Boeing's 787 Dreamliner Could Fly Again in "Weeks"
March 15, 2013 12:12 PM
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New safety upgrades could make this possible
Boeing could have its 787 Dreamliner jets
back in the sky
in "weeks" instead of months thanks to a few new safety upgrades.
According to Boeing, the safety upgrades include improved production/operating processes,
adjustments to the battery
itself and a new enclosure for the battery.
"Our first lines of improvements, the manufacturing tests and operations improvements, significantly reduce the likelihood of a battery failure," said Mike Sinnett vice president and chief project engineer of the 787 program. "The second line of improvements, changes to the battery, helps stop an event and minimize the effect of a failure within the battery if it does occur. And the third line of improvements, the addition of the new enclosure, isolates the battery so that even if all the cells vent, there is no fire in the enclosure and there is no significant impact to the airplane."
Improved production/operating processes entails more rigorous testing. Boeing partnered with battery maker GS Yuasa and integrated power conversion system provider Thales to come up with new testing methods. Now, there are 10 different tests that battery cells must undergo over a 14-day screening period.
They've also adjusted the acceptable level of charge for the battery by lowering the highest charge allowed and raising the lowest level allowed.
As for the battery itself, two kinds of insulation were added: an electrical insulator and a thermal insulator, which will wrap around/below each battery cell to keep them away from each other and the battery case.
The wire sleeving and wiring within the battery were also upgraded to be resistant to heat and chafing. In addition, small holes were added to the bottom of the battery case to allow moisture to drain, and larger holes will allow the battery to vent if it fails.
As far as the new enclosure goes, it is made of stainless steel and will make sure no wire can ignite inside. It has a direct vent to carry battery vapors outside of the plane and isolates the battery from the rest of the equipment.
“It is reasonable to expect that we could be back up and going in weeks, not in months,” said Sinnett. “We understand the work to be done and we’ve got a fairly good notion of how long it will take, and if we miss, it will be by a little, not by a lot.”
Boeing's 787 Dreamliner suffered many issues back in Janury of this year. It started with a 787
operated by Japan Airlines, which
experienced an electrical fire
at Boston's Logan International Airport
after coming in from Tokyo. According to the National Transportation Safety Board, a battery in the auxiliary power unit suffered severe fire damage.
One day later,
a Boeing 787 operated by the same airline at the same airport suffered a fuel leak.
a 787 Dreamliner with All Nippon Airways (ANA), which had arrived at the Matsuyama airport in western Japan from Tokyo on Friday, developed a web-like crack in the cockpit window. That same day,
another 787 Dreamliner with ANA had an oil leak after traveling to the Miyazaki airport in southern Japan.
Finally, an ANA 787 flight to Tokyo
had an issue with its main battery only 15 minutes into a 90-minute flight. After 40 minutes, a burning smell made its way into the cabin and cockpit, and the plane made an emergency landing at Takamatsu Airport on the southern island of Shikoku.
caused all 787s to be grounded
in Japan, the U.S. and India until a safety investigation was conducted and the problems were corrected.
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RE: stating the obvious
3/16/2013 10:34:43 PM
When I was a kid, an experienced engineer told me. To build a bridge which won't fall is engineering, while to build a bridge with minimum material but it still can hold up is the best engineering. Yeah these "band-aid" fixes might be don at the first place but the engineers thought they can get away without them.
Just reminded me about Ford Pinto. They had a bladder design for the gas tank to protect leaking at the early stage. But they cut corner to save a few bugs and maybe a pound or so. That result was disastrous.
Actually beyond these band-aid fixes, Boeing trimmed down the maximum charge and elevated the minimum discharge. These all reduces the battery efficiency (W/lb). But hopefully the change result still within spec and still better then Ni-Cd batteries.
"Intel is investing heavily (think gazillions of dollars and bazillions of engineering man hours) in resources to create an Intel host controllers spec in order to speed time to market of the USB 3.0 technology." -- Intel blogger Nick Knupffer
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