WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 1 AIRCRAFT MANUFACTURER INITIATIVE FOR SEAT/IFE INTEGRATION IMPROVEMENT WAEA Single Focus Workshop Atlanta, February 17/18, 2000 WAEA Single Focus Workshop Atlanta, February 17/18, 2000 Compiled by Thorsten SteinlichtRoland L. Schafer DaimlerChrysler Aerospace AirbusThe Boeing Company

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 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 improve Electrical Installations Required Actions for Seat Vendors to improve Electrical Installations Required Actions for IFE Vendors to improve Electrical Installations Required Actions for Airlines to improve Electrical Installations

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 3 Introduction Due to the steadily increasing amount of electrical equipment to be integrated into passenger seats, the OEMs started initiatives to help the Seat Suppliers to 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 industrial requirements for electrical installations, given in the existing documents, are not detailed enough and that the Seat Suppliers should have more support of the 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“.

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 4 Yesterday

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 5 Global multimedia communication Internet Direct TV PC power/Modem Video/…on demand VCC Gaming/Gambling Passenger Services Music/…on demand Seat electronics In-seat telephone Reservations Shopping Today

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 6 Current Status of Seat/IFE Integration 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 Resulting from an intensified cooperation between A/C manufacturers and Seat/IFE Vendors in 1999, the following main items have been identified as regular points of discussion: 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

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 7 OEM Actions 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

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 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

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 9 Requirements for Electrical Installation Drawings 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 If electrical equipment is installed in a seat without a detailed drawing, following consequences are usually stated: Detailed Electrical Installation Drawings are required to achieve repeatability of seat build and an equal level of quality throughout the complete shipset. In addition, the seat suppliers should establish Process Specifications to assure application and verification of their drawings.

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 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

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 11 General Installation Requirements Installation of electrical units and boxes – Mounting Requirements Cable access Connector access Thermal performance Seat mounting brackets – Cover Installation of electrical wiring and connectors – 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 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:

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 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. – Appropriate protection means are to be applied on the bundles in hazardous areas of 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.

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 13

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 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 proposed part will be added to the catalogue.

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 15 Required actions for A/C manufacturers to improve electrical installations Encourage seat suppliers to develop mechanical provisions for cable routing Attend ARINC and WAEA Meetings Encourage IFE-equipment standardization Accelerate process of seat-to-seat cable length definition Monitor electrical installation definition process more closely Attend and support Design Reviews Support the Seat Suppliers during first installation for a new project and FAI Check and comment test reports and drawings prior to FAI Required Mandatory Train and support Seat/OEMSuppliers to understand airworthiness requirements Successful First Article Inspection !

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 16 Required actions for Seat Suppliers to improve electrical installations Take electrical installations into consideration before designing a new seat Employ or educate specialists for electrical installations Standardize IFE- equipm. provisions 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 Minimize cable overlength (or its effects if unavoidable) Required Mandatory Attend ARINC and WAEA Meetings Provide a fully representative prototype seat for first installation and testing Perform a cycle test for video arms incl. cabling ( cycles minimum) Recommended Successful First Article Inspection !

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 17 Required actions for IFE Suppliers to improve electrical installations Provide a full set of equipment drawings at the ITCM or soon after Attend ARINC and WAEA Meetings Standardize IFE- equipment 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 complete testing without equipment removal Required Mandatory Train and support the Seat Suppliers to understand your requirements Recommended Successful First Article Inspection !

WAEA Single Focus Workshop – Atlanta, February 17/18, 2000 A/C manufacturer initiative for Seat/IFE Integration Improvement Page 18 Required actions for Airlines to improve electrical installations Purchase seats with new contracts that require the new standards to be met Attend ARINC and WAEA Meetings Encourage IFE-equipment standardization Inform OEM and Seat/IFE vendors about definition changes early Attend and support Design Reviews Support the Seat Suppliers during first installation for a new project and FAI Required Mandatory Inform Seat/IFE/OEMSuppliers about systematic in-service quality deficiencies Successful First Article Inspection !