Central Vacuum System for Advanced Aerospace Manufacturing Foreign Object Debris (F.O.D.) Central Vacuum System
Background
During the manufacturing, assembly and rework process of building aircraft, debris is created while forming and joining these structures. Today, aircraft assemblies are procured via the global supply chain. Nose to tail assemblies such as cockpit, passenger compartment, wing, stabilizer and tail cone sections are constructed in a variety of facilities worldwide.
This debris is referred to as Foreign Object Debris or "F.O.D." This debris is generated during the manufacturing process and assembly of aircraft structures and sub-systems. All aircraft systems are vulnerable to FOD intrusion - avionics, power plants, transmissions, gearboxes, electrical distribution, flight controls, cabin controls, fuel and hydraulic systems. FOD affects all manner of aircraft and airborne vehicles including fixed wing, rotary wing, satellite, satellite launch vehicles, missiles and spacecraft.
FOD encompasses all size and type of debris affecting the inside and outside of the craft, including machining dust, metal chips, nuts, bolts, composites, jewelry, coins, tools, clothing articles, coffee cups, remove-before-flight pitot tube covers, foam insulating materials, water from aircraft washing & rain test, super-cooled upper atmosphere water, ice, snow, desert sand, dust, rodents, birds and so on
FOD can drop into and remain suspended in the radial crevasses of an airframe remaining secure and undetected through pre-flight inspection. Seemingly benign items bring the potential of rendering an aircraft system non-responsive or inoperative affecting any phase of flight. Catastrophic consequences do occur when FOD interacts with these aircraft systems. Negative G forces in flight may dislodge FOD causing it to interact with the craft's systems.
This interaction could cause an electrical short, jam flight controls, overheat avionics and navigation systems, puncture in the craft's skin and block airflow to critical components. Military aircraft are especially prone to these circumstances due to their wider flight envelope.
FOD sources in the Advanced Aerospace Manufacturing Environment
Aerospace aircraft manufacturing starts with raw materials such as metal alloys, composites, laminates and carbon fibers. These materials take the shape of wings, fuselage, landing gear and numerous other aircraft parts. The parts require machining, stamping, de-burring, grinding, sanding and cutting. For example, windows are from aluminum or carbon fiber tube section of an aircraft shell. Various size and shapes of debris are generated during the aircraft manufacturing process.
Without detection and removal, FOD is a leading contributor to loss of property and life. Loosely enforced or lack of procedures and sub-standard FOD removal equipment are inevitable contributors to this ever-present risk factor of flight. In a recent single incident, FOD was identified as the cause, costing the company about five billion dollars.
A proven solution for FOD removal
The Engineered Central Vacuum System
Properly planned and engineered, the central vacuum system integrates specialized equipment and worker procedures resulting in a process to collect debris amidst aerospace manufacturing and assembly. The system incorporates a low volume / high velocity collection system designed around the manufacturing processes. Typically, the system parallels the production line with other worker utilities.
FOD critical areas encompass the manufacturing floor and work platforms along the production line including the craft interior. The user guided vacuum system collects FOD with task specific attachments at high velocity. The system operates continuous during production hours incorporating "clean as you go" programs.
Numerous approaches to FOD removal
FOD practices vary considerably between airframe manufacturers as well as between commercial, military, rotary and space programs. In one instance, workers are checked into and out of critical FOD zones with personal item and tool cart inventories to help ensure best practice in a LEAN environment.
Conversely, even today some aircraft manufacturers use a lackadaisical approach incorporating open shop boundaries, no inventories and shop vacuums attached to the outside of overhead handrails on worker platforms twenty or thirty feet overhead, while producing two hundred million dollar aircraft.
One Canadian manufacturer has identified FOD containment the number one priority of the company - for good reason.
Integration of an FOD system
Air Dynamics provides design and integration services for Advanced Aerospace Manufacturing. A site survey is conducted to determine specific needs based on specific operations. Design criterion is developed for the system. Design, manufacture and installation of a system to service a production line area of 100,000 square feet, could take several months from design to installation.
Air Dynamics FOD Central Vacuum System
o Features 2 to 50 simultaneous users
o Covers over 100,000+ square feet of manufacturing floor space
o System turndown ratio of 50:1 saves energy when idle
o 316 stainless steel finish for durable life span
o System is PLC controlled with critical component monitoring & automatic shutdown
o Automatic hopper emptying
Installation includes training and customized tools and vacuum attachments.
FOD vacuum system details
Foreign Object Debris (FOD) Industrial Central Vacuum Systems for advanced aerospace manufacturing.
o Complete Design, Manufacturing & Turnkey Installation of Air Dynamics engineered vacuum systems
o Installed horsepower base of 1300+ over twelve systems, serving 200 system users, covering over 1 million square feet.
The FOD vacuum systems are one of the least understood types of air and material handling systems. System planners must incorporate adaptable designs for a constantly changing manufacturing environment.
Dan Lehman
President
Air Dynamics
dlehman@airdynamics.net
717-854-4050
www.airdynamics.net
