Lufthansa Technik develops new antenna radome for faster data transfer

Courtesy: Lufthansa Technik.

Lufthansa Technik has developed its first radome for the Ka-band. The innovative material layer structure of the TIOS (Two-In-One Solution) radome makes it possible to install Ka-band antennas, providing optimal high-speed internet and TV connections for all Boeing Business Jets I (737-700) and II (737-800). This makes Lufthansa Technik one of just a few manufacturers of such radomes worldwide. In December 2016, Lufthansa Technik received the EASA STC (Supplement Type Certificate) and FAA validation for the Two-In-One Solution. Lufthansa Technik has already registered a patent to protect the new radome housing design.

The innovative approach of installing TIOS on the vertical stabilizer makes it the ideal platform for satcom and satellite TV antennas as well as an HD camera. In combination with the installation of the antenna system in the rear fuselage of the aircraft, this solution not only saves space; it also reduces the weight by up to 100 kilograms.

Andrew Muirhead, head of Lufthansa Technik’s Original Equipment Innovation division, explains further benefits of TIOS: “The special aerodynamic design and the installation on the vertical stabilizer mean that the radome reduces drag and has a positive effect on the aircraft’s center of gravity.”

Lufthansa Technik has offered a radome for Ku/L band antennas since 2000. “As the first version of TIOS is not suitable for Ka-band frequencies with high data rates, we investigated many different materials and their characteristics as part of the development of the new TIOS. Ultimately, we were able to develop an innovative material layer structure that allows frequencies in the Ka band to pass through, providing double speed data transfer for passengers,” reports Beate Rehberg, Product Manager TIOS, Original Equipment Innovation at Lufthansa Technik.

Source: Lufthansa Technik.

Final approval: Lufthansa Technik provides complete support for A350

Courtesy: Airbus.

Courtesy: Airbus.

Lufthansa Technik AG is equipped to perform all work required for the complete maintenance of the new Lufthansa Airbus A350-900, the team is trained and ready to go and the company is licensed by the German Federal Aviation Office (LBA). The handing over of the “Base Maintenance Approval” certificate by the LBA brings to an end an intense period of preparation.

More than 100 employees of Lufthansa Technik spent in excess of 18 months working in eight related sub-projects. Now Lufthansa is to roll out a new aircraft type in Munich for the first time – a special challenge in the framework of the project. 28 employees in aircraft maintenance in the Bavarian capital are already extensively qualified for the new aircraft type. And a good 200 others will complete training in areas such as new methods of damage detection and repair for carbon fiber-reinforced structures among others. Lufthansa Technik will invest just under 10,000 course days in this training.

New tools, equipment, procedures. The engine transport stand represents the most significant resource, on which an engine – split in two – can be transported in Lufthansa Cargo freighter aircraft. There are more than 5,000 new part numbers available in stock in Munich alone.

The maintenance concept was developed in close cooperation between Lufthansa Technik Aircraft Maintenance in Munich and Engineering in Frankfurt. Engineers will relocate their offices from Frankfurt to Munich when the A350 operations commence. And there will also be employees from Airbus, Rolls-Royce and Panasonic on hand to provide support in the first few weeks so that a high level of technical reliability can be ensured from the outset.

A number of different units are preparing the remaining upgrade of the new aircraft. Special fittings requested by Lufthansa, such as self-service racks, for example, are being specified by Engineering in Frankfurt and approved for installation by Engineering in Hamburg in the Aircraft Modifications unit.

An entire class is even being newly installed for the first time in the framework of the remaining upgrade, since the aircraft is being supplied from the OEM without Premium Economy Class.

Because these adaptations are equivalent to a modification, they have to be approved by a Supplemental Type Certificate (STC) by the European Aviation Safety Agency (EASA).

Lufthansa Technik already received an extension of its approval as a design organization for the new Airbus A350 from EASA at the start of the year. According to the EASA Part 21/J provisions (Design Organization Approval), Lufthansa Technik is thus authorized to develop and approve repairs and modifications to a limited extent under its own responsibility.

Aircraft maintenance is usually performed in accordance with the manual. However, if the maintenance company has approval according to the Part 21/J provisions, it can independently approve minor repairs without the involvement of the relevant aviation authority. This privilege accelerates the restoration of airworthiness significantly and can have a major impact on flight operation, supporting its punctuality and regularity.

Source: Lufthansa Technik.

Lufthansa Technik and Lufthansa Cargo test loading of Trent XWB

Together with Lufthansa Cargo, Lufthansa Technik AG has reached another important milestone in its preparations for the entry into service of the Airbus A350 in Lufthansa German Airline’s fleet: In a test carried out in Frankfurt under real-life conditions, a Trent XWB aircraft engine provided by Rolls-Royce was loaded into a Boeing 777F. This successful loading trial means that now the seamless logistics of providing spare engines via air freight are assured.

When prepared for loading, the engine and its transport stand weigh eighteen tons. The engine weighs seven tons (dry weight) and is five meters long; the fan is three meters in diameter. As a result, the engine could only be transported via special flight with an Antonov An-124, an Airbus Beluga or a Boeing C-17. As an alternative, Rolls-Royce developed a completely new type of transport stand upon which the engine can be placed and divided into two large modules.

On this split engine stand, the large-volume fan can be separated from the rest of the engine within a single day. The individual modules are then optimally prepared for transport together with the other tools required for engine replacement, and can be loaded. The unit that results from this approach can also be transported in freighters from the Boeing 747 and 777 aircraft families.

Lufthansa Cargo currently has five Boeing 777 freighters in its fleet. As part of the test, the company had to demonstrate that the transport conditions required by Boeing could actually be met in practice.

“Months of planning preceded the test,” explains Ralf Henker, responsible for Supply Chain Management in Aircraft Maintenance at Lufthansa Technik. “Without the partnership and cooperation of our colleagues at Rolls-Royce and Lufthansa Cargo, we would not currently be able to ensure that we can supply every destination airport of the new fleet with a replacement engine if necessary. Every move we make has to fit, and every wheel of the logistics chain needs to mesh optimally with all the others.”

“Over the last four months, we developed a detailed loading and rigging plan based on our experience with other capital goods that are similarly sensitive and yet difficult to handle,” says Harald Mueller, who is responsible at Lufthansa Cargo for Aircraft Handling Competence & Quality Assurance. “It’s great to see that it works in practice exactly the way we envisioned it.”

“We’re very proud that we can now approve this important step on the way to the entry into service of the A350,” said Dean Raineri, Project Director New Aircraft and Infrastructure Development Aircraft Maintenance at Lufthansa Technik. “We’re right on schedule in other areas as well, such as the training of our employees and the procurement of tools and spare parts.”

For some time now, Lufthansa Technik has supported a variety of A350 operators in the areas of component supply and aircraft maintenance.

More than 800 aircraft of the A350 type have been ordered from Airbus to date. The Rolls-Royce Trent XWB is the world’s most efficient large civil aero engine and the exclusive engine option for the A350.

Source: Lufthansa Technik.

Video: Courtesy of Lufthansa Technik.

Lufthansa Technik and DC Aviation Group sign cooperation agreement

Courtesy: Lufthansa Technik.

Courtesy: Lufthansa Technik.

Lufthansa Technik has concluded a cooperation agreement with DC Aviation Group, a leading operator of business jets in Europe. As part of the agreement signed on May 25, 2016, the two companies plan to offer their VIP customers a first-class package of services at Al Maktoum International Airport (Dubai World Central Airport). An experienced, highly qualified team of engineers and mechanics will ensure cost efficiency and quality that are “made in Germany”. Just like Lufthansa Technik, DC Aviation Group is headquartered in Germany, in this case in Stuttgart.

The contract services will be provided in the hangars and VIP facilities of DC Aviation Al-Futtaim LLC, a joint venture of DC Aviation and the Al-Futtaim Group. They will consist of regular checks as well as maintenance services, including unplanned repairs for example in the case of an AOG (Aircraft on Ground). The portfolio also features services for aircraft cabins, including small modifications. Moreover, plans call for a mobile aircraft and cabin service to serve the region.

The offer is rounded off by extensive FBO services (fixed-base operator) for ground operations at the airport, such as fueling, catering for passengers and pilots, and transport services. A luxuriously equipped terminal with 1,300 square meters of space is available for this purpose. Around-the-clock facilities for entry procedures and customs clearance will ensure seamless support. A hangar extending over 5,700 square meters of floor space will accommodate business jets up to the size of an Airbus A320 or Boeing 737. Last but not least, aircraft management and business jet charters are among the services jointly offered by the cooperation partners.

Source: Lufthansa Technik.

Lufthansa Technik presents interior concept for the A350 VVIP

Courtesy: Lufthansa Technik.

Courtesy: Lufthansa Technik.

At EBACE 2016 Lufthansa Technik’s design department has unveiled its brand-new Airbus A350 VVIP interior concept, called »Welcome Home«. The unique cabin is placing the human being in the center of the story and emphasizes a comprehensive approach towards health and well-being on-board. It promotes flexible areas for privacy or valuable family time and provides super connectivity in regard to all communication channels.

Taking into account the often extremely tense life styles of its VIP customers, the »Welcome Home« concept has been consequently optimized to offer a perfect ambience for recreation and relaxation during travel times.

“This unique VIP cabin concept not only addresses our customers’ requirements, but is also a clear proof of Lufthansa Technik’s design and engineering competency. Under the slogan “Driven by Design, enriched by Technical Product Innovations”, many of our own products, like the »Chair« VIP seat, the steam shower or our inductive cooking plate have been integrated in this cabin”, said Wieland Timm, Vice President Sales VIP & Special Mission Aircraft at Lufthansa Technik.

He added: “Travel time should become quality time. For many of our clients time is a rare commodity and family is immensely important. A demanding lifestyle that requires frequent travelling and constant high attention to business and other topics must be balanced by valued family time and relaxation in a healthy environment. The »Welcome Home« concept offers the perfect cabin to fulfill these different aspects.”

“The idea is much more than just a healthy surrounding in an aircraft. We strive to create a flying experience that lets you arrive more relaxed and strengthened then when you start the journey”, added Lufthansa Technik interior architect Michael Reichenecker, who designed the »Welcome Home«  cabin.
“Environment and materials, food quality, relaxation and noise, smell and other factors have an impact on how we humans feel. So taking into account the specific requirements our customers have, the design solution must result in a combination of features that can all potentially cater to a higher sense of well- being.”

Courtesy: Lufthansa Technik.

Courtesy: Lufthansa Technik.

Consequently, the first design priority was to move away from the ever adding of box type rooms and instead to create more flexible areas that can be opened and combined for better social interaction and closed for full privacy if so desired. Located in the most favorable area in regard to noise and aircraft movement, the front part of the aircraft, the “Family Flex Area” facilitates a large and airy private space comparable to an expensive hotel suite. An office within this area focuses on private conversations or interactive video conferencing, allowing the VIP to place himself in the midst of his staff whenever required.

The guest lounge entertains with a cinema size screen and offers a new lighting approach. In Lufthansa Technik’s patent pending new “Living Lining” concept ceilings and walls themselves turn into lighting elements. Dedicated areas such as the ceiling over the dining table can be specifically lit up, while other areas are moodily dimmed down. Imitations of clouds can be depicted, even animated, and aside of presets any individual lighting requirement can be reproduced.

 »Welcome Home« also sets new standards in regard to healthy on board food preparation. Lufthansa Technik’s new induction platform has been integrated and allows for fresh food cooking on board. The all-in-one solution includes a power unit, an exhaust fan and a special cover, which ensures that pots and pans remain in place even during turbulence.

In the AFT of the cabin a large SPA area has been introduced which welcomes guests with a humidifying water feature and otherwise offers a relaxing steam bath, a massage shower, and a massage table that may also double as a passenger transport unit (PTU) if so required. Top sound quality and individual lighting let guests immerse fully in a deeply relaxing surrounding.

The whole cabin comprises about 270 square meters (about 2,900 sq ft). Despite the fact that the design was originally developed for an A350 cabin, the flexibility of the concept allows the adaption to other wide-body aircraft, too.

In addition to its VVIP cabin completion capabilities for the Airbus A350, Lufthansa Technik is already offering a broad portfolio of maintenance, repair and overhaul services to various commercial carriers for this aircraft type.

Source: Lufthansa Technik.

Lufthansa Technik: Qantas extends its A380 support contract with Spairliners until 2025

Courtesy: Qantas.

Courtesy: Qantas.

Qantas Airways Ltd., the Australian flag carrier based in Sydney, has renewed its Integrated Component Care contract with Spairliners who have been providing services since the A380 entry into service in 2008. The contract is effective from 01st of January 2016 and covers component pooling and repair solutions of all Line Replaceable Units (LRUs) for Qantas’ Airbus A380 aircraft fleet. As a result of the new agreement the contract provides an additional transportation service to and from Qantas’ Homebase in Sydney and all line stations.

The contracted services include the scope of about 1,000 part numbers (P/N) in total. Qantas offers A380 passenger transport services with 14 daily flights connecting Sydney and Melbourne to Dubai, London, Hong Kong, Los Angeles and Dallas. Since operation of Qantas’ first A380 in 2008, the component provider has served the airline for over 350,000 flight hours. “Spairliners is our preferred component provider thanks to the successful partnership and improving high service levels through the time of the existing contract” says Mike Legrand, Procurement Engineering CAM Manager at Qantas Airways.

Source: Lufthansa Technik.

Lufthansa Technik: Well prepared for technical support of the Boeing 737 MAX

Courtesy: Boeing.

Courtesy: Boeing.

When the new Boeing 737 MAX commences regular flight operation as planned next year, Lufthansa Technik will be well prepared to provide technical support for the most recent member of the Boeing 737 family.

Backed by its extensive expertise in the introduction of new aircraft types, Lufthansa Technik will provide a full featured product portfolio for ensuring smooth operation of the Boeing 737 MAX from the very outset. This includes a broad range of maintenance services for components, from individual repair to loan and exchange parts from regional spare parts warehouses through to the most comprehensive and integrated Total Support products.

Lufthansa Technik already offers an extensive range of globally available products and services for operators of the various Boeing 737 types. The spare parts warehouses for the Boeing 737 of the Classic and current Next Generation versions, which are established within easy reach of the customer, are to be extended in the process for the 737 MAX. For the operators of the new medium-haul aircraft, this means availability of material supply matching the high quality standards of Lufthansa Technik with fast response and turnaround times.

The Boeing 737 MAX will be powered exclusively by CFM LEAP-1B engines, whose maintenance – as with the current CFM56 engines – will likewise be included in the Lufthansa Technik portfolio.

When it comes to the Americas, which represents the largest market for the Boeing 737, Lufthansa Technik offers services specially tailored to local customer requirements. The company takes account of this market with regional customer service teams, sales offices and material pools at various locations on the continent as well as a 24/7 hotline for non-routine defects (Aircraft on Ground, AOG), which is based in Southern Florida.

The MRO provider’s subsidiary Lufthansa Technik Component Services (LTCS) in Oklahoma is also well positioned in terms of aircraft components thanks to its broadly diversified service portfolio – in particular this also includes testing, repair and overhaul of components. The new American location for aircraft overhauls, Lufthansa Technik Puerto Rico, which commenced operation in November 2015, will also offer overhaul services for Boeing 737 aircraft to North and South American airlines from 2017 in addition to the Airbus A320 family.

With the introduction of the new aircraft, Lufthansa Technik will guarantee smooth operation from day one in its role as integrator. Lufthansa Technik has already been able to demonstrate its accumulated experience and expertise in the introduction of new aircraft types on many occasions, as for example recently with the introduction of the Airbus A350 in January 2015 as well as the entry into service of the Airbus A320neo with Lufthansa in January 2016.

Source: Lufthansa Technik.