New vaccine mandate raises questions for defense contractors

On the same subject

• 

  July 18, 2023 | International, C4ISR

  White House unveils cybersecurity labeling program for smart devices

  U.S. Cyber Trust Mark initiative to be overseen by the Federal Communications Commission, with voluntary industry participation.

• 

  April 9, 2020 | International, Aerospace

  Boeing’s KC-46 tanker now has a pathway for autonomous aerial refueling

  By: Valerie Insinna WASHINGTON — Last week's deal between Boeing and the U.S. Air Force on a fix for the KC-46 could pave the way for the tanker to refuel other aircraft without a person needed to manually control the process, a top service official said Thursday. On April 2, Boeing agreed to fix the KC-46's troubled Remote Vision System by creating an overhauled RVS 2.0 with new hardware and software. Air Force acquisition executive Will Roper told reporters those changes would include the addition of 4K high-definition cameras that will display imagery in color as well as modern processors and LiDAR (light detecting and ranging) sensors that will help improve depth perception. “A proper RVS like that is right on the doorstep to autonomy,” Roper said. “All you have to do is take that data that tells the world inside the jet the reality of geometries between the airplane and the boom outside the jet. Once you have that, you simply need to translate it into algorithms that allow the tanker to tank itself.” The KC-46's Remote Vision System has been a thorn in the side of the aircraft program since 2017, when issues with the system were first discovered. The RVS is basically a suite of cameras, sensors and software that is supposed to allow boom operators sitting inside the aircraft to safety steer the boom into the aircraft needing fuel. But in certain conditions, the system produces distorted imagery that increases the risk of the boom hitting another aircraft. The new LIDAR system will be key to fixing that problem, said Roper, who likened it to a backup camera on a car that also provides cues to a driver for parallel parking or assessing whether a vehicle is aligned flush to a curb. “We'll have something very similar to that for the boom operators, so telling them are they left, right and how close are they getting to the airplane,” he said. “[It's] something very intuitive and easy to work with, and I think that will help significantly with them understanding their distance [from the other aircraft] because LIDAR is extremely accurate.” Because Boeing is locked into a firm fixed-price contract for the development of the KC-46, it will have to pay for the upgrade to RVS 2.0 out of its own pocket, as the Air Force maintains that the current system does not meet requirements. But the service is so confident in the prospect of using the RVS 2.0 as a stepping stone to an autonomous tanker that it included an option in last week's agreement to fund the development of technologies that enable autonomous or semiautonomous refueling. “We have added an engineering change proposal into the deal with a not-to-exceed threshold of $55 million, so that when RVS 2.0 is done, we can then take the next step beyond 2.0 to develop those autonomy algorithms and install them if we think we can certify them for safe use,” Roper said. “We took that step because, one, we're excited about being on the doorsteps of autonomy and, [two], we wanted to send a clear signal in the deal that this is our tanker for the future,” he said. If the Air Force decides to move forward with those design changes, more will need to be done to hammer out the contractual details, said Jamie Burgess, Boeing's KC-46 program manager. “There was no commitment one way or another on who pays for what. But there's definitely a strong partnership between Boeing and the Air Force as far as developing this technology,” he said. Autonomous refueling capability has been of increasing interest to the Air Force over the past few years, as sensing and artificial intelligence technologies grow by leaps and bounds. Boeing previously signaled it could include such technology as part of a menu of potential upgrade options for the KC-46, as reported by FlightGlobal in 2018. https://www.defensenews.com/air/2020/04/08/boeings-kc-46-tanker-now-has-a-pathway-for-autonomous-aerial-refueling

• 

  September 9, 2020 | International, Aerospace

  New policy addresses 3D parts for Army aircraft

  By Courtesy As the Army explores the potential of some advanced manufacturing methods and 3D-printed parts to maintain and sustain its aviation fleet, recently published guidance aims to strike a balance between safety, improvements to readiness and escalating costs. Advanced manufacturing refers to new ways of making existing products and the production of new products using advances in technology. Advanced manufacturing includes additive manufacturing, a process of joining materials to make parts from 3D-model data. Additive manufacturing differs from the traditional subtractive process that cuts away material to shape and produce parts. The U.S. Army Aviation and Missile Command recently published a policy memorandum addressing advanced manufacturing for Army aircraft parts, components and support products. “Evolving technologies create a unique challenge as we determine the airworthiness of parts when the data is immature, incomplete or even non-existent,” said AMCOM Commander Maj. Gen. Todd Royar, who serves as the Army's airworthiness authority, responsible for ensuring the safety of the service's aircraft components. As enduring aircraft, like the UH-60 Black Hawk helicopter, continue in service, the supply system with face challenges with obsolescence, meaning parts that are difficult to acquire or receive no bids from potential vendors to manufacture. As the Army keeps pace with technology, advanced manufacturing creates opportunities to optimize long-term sustainment efforts. The Army established a partnership recently with Wichita State University's National Institute for Aviation Research (NIAR) to create a “digital twin” of an aging Black Hawk model. “One of the primary tasks in this effort is to convert all legacy 2D drawings of this aircraft into modern 3D parametric models,” said John Tomblin, senior Vice-President for Industry and Defense Programs and Executive Director of NIAR at Wichita State University. “This will allow the Army to source parts that are out of production as well as use advanced techniques, such as additive manufacturing, to produce parts.” The digital twin opens a door to the 3D modeling and more opportunities to use parts made through additive manufacturing. The NIAR project is not the Army's only effort. Army Aviation is already using advanced manufacturing methods and 3D-printed parts to solve specific challenges. When several CH-47 helicopters experienced structural cracks at a certain portion of the frame assembly, an initial solution was to replace the entire frame assembly. “Replacing the entire assembly is a time-consuming task that also poses logistical challenges because replacements are difficult to obtain,” said AMCOM's Aviation Branch Maintenance Officer, Chief Warrant Officer 5 Michael Cavaco. Instead, engineers designed a solution to restore the cracked frames to their original strength by creating repair fittings using Computer-Aided Design models. “After five iterations of 3D-printing prototypes, test fit and model adjustments, a final design solution was achieved,” Cavaco said. Additionally, 3D printers have created several tools and shop aids that have benefitted the field. Many of these stand-alone items that support maintenance operations are authorized within Army technical manuals, depot maintenance work requirements or similar publications. While too early to predict overall cost and time savings, the advantages of advanced manufacturing are significant. The use of advanced manufactured parts will eliminate wait time on back-ordered parts that, ultimately, delay repairs. A key focus of AMCOM's AM policy is on inserting evolving technologies into enduring designs that have relied on traditional manufacturing processes throughout their acquisition lifecycle. However, future Aviation are benefiting as well from advanced manufacturing. The Improved Turbine Engine Program (ITEP) includes a number of advanced manufacturing elements. “ITEP benefits from advanced manufacturing include reduced cost, reduced weight, increased durability, and enhanced performance when compared to traditional manufacturing methods,” said Col. Roger Kuykendall, the project manager for Aviation Turbine Engines. “The benefits of AM stem from the unique capability to produce more complex hardware shapes while simultaneously reducing part count.” The fine details of airworthiness expectations asserted in this policy were crafted by a team of engineers at the U.S. Army Combat Capabilities Development Command Aviation and Missile Center, led by Chris Hodges, the current acting associate director for Airworthiness-Technology. Hodges said the new policy was drafted after his team collaborated with stakeholders from across the aviation enterprise, reaching across Army organizations and out to sister services and the Federal Aviation Administration. “We considered a lot of input and ultimately organized expectations and requirements by category, spanning from tools and shop aids to critical safety items,” Hodges said. “The resulting policy sets a solid foundation with room to grow and fill in details as the story evolves.” For Army aviation applications, advanced-manufactured parts and components will be managed under six categories that range from articles that support maintenance operations to those aviation critical safety items, whose failure would result in unacceptable risk. The designated categories prescribe for engineers and manufacturers the allowed materials and appropriate testing methodology for each particular part. The new guidance is not intended as a replacement for other existing policies that address advanced manufacturing. “We intend to be in concert with Army policies and directives that pertain to readiness, maintenance and sustainment,” Royar said. “Our policy provides a deliberate approach to ensure airworthiness and safety while determining where research and efforts may best supplement the supply chain and improve performance while balancing cost.” AMCOM Command Sgt. Major Mike Dove acknowledged the methodology must continue to mature in multiple areas before confidence grows in the ability to measure airworthiness qualification requirements for advanced-manufactured parts. “We fully support the maturation requirements for advanced-manufacturing technology, but not at the expense of flight safety,” Dove said. As Army aviation continues to pursue and include advanced-manufacturing methods, Royar noted the potential impact as the technology evolves. “Advanced manufacturing touches units, depots and the broader supply chain,” Royar said. “As we sustain our enduring aircraft and look to future systems, it is important that we keep pace with this and other emerging technologies for the sake of the warfighter.” https://www.army.mil/article/238868/new_policy_addresses_3d_parts_for_army_aircraft