General Discussion
In reply to the discussion: Boeing 787 pilot training...first hand: [View all]Flybywire
(7 posts)Al Baker is correct. The 787 electrical system was started on the drawing board over 9 years ago then, major parts of the generator system were designed and tested over over the next few years by Hamilton Sundstrand. HS has had many, many years to uncover "new" glitches. I believe Boeing is misleading the media, their customers and the public when they try to make us think that the 787 was "new" just last year. If new, that would be a reasonable excuse.
Here is my take on the generator problem:
I have worked for several firms which designed electrical products for the 787. The amount of engineering worst-case-analysis (WCA) was huge compared to any aircraft I have worked on before. At each company which designed these products, there would be like 3 engineers working for 4 months straight analyzing every single transistor to find What is the effect if each part was too hot? too cold? bad tolerance? etc etc.
THE BIG PROBLEM that I saw though was that, often the equations the engineers were ordered to use were just simply incorrect. If the tier-2 supplier had never heard of tail-loss in an IGBT for example, then you weren't allowed to use tail-loss in your equations. Reliability equations for some parts were based on failure modes which were only common in 1942, now they're completely different (example: failure modes for transistors are NOT the same as for old fashion tubes).
Try to bring up this madness to the tier-2 supplier? They would get angry and say, "Schedule!"
The effect was that we got paid (and paid well) to create huge documents with the word, "quality" stamped on the front of each page.
Our mission was NOT to create a quality airplane. Our mission was to create quality paperwork.