AIR CRAFT MANUFACTURER INITIATIVE FOR SEAT/IFE INTEGRATION IMPROVEMENT

1. WAEA Single Focus Workshop Atlanta, February 17/18, 2000 AIRCRAFT MANUFACTURER INITIATIVE FOR SEAT/IFE INTEGRATION IMPROVEMENT Compiled by Thorsten Steinlicht Roland L. Schafer DaimlerChrysler Aerospace Airbus The Boeing Company

2. CONTENTS: • Introduction • Current Status of Seat/IFE Integration • OEM Actions for Integration Improvements • Requirements for Electrical Installation Drawings • General Installation Requirements • Cable Installation and Protection Means • Required Actions for A/C manufacturers to improveElectrical Installations • Required Actions for Seat Vendors to improveElectrical Installations • Required Actions for IFE Vendors to improveElectrical Installations • Required Actions for Airlines to improveElectrical Installations

3. Introduction Due to the steadily increasing amount of electrical equipment to beintegratedinto passenger seats, the OEMs started initiatives to help the Seat Suppliersto understand their specific requirements. Looking at the high number of queries raised at First Article Inspections, Final Assembly Lines and In-Service, it has to be concluded that the industrialrequirements forelectrical installations, given in the existing documents, arenot detailedenough and that the Seat Suppliers shouldhave more supportofthe OEMs. Therefore the OEMs appreciate and fully support the intention of this WAEA Workshop. We hope to achieve a better understanding of the Seat/IFE Integration „challenges“ in order to transform them into „tasks“ and later into „solutions“.

4. Yesterday

5. Today VCC Video/…on demand PC power/Modem Global multimedia communication Internet Direct TV Gaming/Gambling Shopping Reservations Passenger Services In-seat telephone Seat electronics Music/…on demand

6. Current Status of Seat/IFE Integration Resulting from an intensified cooperation between A/C manufacturers andSeat/IFE Vendors in 1999, the following main items have been identified asregular points of discussion: • Unclear definition of how to integrate electrical components into seats due to a lack of specific industry guidelines • Electrical installations are not sufficiently taken into account during basic seat design • Incomplete electrical installation drawings • LRUs are difficult to remove • Excessive cable length, coiled up inside the seat, leading to cable failure • Covers and shrouds are often not adequate • Testing of IFE equipment sometimes not performed prior to shipping

7. OEMActions for Integration Improvement • Improvement of the Requirement Documentation for Electrical Installations • Establishment of a „Single Point Of Contact“ for Seat and IFE Vendors • Workshops and Fora with Seat- and IFE-Vendors • Intensified Cooperation with other OEMs, ARINC and WAEA • Increased Personnel Capacity for Seat Integration Tasks

8. What are the first results of the improvement initiative? • There is a growing awareness about the importance of electrical installations • The IFE vendors released installation guides for their equipment • OEM‘s and IFE vendor‘s documents were reviewed and streamlined • Contribution to ARINC 628 Part 5 with general installation requirements for seats • Establishment of a catalogue of recommended standard cable installation parts • Introduction of a new type of open, textile conduit for cable protection • Process of continuous discussion and knowledge exchange has started

9. Requirements for Electrical Installation Drawings If electrical equipment is installed in a seat without a detailed drawing, following consequences are usually stated: • No systematic installation principle can be realized • Cables are arbitrary attached to the structure just by a tie strap • Inadequate protection means on wires and bundles • Different cable installation on same seat models • Installation quality depending on capability of worker only • Trouble after delivery with regard to certification and documentation DetailedElectrical Installation Drawings are required to achieve repeatabilityof seat build and an equal level of quality throughout the complete shipset. In addition, the seat suppliers should establish Process Specifications toassure application and verification of their drawings.

10. Electrical Installation Drawings should contain the following: • Position of all electrical in-seat components • Partnumber list of all electrical in-seat components • Front and side view of seat leg including cable routing and dimensions for STS-cable interface points • Position of all seat installation/protection accessories for electrical in-seat components (spacers, tie straps, cable ducts, conduits, clamps etc.) • List of all in-seat cables including both cable connection points • Views and designation of in-seat cable routing • Principle wiring diagram of all harnesses and boxes which are designed and manufactured under seat vendor responsibility

11. General Installation Requirements In order to help seat suppliers to meet design requirements of A/C manufacturers,Vendors and ARINC, all specifications and guides should agree on following items: • Installation of electrical units and boxes • Installation of electrical wiring and connectors • Mounting Requirements • Cable access • Connector access • Thermal performance • Seat mounting brackets • Cover • Wiring • Clearances • Bend radius • Slack in wiring • Drip loops • Protection of wiring • Fixing of cables and wire bundles • Cable ducts, clamps, supports, brackets • Fixing of coaxial cable • Tie-up of cable bundles • Wire bundle separation • Plastic tie straps • Rework and modification • Terminations and connectors • Bending of terminals • Connector installation and stowage • Protection against magnetic fields

12. In order to achieve a safe cable routing, two basic requirements have to be respected: • Cable bundles shall never be fixed directly to the structure. The use of cable ducts, clamps and brackets is recommended. When using tie straps, a spacer shall be mounted between structure and cable. • Appropriateprotection means are to be applied on the bundles in hazardous areasof movement, vibration, contamination etc. Following page shows examples of how to attach cables to the seat structure. These figures have now been incorporated into ARINC 628 Part 5.

14. Cable Installation and Protection Means The OEMs have commonly established a catalogue of protection sleeves,conduits, brackets, rub strips etc. These means are approved with regard to fireworthiness and other requirements and shall allow the seat supplier to standardize electrical installations independantly from the A/C type. The catalogue is now incorporated in the latest revision of ARINC 628 Part 5. Any other parts deemed useful by Seat/IFE vendors for installation or protection of cables are appreciated and should be presented to the OEMs. If no objections with regard to specific requirements exist, the proposedpart will be added to the catalogue.

15. Required actions for A/C manufacturers to improve electrical installations Train and support Seat/OEMSuppliersto understand airworthiness requirements Encourage IFE-equipmentstandardization Attend ARINC andWAEA Meetings Encourage seat suppliers to develop mechanical provisions for cable routing Accelerate process of seat-to-seat cable length definition Monitor electrical installation definition process more closely Attendand support Design Reviews Support the Seat Suppliers during first installation for a new project and FAI Check and comment test reportsand drawings prior to FAI Required Successful First Article Inspection ! Mandatory

16. Required actions for Seat Suppliers to improve electrical installations Employ or educate specialistsfor electrical installations Standardize IFE- equipm. provisions Attend ARINC andWAEA Meetings Take electrical installations into consideration before designing a new seat Install mechanical provisions for cable routing inside the seats (cable ducts, clamping points etc.) Establish detailed Electrical Installation Drawings and Process Specifications Prepare efficient Design Reviews according to engineering requirements Install electrical equipment according to your Drawings,OEM Specification and IFE Vendor Installation Guides Provide a fully representative prototypeseat for first installation and testing Minimize cable overlength (or its effects if unavoidable) Perform a cycle test for video armsincl. cabling (40.000 cycles minimum) Required Successful First Article Inspection ! Mandatory Recommended

17. Required actions for IFE Suppliers to improve electrical installations Train and support the Seat Suppliersto understand your requirements Standardize IFE- equipment Attend ARINC andWAEA Meetings Provide a full set of equipment drawings at the ITCM or soon after Establish common definition exchange forms to ease the transfer of techical data Help the Seat Vendors to define the in-seat cable lengths - come together early Prepare efficient Design Reviews according to engineering requirements Support the Seat Suppliers during first installation for a new project and FAI Provide a seat tester allowing completetesting without equipment removal Required Successful First Article Inspection ! Mandatory Recommended

18. Required actions for Airlines to improve electrical installations Inform Seat/IFE/OEMSuppliersabout systematic in-service quality deficiencies Encourage IFE-equipmentstandardization Attend ARINC andWAEA Meetings Purchase seats with new contracts that require the new standards to be met Inform OEM and Seat/IFE vendors about definition changes early Attendand support Design Reviews Support the Seat Suppliers during first installation for a new project and FAI Required Successful First Article Inspection ! Mandatory