training techniques and methodologies for helicopter rotor ... · weight maxed out (5 lbs)...
TRANSCRIPT
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Rotary Wing Aircraft Maintenance SchoolAeroskills Division of the Army Aviation Training Centre
Training Techniques and Methodologies for Helicopter Rotor Track and Balance
presented by
Mick RichmondTechnical Instructor/Development Officer
Technical Mastery Wing Rotary Wing Aircraft Maintenance School
OVERVIEW
ARMY ROTOR TRACK AND BALANCE (RTB) BACKGROUND
INCREMENTED TRAINING
CURRENT AND PROPOSED METHODS FOR ADVANCED OPERATOR TRAINING
RTB METHODOLOGY
AN INTEGRATED APPROACH TO RTB & VIBE ANALYSIS
CH47D CM PROGRAM OVERVIEW
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RTB - THE ARMY EXPERIENCE
CONTINUED INEFFICIENCIES ARE LEADING TOUNNECESSARY A/C DOWNTIME.
ON AVERAGE - APPROX 80% OF ALL TEST FLYING FOR RTB
CONTINUAL WASTED MAN HOURS AND AFHRSDIRECTLY RELATED TO RTB TASKS
TYPICALLY, EVERY SQUADRON HAS ITS RESIDENT ‘EXPERT’DILUTION OF EXPERIENCE
‘EXPERTS’ FREQUENTLY ILL INFORMED AND COMMUNICATIONBETWEEN SQUADRONS IS LIMITED, TRAINING BY OSMOSIS
RTB BACKGROUND
EXPERIENCE & EXPERTISE WITH RTB IS ESSENTIAL TO MINIMISE A/C DOWNTIME, INCREASE AVAILABILITY FOR
TASKING AND EFFICIENT ‘TIMES TO SERVICEABLE’ (TTS)
CONTINUATION TRAINING, RE FAMILIARISATIONWITH EQUIPMENT AND DEVELOPING EXPERTISE DIFFICULT
TO ACHIEVE WITH INCREASING DEMANDS ON TRADESMAN’S TIME
PREVIOUS LACK OF ADF ACKNOWLEDGMENT OF RTB AND VAAS A SPECIALITY AND THE QUANTUM SAVINGS
ACHIEVABLE IF CORRECTLY IMPLEMENTED THROUGHOUT ADF.
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EXISTING RTB METHODOLOGY
CONSERVATIVE - SLOW TO EMBRACE CHANGE INSISTENCE ON GOING BACK TO THE “OLD” CHARTS
BECAUSE OF NOT UNDERSTANDING THE METHODOLOGY OF THE NEWER EQUIP
TRADITIONAL - “ALWAYS DONE IT THIS WAY”
EXISTING RTB METHODOLOGY
BY NUMBERS APPROACH - DOGGED NATURE OF REPEATINGEXACTLY THE SAME MISTAKE AGAIN IF THE RTB DOESN’T
WORK OUT - FAILS TO LOOK AT THE BIG PICTURE ORTROUBLE SHOOT ADEQUATELY
LACK OF UNDERSTANDING - BY NOT UNDERSTANDING HIS ACTIONS, CAUSE & EFFECT ETC,
IN-ABILITY TO TROUBLESHOOT
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EXISTING RTB METHODOLOGY
VERY LITTLE INNOVATION OR CHANGE IN HELICOPTER RTB
LONG HELD BELIEF IN ONLY THE DYNAMIC PORTION OFRTB - “ALWAYS DONE IT THIS WAY”
EXISTING RTB METHODOLOGY
VERY LITTLE ATTENTION TO STATIC BALANCE,SPAN AND CHORD MOMENT ARMS AND THEIR EFFECT
ON THE DYNAMIC RTB.
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BLACK HAWK INCIDENTS
GROUND ROLL VIBRATION IN EXCESS OF 1.5IPS
WEIGHT MAXED OUT (5 lbs) RESULTING IN GROUNDROLL OF 0.6IPS
SOFTWARE INVOKED SIKORSKY BLADE SWAP ROUTINE
RESULTED IN OPERATORS COMPLETING UP TO 8 GROUND RUNS AND MULTIPLE BLADE SWAPS WITH NO EFFECT
BLACK HAWK INCIDENTS
STATIC BALANCE, AT BLADE REPAIR VENUE, SHOWED CONSIDERABLE VARIATION IN STATIC MOMENT
AS A RESULT, INTERIM RECOVERY PLAN ISSUED BY WSLM
DUE TO INABILITY TO STATICALLY BALANCE AT UNIT, CHANGE 1 BLADE - CHANGE ALL 4
2 X AVION STATIC BALANCE FIXTURE PURCHASED, ONE AT UNIT, ONE AT BLADE REPAIR VENUE
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BLACK HAWK INCIDENTS
RESULTS:• CONFIDENCE LEVELS OF OPERATOR GREATLY INCREASED AFTER BLADES ARE PASSED OVER USBF (STARTING POINT,
UNDERSTANDING OF THE ENTIRE PROCESS)
• CONSIDERABLE REDUCTION IN TEST FLIGHTS (FROM 4 TO 2)
• APPRECIATION OF THE ENTIRE PROCESS SIGNIFICANTLY IMPROVED RESULTING IN GREATER EFFICIENCY
INCREMENTED TRAINING
ALL TRAINING - COMPETENCY BASED
TRAINED TO EXPECTED LEVEL OF PERFORMANCEIN THE WORKPLACE
ASSESSED AT STANDARDS REQUIRED IN THE WORKPLACE
3 LEVELS
1. INITIAL EMPLOYMENT TRAINING
2. AIRCRAFT TYPE CONVERSION TRAINING
3. SQUADRON ADVANCED TRAINING
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INITIAL EMPLOYMENT TRAINING
GENERAL VIBRATION THEORY
GENERIC EQUIPMENT TYPES AND BASIC FUNCTION
BASIC FAMILIARISATION WITH PROCEDURES
LIMITED OPPORTUNITIES FOR PRACTICAL APPLICATION
AIRCRAFT TYPE CONVERSION TRAINING
AIRCRAFT TYPE SPECIFIC THEORY
EQUIPMENT APPLICATION TO SPECIFIC TYPE
TYPE SPECIFIC PROCEDURES
LIMITED OPPORTUNITIES FOR PRACTICAL APPLICATION
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AIRCRAFT ADVANCED TECHNICIAN COURSE
• IN THE PAST, EXPERIENCE LEVELS OF TRADE SUPERVISORS WERE CONSIDERABLE.
• ON AVERAGE, FROM TRADESMAN TO SUPERVISOR WAS APPROX 3-4 YEARS.
• IN THE CURRENT ENVIRONMENT, AS QUICKLY AS 1-2 YEARS.
• SYSTEM KNOWLEDGE AND FAULT FINDING ABILITIES HAVE SUFFERED CONSIDERABLY AS A RESULT.
AIRCRAFT ADVANCED TECHNICIAN COURSE
ADVANCED DIAGNOSTIC TECHNIQUES
COMMON TYPE SPECIFIC FAULTS
REMOVE GENERIC INFORMATION AND CONCENTRATEON AIRCRAFT SPECIFIC ISSUES
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AIRCRAFT ADVANCED TECHNICIAN COURSE
INCORPORATION INTO TRAINING OF THEBLACK HAWK FULL MISSION FLIGHT SIMULATOR
SIM ALLOWS INTEGRATION OF SIMULATEDSIGNAL AND PHYSICAL VIBRATIONS OF THE AIRCRAFT
ASSESSMENT CONDUCTED IN THE SIM TO BEST REPLICATE THE TASK ENVIRONMENT (THE WORKPLACE)
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TIME OF TASK
THERE IS NO ESCAPING THE ACTUAL TIME TAKEN FOR RTB DATA ACQUISITION AND ROTOR ADJUSTMENTS IN THE
CURRENT ENVIRONMENT
HOWEVER, THERE IS SCOPE FOR IMPROVEMENT OF CURRENT PRACTICES
SETTLE FOR QUOTED PRACTICES ?
DEVELOP AND REFINE YOUR OWN
CONSOLIDATE THE PRACTICE AND DOCUMENT IT
WHAT TO DO?
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AN ALTERNATIVE APPROACH TO RTB
2. INCREASING IMPORTANCE OF STATIC BALANCE SPAN MOMENT ARM ON THE SUCCESS OF THE
DYNAMIC RTB EXERCISE.
3. INCORPORATE IT INTO ROUTINE MAINTENANCE
1. LOOK AT ENTIRE RTB PICTURE - STATIC & DYNAMICAT UNIT/OPERATOR LEVEL.
4. ENCOURAGE INNOVATION, FEEDBACK AND DOCUMENTATION OF NEW PROCEDURES, EFFECTS,
TECHNIQUES AND OBSERVATIONS.
5. MODIFY, UPDATE AND TEACH NEW PROCEDURES.
(ENSURES MAXIMUM BENEFIT IS MADE OF THE NEWEST TECHNOLOGIES TO IMPROVERTB EFFICIENCIES).
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INTEGRATED AND EASILY EXPANDABLE APPROACH TO RTB, VIBRATION ANALYSIS
& CONDITION MONITORING
IMPLEMENT 3 TIER TRAINING SYSTEM.
CENTRE OF EXPERTISE:- TRAINING- TROUBLESHOOTING/ASSISTANCE - PROCEDURES- RTB DOCTRINE
INTEGRATED AND EASILY EXPANDABLE APPROACH TO RTB, VIBRATION ANALYSIS
& CONDITION MONITORING
FOOD FOR THOUGHT
THIS APPROACH HAS REDUCED TIMES TO SERVICEABLEFOR VIBRATION RELATED TEST FLIGHTS FOR
THE BLACK HAWK FLEET IN 5 AVIATION REGIMENTBY 50% BETWEEN 1997 AND 2001.
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SUMMARY
AIRCRAFT ADVANCED TECHNICIAN TRAINING PROGRAM MOVING AHEAD WITH EXCELLENT RESULTS
USE OF BLACK HAWK FMFS PROVING VERY EFFECTIVEIN RAISING AWARENESS OF WHAT RTB TASKS ARE
ALL ABOUT
ANY QUESTIONS?