A new A320 Airbus aircraft must pass rigorous testing before it can be put into service, so to ensure a smooth flight, not only the aircraft itself needs to be protected from overheating, but also the test hardware needs to be properly protected. Airbus relies on Rittal Blue e+ cooling units to keep its test equipment in the best possible condition.
The 28 test stations operate 5 days a week and operate in two shifts.
As the pilot's seat was not yet installed, two Airbus engineers sat in a simple seat in the cockpit of the new A320, and through the cockpit window, instead of white clouds, they saw four displays showing the "ground test instructions" they needed to read carefully. Volker Jacobs, Ground Test Supervisor for the A320 · Fourth Final Assembly Line, said: "We simulated all flight maneuvers on the final assembly line. ”
(1) The cooling unit in the Icy Marathon Blue e+ series runs continuously to prevent the hardware from overheating.
(2) Digital view Engineers can't see the best view from the air: a display is mounted in front of the cockpit to display ground test instructions.
As soon as the fuselage part of the new aircraft was assembled, the laying of cables and tests began immediately. At each assembly station, all newly installed components and systems are immediately tested to ensure that they are working properly. The full test package for the A320 takes about 400 hours, depending on the aircraft configuration. On the final assembly line, the aircraft simulates refueling, taxiing, take-off and landing, as well as various flight maneuvers.
"Our engineers are not pilots, but they can fly airplanes." Jacobs noted. All functions that are critical to the safety of Airbus flights must be 100% reliable. An A320 must pass all tests before it can be transported to Airbus' Finkwild factory for take-off from the runway and complete the flight.
Rittal cabinets with high-performance hardware
Flight simulation
A variety of tasks will be carried out on the final assembly line, including the provision of a full set of equipment for the cockpit. "We checked everything again – from the headphone sockets and in-flight entertainment system screens in each passenger seat, to the coffee machine in the kitchen," Jacobs said. Testing all the functions on the aircraft requires three high-performance computers, which are connected to the aircraft's sensors and controls to run complex simulation programs. Arm-thick cables extend from the cabinet to the inside of the aircraft, making flight simulation possible. The idea of upgrading to the energy-efficient Blue e+ cooling unit was born during the energy management work in accordance with the requirements of the ISO-14001 certification. As Jacobs explains, the Rittal support software has been a crucial help for Airbus in this process: "Thanks to the energy efficiency calculator, we were able to calculate in advance the amount of energy that would be saved by upgrading to the new cooling technology. ”
Timely maintenance is key to ensuring the reliable operation of the cooling system, and by networking the equipment, the system can report on the condition of the cooling unit, and the maintenance team can then take action in a timely manner and work at the most appropriate time.
Airbus executives were also impressed with the cooling system, which made it easy to adjust all parameters using two buttons on the control panel, and the display showed status and error messages clearly. Jacobs concludes: "The quality is excellent and the Rittal has provided us with great customer service. ”
Airbus has developed analog computers, which are installed in Rittal cabinets, and when the computers work, they generate a lot of heat, especially the voltage transformers that connect the parts of the aircraft can become very hot and therefore need to be cooled.
Jacobs recalls, "In the past, before we started using active cooling systems for computers, they often broke down in the summer. Given the tight and interlocking schedule of Airbus' production schedules, this must not be allowed to continue. The cabinet was fitted with an active temperature control system in 2006 to avoid such downtime. Today, there are 28 such test stations at the Airbus plant, all of which are in a similar configuration.
What's more, all devices are equipped with Rittal Blue e+ cooling to prevent sensitive hardware from overheating. For Airbus, the reliability of the Blue e+ unit is particularly important.
"If the cooling system of the simulated computer fails, we won't be able to test it," Jacobs noted. "The test bench runs at least five days a week in two shifts. "We turn on the cooling units in the morning and they work very reliably," he says. "The cooling system on the test bench is monitored. If a unit malfunctions, a warning light is lit to warn the staff.
Satisfied customers Walker ·Jacobs (left), Head of Airbus Ground Testing, and Werner Wohlfart (right), Key Account Manager · Rittal Aviation, are delighted that they have chosen the Blue e+ cooling unit for the functional testing of the new aircraft.
Energy-efficient and reliable
The idea of upgrading to the energy-efficient Blue e+ cooling unit was born during the energy management work in accordance with the requirements of the ISO-14001 certification. As Jacobs explains, the Rittal support software has been a crucial help for Airbus in this process: "Thanks to the energy efficiency calculator, we were able to calculate in advance the amount of energy that would be saved by upgrading to the new cooling technology. ”
Timely maintenance is key to ensuring the reliable operation of the cooling system, and by networking the equipment, the system can report on the condition of the cooling unit, and the maintenance team can then take action in a timely manner and work at the most appropriate time.
Airbus executives were also impressed with the cooling system, which made it easy to adjust all parameters using two buttons on the control panel, and the display showed status and error messages clearly. Jacobs concludes: "The quality is excellent and the Rittal has provided us with great customer service. ”
Article source: Rittal service account
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