What Makes New Helicopters Challenging to Service?
A next generation helicopter incorporates new technologies, digital control systems, and advanced structural materials that are advanced far beyond the sheet metal and steel found in an older aircraft. “Next-generation helicopters are designed to minimize maintenance downtime and maximize aircraft availability through the use of new technology. They require a new way of thinking,” says David Stilianos, general manager of Sikorsky Helitech, a helicopter MRO based in Australia. To cope with these new helicopters’ complex maintenance programs and integrated systems, Stilianos explains, “An effective MRO must be able to provide a much higher level of support services, including program management, logistics, and engineering support to perform MRO work.”
Servicing these advanced aircraft is not just a matter of working with digital/computer-based avionics instead of analog/ mechanical systems. Today’s next-generation helicopters are computer-driven platforms where fly-by-wire systems, servomotors, and electronic sensor inputs are replacing hydraulics and direct feedback mechanical systems. Today’s MRO technicians must have the skills to work on them; being able to shape sheet metal isn’t enough. “It’s also a matter of having detailed operational experience and the know-how to develop supplemental systems and mission equipment to address the ever-changing operational parameters demanded of these helicopters,” adds Dave McGrath, VIH Aerospace Group’s director of sales. He cites search and rescue and offshore operations as two areas where such change is ongoing.
Vector Aerospace is a rotary- and fixed-wing MRO with facilities around the world. Their vice president of business development for airframe and avionics solutions, Elvis Moniz, points out, “The cockpit and engine control systems in next-generation helicopters require a higher degree of skill and maintenance to properly integrate and shield these sophisticated digital systems to ensure system integrity.” Furthermore, he says that avionics and electronics in next- generation helicopters are increasingly sensitive to externally induced electromagnetic interference.
A particular concern with these new helicopters, compared to their analog ancestors, is the high degree of interdependent systems integration. The downside of intensive integration is that an error in the configuration of one seemingly isolated element can actually impair a number of onboard systems. Moniz explains, “Today’s next-gen helicopter cockpit systems are heavily integrated with flight management systems, digital autopilots, and caution advisory systems, including traffic and collision avoidance. All these systems must be thoroughly understood by the integrator, as any changes to these systems—even minor changes—will often impact other systems in a negative and sometimes unforeseen way.”
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May/June 2016
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