO, GE Aviation and Jean Lydon-Rodgers, President and CEO, GE Aviation Services represented the two shareholders.

Dr. Johannes Bussmann, CEO of Lufthansa Technik, commented: "For decades, Lufthansa Technik has been known as a centre of excellence in the maintenance, repair, and overhaul business of engines and engine components. The succesful opening of the XEOS engine shop with our partner GE is a cornerstone for our long-term growth strategy to offer comprehensive MRO services also for the latest generations of aircraft engines. On this occasion I would like to thank the whole XEOS team. Over the past two years you have done an extraordinary job to realize this project. You can be really proud of the creation of hundreds of high-level technical jobs and the implementation of the highest levels of international environmental and social compliance standards."

Jean Lydon-Rodgers, President & CEO, GE Aviation Services, said, "XEOS represents a unique collaboration between Lufthansa Technik and GE Aviation. Our combined capabilities and technological knowledge have merge to create one of the most advanced MRO facilities in the world for the GEnx-2B and GE9X engines. I congratulate the XEOS team for building this world-class MRO engine shop and look forward to a long future of working together to meet our customers' services needs."

Thomas Böttger, XEOS Managing Director of Business said: "In June 2015, at the Paris Air Show, two global aviation industry leaders – Lufthansa Technik and GE Aviation – took the decision to jointly develop a modern service centre for GEnx-2B and GE9X engines. Today we are fulfilling this dream and we are proud to take up further challenges. XEOS means innovative technologies, world-class solutions as well as the highest quality and safety standards."

The joint venture partners invested about PLN 1 billion (about 250mln USD)  to construct the facility and their own training centre from scratch, along with a test cell which is still in the ongoing second construction phase of the project.

Ultimately, the plant will employ about 600 people. At the moment XEOS team consists of 300 people: aircraft engine mechanics, engineers, logistics specialists and administration staff. They come not only from Środa Śląska and Lower Silesia  but from all over the world – with 12 nationalities in total. A considerable part of production staff have only started to become experts in the aviation industry in the XEOS centre. It has been possible owing to an 18-month theoretical and practical training programme, conducted in XEOS Training Centre in Bielany Wrocławskie and in similar facilities of Lufthansa Technik and GE Aviation – in  Germany and the UK.

At the Red Dot Design Awarding Ceremony 2019 in Singapore, Ameco's and Lufthansa Technik's jointly developed narrow-body VIP aircraft cabin ‘Nature's Touch' has been honored with a prestigious Red Dot award in the category "Design Concept". ‘Nature's Touch' is a business jet cabin interior concept that combines the cultures of East and West by using traditional Chinese elements and smart technology to create a convenient and comfortable travel experience.

The unique cabin concept brings a brand-new business travel experience to customers for the interior of the Airbus ACJ320neo business jet, which features a live-cooking aircraft galley, guest area, lounge, dining/meeting area, cinema, and master bedroom. The design explores the harmonious beauty in the symbiosis of nature and technology. Due to its flexibility the concept anticipates the adaption to a Boeing 737 BBJ configuration as well.

Feng Bin, Ameco's Deputy General Manager of Beijing Base & Leading Head of Aircraft Cabin Solutions Product Business Unit, said: " ‘Nature's Touch' is a deepening cooperation between Ameco and Lufthansa Technik in the cabin interior concept design, which combines Chinese cultural elements with Western intelligent technology. At the same time, the success of the ‘Nature's Touch' also reflects the cooperation advantages of the two companies. We will strive to bring more unique designs to the business jet aviation market and enhance the cabin experience for our customers. "

Jan Grube, Head of Asia Sales for VIP & Special Mission aircraft at Lufthansa Technik, added: "We are grateful for having had the chance to jointly develop this project with our partner Ameco. Such cooperation shows the synergies of our both company's strengths. This new design as such as well as the innovative features is separating it from similar concepts and the fact that we won the Red Dot Award shows its excellent reception in the market."

The cabin's interiors blend Confucianism with Modernism philosophy. Bamboo knuckles, leaves and woven artefacts are used as recurring motifs alongside traditional Chinese colors such as cream, moonlight beige, bamboo green, jade and crimson. Natural materials such as marble, genuine leather, wool and silk, complement textiles — which have subtle stripes simulating bamboo wood grain — are also used to embrace the eco-friendly trend, thereby adding warmth, depth and visual interest to the interiors.

Smart technology and digital interfaces — such as passenger system control units, wireless charging, intelligent cabin signs, smart touch-screen desktops, smart window shade glass and ambient lights — are incorporated in an unobtrusive and natural way to create a convenient and comfortable flight experience that seamlessly blends in with the cabin décor. In the lounge, a convertible sofa and coffee table, and bar with transformable dividers allow a variety of entertainment options.

The flexible dining/meeting area also offers several scene modes that can be adjusted depending on the situation, facilitating a comfortable and natural atmosphere. For business trips, the cabin displays, connected to news networks via cloud services, show the latest market data or news updates. In a leisure or entertainment scenario, the cabin displays connect to music and entertainment servers to broadcast visualisations that match the mood.

In addition, the cabin lighting and ambience can be programmed to suit a range of scenarios. The jet's cinema is fitted with today's largest roll-up screen — a 75-inch ultra-bright 4K display — and incorporates ambient lighting and an all-new louvered ceiling concept.

About the Red Dot award

Red Dot stands for belonging to the best in design and business. The international design competition, the "Red Dot Design Award", is aimed at all those who would like to distinguish their business activities through design. The distinction is based on the principle of selection and presentation. Excellent design is selected by competent expert juries in the areas of product design, communication design, and design concepts.

In order to appraise the diversity in the field of design in a professional manner, the award breaks down into three disciplines: the Red Dot Award: Product Design, Red Dot Award: Brands & Communication Design and Red Dot Award: Design Concept. Each competition is organised once every year. 

The products, communication projects as well as design concepts and prototypes entered in the competition are evaluated by the Red Dot Jury, which convenes once a year for each competition based on the individual specialist areas of the members. 

China Cargo Airlines has entrusted Lufthansa Technik AG with the component support for three Boeing 747-400 freighter aircraft. The five-year Total Component Support (TCS®) agreement is the first major collaboration between the two companies – and the first TCS® contract with a direct service provision to a Chinese customer.

Lufthansa Technik's Total Component Support offers operators optimal component availability without the task of setting up and maintaining their own spare parts inventories. China Cargo Airlines will benefit from a unique pooling concept which guarantees 100 percent reliable delivery at a pre-determined service level and resulting lower operating costs, especially through effects of scale. The agreement with the all-cargo airline comprises 427 part numbers.

Ji Shuhu, Vice President of China Cargo Airlines, says: "China Cargo Airlines is very glad to sign the agreement with Lufthansa Technik and we realize that China Cargo can obtain more professional and stronger support from Lufthansa Technik. We are looking forward to the further cooperation and good relationship with Lufthansa Technik in many fields."

Gerald Steinhoff, Vice President Corporate Sales Asia Pacific at Lufthansa Technik, commented: "We are very delighted that China Cargo Airlines chose us as trusted component support partner. We guarantee to provide the best service as always to keep their Boeing 747 aircraft flying – and we are looking forward to further collaborations in the nearest future."

For the first time ever Lufthansa Technik presents the full concept of its VIP cabin design SkyRetreat, whose unconventional approach provides travelers with an unseen level of freedom on the occasion of the Monaco Yacht Show 2019,. The design study for the cabin of an Airbus A220 envisions a minimalistic approach based on natural materials and offers an open, versatile place of retreat above the clouds.

The principal idea behind the spacious SkyRetreat design follows a natural look based on authenticity, dominated by its striking wooden floor and the pure and calm design language of the various cabin monuments. The latter´s design, though enriched by a number of modern technical features, never inhibits  the natural feel of the cabin and its  "barefoot experience" for passengers.

The centerpiece of the concept is the Observation Deck that for the first time in VIP aviation extends the passenger cabin seamlessly into the aircraft´s flight deck – allowing all occupants to enjoy unprecedented and totally immersive views of new horizons.

Moreover, the latest high end technologies are discreetly integrated into the cabin´s design – from smart touch surfaces and a distinctive lighting concept to an open deck with a centre buffet as the main element. This multifunctional element allows flexible utilisation in any direction; a  DJ console can be switched into a catering buffet or a gaming interface in seconds – creating an individual way of living on board.

As Wieland Timm, Senior Director Sales, VIP & Special Mission Aircraft at Lufthansa Technik states: "With its immersive Observation Deck and technical features, SkyRetreat provides a  revolution when it comes to offering a unique and pure flying experience. Tailoring the  concept to the Airbus A220, we are targeting an entirely new business section in which especially first time VIP jet owners benefit from this extremly  versatile VIP design for a reasonable investment."

Besides the VIP completion capabilities, Lufthansa Technik already supports the Airbus A220 family with a comprehensive portfolio of services ranging from line maintenance and component services to engine services for its PW1500 geared turbofan engines.

You´ll find us during #MYS2019 from 25th to 28th of September 2019 in our lounge in the Monaco Yacht Club (ground floor, facing in the harbour) or in the BRABUS area of the car deck.

Lufthansa Technik Component Services (LTCS) in Tulsa / Oklahoma continues its growth path by expanding into further capabilities. Recently, the company received the approval of the Civil Aviation Administration of China (CAAC). The Chinese authority has approved LTCS as an "adequate organization to accomplish maintenance of components". Additionally, LTCS has become the 33rd design department of Lufthansa Technik's EASA 21/J Design Organization (DO) and the first one in the Americas.

The DO status allows LTCS to create their own approved data which differentiates the company from many other repair stations. This is a big step forward in developing further repair methods to improve the component services of the company. Customers can benefit from shorter turnaround times, reliability improvements and from overcoming material obsolescence.

 "In 2017 the idea was born, that LTCS should have their own Design Engineers to be as flexible as possible in a constantly changing aftermarket environment. After two years of training and mentorship program, LTCS is very proud to start this new chapter with three Design Engineers", said Tobias Baumgart, COO of Lufthansa Technik Component Services. 

LTCS is now certified by the FAA, the EASA and the CAAC. Today, more than 680 employees are working at its eleven locations throughout North, Central and South America. The company offers a comprehensive bandwidth of Maintenance, Repair and Overhaul services for aircraft components. The maintenance of commercial aircraft components encompasses a wide range of services from repairs of single components all the way to a complete material management system with access to Lufthansa Technik's comprehensive component pool.