787 dreamliner
battery system problems
and
thought manipulators

First posted
Monday January 28, 2013 06:41
Updated
Tuesday December 2, 2014 07:37

9 V and 1.2 V AA, AAA battery discharge video.

Saturday February 9, 2013 07:10

Bill is one of three coauthors of the Boeing 767 software certification policy written in Everett, WA in 1980.

Boeing insiders opinion on 787 solicited on salmon fishing trip to WA.

'An airplane designed by MBAs instead of engineers.', bill was told.

__

Yuasa's production process apparently allowed for defects that could cause short-circuiting in the battery's internal cells, and the final battery design was actually different than the one tested and certified.

SEATTLE (Reuters) - The U.S. aviation safety regulator has proposed requiring operators of some Boeing Co 787 Dreamliners to replace parts near the plane's lithium battery in an effort to improve the plane's ability to fight an on-board fire.

The government failed to properly test the Boeing 787's lithium-ion batteries and relied too much on Boeing for technical expertise, a new report says. 05/22/2014

FAA, Boeing conclude 787 is safe after battery problem.

Boeing is confirming an incident with a battery on a Japan Airlines 787, in a reminder of the problems that grounded the plane for three months last year.

The liquid-cooled 85 kilowatt-hour battery in the Tesla Model S is mounted below the passenger compartment floor and uses lithium-ion chemistry similar to the batteries in laptop computers and mobile phones. Investors and companies have been particularly sensitive to the batteries' fire risks, especially given issues in recent years involving the Chevrolet Volt plug-in hybrid car and Boeing's new 787 plane.

However, there were three new transport airplanes on the horizon. These were the Airbus A-310 and the Boeing B-757 and B-767. The airlines, along with the airframe and equipment manufacturers, established a goal to create an all-new suite of avionics using digital technology.

But while airlines love how this lightweight concoction saves fuel, the recent fire on a 787 at Heathrow Airport in London provides the first test of how difficult and costly it will be to repair serious damage.

British investigators said on Tuesday a transmitter made by U.S. firm Honeywell was one of several components that may have caused a fire on a Boeing Dreamliner in London last week.

Investigators started work on Saturday to establish the cause of a fire on a Boeing Dreamliner at London's Heathrow airport, a new setback for the high-tech model after it was grounded at the start of the year over battery problems. July 13, 2013

Mechanical glitches that caused three United Airlines flights to be cut short in the past week might have gotten little notice except for one detail: All the planes were Boeing 787s.

The 787, which Boeing calls the Dreamliner, faces more scrutiny than normal because it was grounded for three months by concern about overheating lithium-ion batteries.

In April, Boeing announced a further $1 billion investment in North Charleston, following the jet-maker’s earlier purchase of 320 acres of land adjacent to its existing 265-acre factory site where big 787 fuselage sections are fabricated and complete jets are assembled and delivered.

I worked as a contract engineer testing several hardware and software components of the 787s. These were the flight control surface controls, the brake systems, and the Power Conditioning Module that controls the power to the avionics. The common thread among the places I worked was that none had a lot of background in DO-178B. They bid work to Boeing based on past results but did not have the processes nor manpower in place to implement what was needed. I will NEVER fly on a 787.

U.S. Dreamliner service gives Boeing a chance to buff the 787’s reputation in the world’s biggest aviation market after the first grounding of an entire fleet type since 1979. Qatar Airways Ltd., Ethiopian Airlines Enterprise and Air India Ltd. are the only carriers whose 787s are flying commercially again.

The U.S. Federal Aviation Administration on Friday approved Boeing’s plans to install modification kits intended to reduce the risk of overheating in the planes’ lithium-ion batteries. [?]

Investigators in the United States and Japan have not yet identified what caused the 787’s batteries to overheat.

Each modification kit — which includes a new steel containment box for the battery, a new venting system, battery chargers, wiring and other associated hardware built by Boeing itself — should take about five days to install, Mr. Loftis said. Modified batteries, which include better insulation between the cells, are to be shipped separately to airlines by GS Yuasa, the Japanese maker of the 787’s original batteries.

"These changes to the 787 battery will ensure the safety of the aircraft and its passengers," Transportation Secretary Ray LaHood said in a statement. [Raymond H. "Ray" LaHood (born December 6, 1945) is an American politician]

The revised battery includes more protection around cells to contain overheating, a steel case to prevent any fire from spreading and a tube that vents fumes outside the fuselage. [But why did it overheat?]

Japanese air regulators are in the final stage of reviewing a report by Boeing Co. (BA) detailing the testing of its battery fixes for the 787 Dreamliner, the latest indication that the grounding of the high-tech jet could end soon.

Boeing completed the test on April 5 and said it will analyze flight data and submit the required materials to the U.S. Federal Aviation Administration “in the coming days.” [MBA strategy and the liberal arts 'educated' msm ccooper1@bloomberg.net; kmatsuda@bloomberg.net;anandk@bloomberg.net ]

Boeing is losing an estimated $50 million a week while its 50 Dreamliner planes are grounded, and the groundings have cost the company an estimated $450 million in lost income and compensation payments to airlines

(Reuters) - As Boeing works to regain permission for its 787 Dreamliner to resume flights, the company faces what could be a costly new challenge: a temporary ban on some of the long-distance, trans-ocean journeys that the jet was intended to fly.

The flight - intended to provide a standard check on all landing gear, backup and electrical systems - went “according to plan” said Boeing’s crew.

Boeing Co. said it plans a nearly two-hour test flight of a 787 Dreamliner to test its proposed fix for the lithium-ion battery systems that led to the commercial jet’s grounding in January.

Boeing plans workforce reduction of about 2,000 this year

Though the cutbacks involve employees working on the 787 Dreamliner, the reduction is unrelated to halted deliveries of the highly touted plane, which was grounded worldwide after two separate issues with burned batteries on the plane model. [MBA strategy?]

The National Transportation Safety Board said Boeing didn’t inform investigators about what it planned to say in the March 15 briefing in Tokyo, which is “inconsistent with our expectations” from a company involved in an accident probe, agency General Counsel David Tochen wrote in a letter yesterday. [Reason for 'and thought manipulators']


Boeing is redesigning its batteries to ensure a fire isn’t possible. Among the new features will be a fire-resistant stainless steel case that will prevent oxygen from reaching the cells so fire can’t erupt, Sinnett said. [MBA fix?]

The Federal Aviation Administration (FAA) has signed off on the company’s plan to modify the lithium-ion batteries used in the high-tech jet to prevent overheating. Under the new plans, Boeing will apply new venting, containment and insulation features to the batteries, the Associated Press notes. [MBA fix?]

As a result, George W. Hamlin, an aviation consultant, said he believed that to justify even its current ability to fly up to three hours from the nearest airport, Boeing would have to demonstrate that its new battery case could contain a fire for at least 180 minutes. Otherwise, he said, the plane’s appeal could diminish.

Boeing wants to insulate the battery and build a better box to contain any fire, according to published reports. Federal Aviation Administration officials are expected to make a decision soon on whether to approve a plan by Boeing to revamp the 787's lithium ion batteries to prevent or contain future fires.

Donald Sadoway, John F. Elliott Professor of Materials Chemistry at MIT, thinks that won't be enough to get the Dreamliner back in the sky

Boeing did not propose abandoning the lithium-ion batteries and is not working on a backup or longer-term fix for the problem that has grounded its entire fleet of 50 Dreamliners for nearly five weeks, three sources familiar with the plan said.

Boeing did not propose abandoning the lithium-ion batteries and is not working on a backup or longer-term fix for the problem that has grounded its entire fleet of 50 Dreamliners for nearly five weeks, three sources familiar with the plan said. 38 days after the Federal Aviation Administration grounded the Boeing 787, executives from the airplane maker are laying out their plan to get the Dreamliner back in the air.

According to the AP, the Transport Safety Board’s report said “the battery of the aircraft's auxiliary power unit was incorrectly connected to the main battery that overheated, although a protective valve would have prevented power from the APU from doing damage.”

Boeing Co (BA.N) has found a way to fix battery problems on its grounded 787 Dreamliner jets that involves increasing the space between the lithium ion battery cells, a source familiar with the U.S. company's plans told Reuters.

A second battery on a Boeing Dreamliner that made an emergency landing due to smoke linked to its main power unit had also expanded, a Japanese safety board official said Tuesday.

Airbus has started informing airlines that have ordered the new A350 that the new plane will have Nickel-Cadmium batteries, rather than lithium-ion batteries, the European plane maker told CNBC Thursday.

A U.N. agency that sets global aviation safety standards is moving to prevent aircraft batteries like the one that caught fire on a Boeing 787 last month from being shipped as cargo on passenger planes, people familiar with the effort said.

Boeing Co told two European airlines their deliveries of 787 Dreamliner jets would be delayed, underlining the uncertainty surrounding the future of the plane and the mounting costs related to its grounding.

The new lightweight, carbon-composite aircraft were grounded worldwide on January 16 after a series of battery incidents, including a fire on-board a parked 787 in Boston and an in-flight problem on a plane in Japan.

Airbus SAS is developing plans to use standard batteries in its A350 model and jettison the lithium- ion power source that grounded Boeing Co.’s rival 787 Dreamliner, two people familiar with the plans said.

When he looked at photographs of the 787's lithium-ion battery, he saw that it is actually eight notebook sized batteries all packed next to each other in a closed box. This means that only the batteries on the ends have any hope of venting the heat they generate. The other six batteries just heat each other up since they can’t release their heat outside the box.

But the Times reports that Boeing has a Plan B — tasking engineers to use more conventional batteries in case regulators banned the lithium-ion ones. And the alternatives they consider should include the one that Sadoway recommended — a safer, but less powerful Nickel Metal Hydride (NiMH) battery. [More viz.]

Boeing is looking at changes within the 787's lithium-ion battery to keep heat or fire from spreading, though technical details have not yet been finalized or approved, the Wall Street Journal reported, citing unnamed government and industry officials. One of the paper's sources added that, under a best-case scenario, passenger flights could resume in March.

Boeing is asking the Federal Aviation Administration for permission to fly test flights on its 787 Dreamliner as the company searches for the cause of battery problems in the innovative plane. 10:05a.m. EST February 5, 2013 [?]

Aerospace giant Boeing Co. has asked the Federal Aviation Administration to let it begin test flights on its grounded 787 Dreamliner passenger jet. [?]

Japan Airlines Co Ltd said it will talk to Boeing Co about compensation for the grounding of the 787 Dreamliner, adding that the idling of its jets would cost it nearly $8 million from its earnings through to the end of March.

At the same time the government certified Boeing's 787 Dreamliners as safe, federal rules barred the type of batteries used to power the airliner's electrical systems from being carried as cargo on passenger planes because of the fire risk.

Now the situation is reversed.



The grounding of Boeing's 787 Dreamliner over safety concerns has cost All Nippon Airways some $15 million in lost revenue, and if prolonged will have a significant impact on its business, the Japanese airline said Thursday.

Despite two serious safety failures and new questions about the reliability of its lithium-ion batteries, Boeing’s chief executive said Wednesday that he saw no reason to retreat from using the new but volatile technology on its 787 jets.
[MBA or engineer?]

Battery Was a Concern Before Failure (January 30, 2013) Add to Portfolio Boeing Company Go to your Portfolio » The executive, W. James McNerney Jr., acknowledged that some airlines had needed to replace the new batteries at a “slightly higher” rate than Boeing had expected. But he also said that the replacements were related to maintenance issues rather than safety concerns. So far, Boeing appears reluctant to consider alternatives. Lithium-ion, experts say, is particularly attractive because it packs more power in a smaller size, and is therefore lighter than more traditional battery designs — a factor that was part of Boeing’s strategy to build a lighter aircraft.

Another risk of lithium batteries also became apparent with the Cessna episode in 2011, when a technician working on a new model plane, the CJ4, hooked up the plane to a power source to recharge the battery and soon after saw smoke coming out of it.

According to a government safety official with knowledge of the episode, the Cessna battery had drained below 5 percent of its charge. The problem with lithium batteries, however, is that recharging a battery that has been drained to a low point can create a risk of fire because the battery is unable to accept a charge. Recharging it then creates heat that can cause it to ignite.

US and Japanese regulators have yet to establish causes for the battery failures, which suggests there is unlikely to be a quick lifting of the Dreamliner grounding.

Dreamliner: Boeing 787 aircraft battery 'not faulty'

Attention has now shifted to the electrical system that monitors battery voltage, charging and temperature.

[Over temperature was clearly a problem.

What does the electrical system do if it senses over temperature? Turn off off the power? Perhaps selectively power-down flight-unessential devices.

What did the 767 do? The Gimli glider.]

The slow progress of investigations into battery problems on Boeing Co's 787 Dreamliner jets suggest the new plane could be grounded for months, raising fears that the financial hit to Boeing will be greater than had been initially predicted.


Thought manipulators at work on 787 battery problems.
















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