© vibro-meter confidential and subject to export control as per front pagegenx emu ddr 18 november...

© Vibro-Meter Confidential and subject to Export Control as per Front Page GEnx EMU DDR 18 November 2008 Section 2.2 Flexes Slide 1

EXPORT CONTROL

EXPORT CONTROLTHE INFORMATION AND TECHNICAL DATA CONTAINED IN THIS DOCUMENT ARE CLASSIFIED UNDER CATEGORY 4E001.A ACCORDING

TO THE SWISS EXPORT CONTROL REGULATIONS. EACH RECIPIENT IS RESPONSIBLE TO ENSURE THAT USAGE AND/OR TRANSFER ORDELIVERY OF THIS INFORMATION COMPLIES WITH ALL RELEVANT EXPORT CONTROL REGULATIONS.

PROPRIETARY INFORMATIONTHE INFORMATION CONTAINED IN THIS DOCUMENT IS THE PROPERTY OF THE VIBRO-METER GROUP OF COMPANIES AND SHALL BE

USED ONLY BY THE RECIPIENTS FOR THE PURPOSE FOR WHICH IT HAS BEEN SUPPLIED AND SHALL NOT BE DISCLOSED TO ANY THIRDPARTY WITHOUT THE WRITTEN CONSENT OF VIBRO-METER


GEnx 1B Engine Monitoring Unit

P0x Delta DDR – Section 2.2 Flexes

18th November 2008


GENx EMU Drawing Tree - Flexis

EMU 127271-127-0SS-HHh

BOX / COVER (TOP)271-127-108-XXX271-127-101-XXX

FRONT PLATE271-127-110-XXX

FRONT BACKPLANE

271-127-120-XXX

REAR COVER271-127-150-XXX

REAR BACKPLANE271-127-160-XXX

PSMPower Supply Module

271-127-200-XXX

DC/DC271-127-220-XXX

AC/DC271-127-260-XXX

VSMVibration Signal Processing

Module

271-127-300-XXX

Programmable component

271-127-311-XXX

BOOT271-127-713-XXX

CPMCommunication and Processing Module

271-127-400-XXX

CPU1Programmable Component

271-127-411-XXX


271-127-412-XXX


271-127-413-XXX

CPU1 BOOT271-127-710-XXX



FLEX forPSM/Rear Backplane

271-127-270-XXX

FLEX for PSM/VSM/CPM

271-127-280-XXX

FLEX forVSM/Front Backplane

271-127-350-XXX

FLEX forVSM/Rear Backplane

271-127-360-XXX

FLEX forCPM/Front Backplane

271-127-450-XXX

FLEX forCPM /Rear Backplane

271-127-460-XXX

FLEX forCPM /VSM

271-127-470-XXX


Action Items from last mini-reviewAction Item Required Action Owner Status Resolution

Flex Mini 1 Flex Form Fitting Test Plan Review Define and submit for review the proposed test plan for performing DAT thermal cycle testing that demonstrates the durability of the pre-formed flex.

Meggitt Open Flex durability will be verified by combination of Temperature cycling (-55 to +85Deg C) and Vibration endurance (Levels TBD)

Flex Mini 2 Flex Form Fitting Test Perform additional DAT thermal cycles to substantiate the stability of the pre-formed flex.

Meggitt Closed Pre-Formed Flexes will not be used

Flex Mini 3 Flex Vibration Characterization Perform DAT vibration surveys using a cut-away chassis on the current and proposed designs to establish that the relative motion of each of the flex is acceptable (or if additional flex control features are needed).

Meggitt Closed Additional control / fixation features have been included in revised P0x / Flex design - as presented at this DDR.

Flex Mini 4 Flex Unit Assembly Jigs Review the manufacturing process for controlling the end plate installation / removal processes (to preclude excessive bending or loss of pre-form) and adequacy of the revised flexes to ensure no potential abrasion damage during engine vibration.

Meggitt Closed Jig(s) have been designed to aid EMU assembly and flex strain relief during assembly - as presented at this CCR

Flex Mini 5 Flex Lengths Review the lengths of each flex relative to the need for the identified installation / removal processes (including mfg jigs).

Meggitt Closed Flex lengths HAVE been changed based on assessment of Production (& Repair) needs. Manufacturing Jig has been designed - as presented in this DDR

Open 1 20%Closed 4 80%

Total 5

ID

GE PROPRIETARY INFORMATIONThe information contained in this document is GE Proprietary Information and is disclosed in confidence. It is the property of GE and shall not be used, disclosed to

others or reproduced without the express written consent of GE, including, but without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or configuration changes or to obtain FAA or any other government or regulatory approval to do so. If

consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole


Changes since PDR mini-review

Resolved Minimum Bend Radius Issues

RTV on Hard surfaces

Flex re-routing to eliminate tight bend radii

Addition of Velcro 3HA5 material to restrain movement of flexes FASTECH Velcro 3HA5 SUPER GRIP HOOK (2040) In F.R.T. (Fire Retardant) quality

EMU Assembly procedure changed to eliminate « blind assembly »

Assembly Jig designed for ease / repeatability of EMU assembly and Flexes


Characteristics of EMU Flex / Stack Up

Flex Part

Thickness (μm)

COVERLAY 25

INT1 35

KAPTON 25

INT2 35

COVERLAY 25

KAPTON 25

INT3 35

COVERLAY 25

t = 230

R = 18 x 230 = 4140 μm # 4.2 mmRoptimum = 20 x 230 μm # 5 mmRdefined = 26 x 230 μm # 6 mm


Flex Position Control Features

Selective use of Velcro to control position of certain flexes within the unit (4 out of the 7 Flexes) FASTECH Velcro 3HA5 SUPER GRIP HOOK (2040)

• Temperaure compliant and resistant to humidity 3M 468MP Acrylic Adhesive

• Conforms to specification MIL-P-19834 1, Type 1

• Temperature compliant and resistant to humidity / Water

• Adhesion 7.6N/10mm, High Shear strength

Flex Print with re-enforced zone


Flex (1) - 350 VSM/Front Backplane

P0X Revised

RTV

Flex is restrained Here


Flex (2) – 280 PSM/VSM/CPMP0X


Flex (3) – 450 CPM/Front BackplaneP0X



Flex (4) – 470 CPM/VSMP0X


Flex (5) – 460 CPM/Rear BackplaneP0X


Flex (6) – 360 VSM/Rear BackplaneP0X


RTV Standoff


Flex (7) – 270 PSM/Rear BackplaneP0X Flex is restrained Here


Flex Issues – P0X Overall Solution

Flex chaffing on back of Backplane connector pins Connector Pins covered with RTV fillet

Chaffing on Backplane Components (Cans) Additional space within unit, Flex re-routing and Flex fixation now alleviates

all instances of chaffing

Chaffing on VSM / CPM / PSU Board edges Flex re-routing, Flex controlled fixation and RTV on remaining “exposed”

edges alleviates all instances of chaffing

Bend Radii Design Guidelines established


Flex Print Design and Manufacturing Drawings

A Complete Set of Flex Print manufacturing drawings has been supplied for this DDR


3-D View of Chassis / Flexes

JPEG Image


Manufacturing / Assembly

Revised Procedure for EMU Assembly

Design of Assembly Jig


P0x Exploded Assembly Drawing


Revised Procedure for EMU Assembly

EMU and Flex Assembly Process totally reviewed

Design of Jig to enable repeatable and non-Blind Assembly process

Alignment and fixation of flex prints in an « open chassis »


- PSU board, previously screwed to the cover is put on the jig, locked in place

EMU127 & Flex Assembly operation


- The 2 boards, VSM and CMP are slid into the jig, locked in placed with 2 soft screws for each board at the back of the jig



- Front flexes are screwed to the 3 boards (PSU, VSM, backplane) and visually checked for alignment. On existing EMU this is a blind process.



- Additional part of the jig is put to added the frontplate to restrain the backplate assembly (Flex strain relief and repeatability of assembly process)

- Jig is turned 180° flexes are connected to the frontplate.



- Cover is slid on until approx 2/3

- The 2 side parts of the jig are unlocked and removed



- Cover is in place



- Boards are locked with calmarks



- Frontplate is secured



- The unit is turned, feet on the jig, backside in the front of the jig

- Flexes are secured



- Additionnal part of the jig is added to maintain the frontplate in the right place

- Jig is turned 180°, flexes are connected to the frontplate



- Backplane and cover are completely secured



Flex Verification

Vibration and Temperature DAT testing Was scheduled week of 17-Nov-2008 but delayed due to Flex print Supply

problems (Fire at Supplier) Re-scheduled for Early Jan 2009

Certification plan as per 25-Point Certification Matrix to be performed at Component Level for – 2B certification (Currently scheduled Feb to May 2009)

© vibro-meter confidential and subject to export control as per front pagegenx emu ddr 18 november...

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