Maintenance Solutions for Modernized Flight Control Complex Assemblies

NCMS Project #: 142004

Problem: Electrification and hybridization of legacy, hydraulic based on-board equipment such as flight controls, powertrain, auxiliary equipment, and other control systems are at the forefront of technological development for ground and air vehicles.  Integrating cost-efficient, safe, optimized maintenance solutions is of paramount importance to commercial and military fleets alike.  

Benefit: The overarching objective of this effort is to demonstrate improved maintenance and sustainment solutions for modernized flight control assemblies on a variety of platforms, with the CH 47 used as a surrogate to prove out the latest technology that will help improve capability, safety, readiness, and efficiency.  The initiative will show the potential benefits of electrified components across a broad spectrum of other military and commercial applications.   Lessons learned can be applied across other organizations within the DOD, throughout the U.S. government, and into the commercial realm.

Solution/Approach: The existing Longitudinal Cyclic Trim Actuator (LCTA) maintenance is performed using the Linear and Rotary Electric Actuator Test Systems at the Corpus Christi Army Depot (CCAD).  Actuators that are removed from the CH-47 during overhaul at CCAD or in the field are refurbished and thoroughly tested at CCAD before reentering the Army supply system.  In this demonstration, the test system hardware and software will be upgraded to allow functional testing at CCAD.  Environmental testing of the improved LCTA is also required for acceptance at the depot.  The proposed solution also includes validation and verification of the functional and environmental Army maintenance instructions that guide the test system operators to ensure accuracy and completeness.

Impact on Warfighter:

  • Reduce maintenance and sustainment costs
  • Lower failures and mishaps
  • Increase system internal load and sling load capacities
  • Provide better dynamic stability and safety
  • Ensure greater warfighter readiness and lethality

DOD Participation:

  • U.S. Army Maintenance Engineering Division Aviation Engineering Directorate

Industry Participation:

  • Southwest Research Institute
  • NCMS

Benefit Area(s):

  • Cost savings
  • Repair turn-around time
  • Positive environmental impact
  • Safety
  • Improved readiness
  • Reliability improvement

Focus Area:

  • Reliability improvement