Eaton's Fuel System Onboard Boeing's First Commercial Composite Aircraft

Background

For the entire Boeing 787 Dreamliner partner team, 2011 has been a milestone year. The successful first delivery and first commercial flight marked the Dreamliner’s official entry into service, as well as the culmination of an unprecedented teamwork effort that produced the world’s most advanced passenger jet.

The more efficient aircraft, which brings big-jet ranges to mid-sized airplanes, features innovative materials and technologies developed by Eaton that offer combined advantages of reduced aircraft weight and improved fuel efficiency, as well as increased safety.

Challenge

Eaton began playing a developmental role in the 787 before Boeing’s official launch of the program. The 787 is the first commercial wide-body composite aircraft, which required new ways of thinking related to the way all components are integrated into aircraft systems, particularly fuel systems.

Eaton’s fuel systems division knew it was important to learn the customer’s needs before contracts were awarded to gain a full understanding of the 787 program and to prepare for design goals and challenges. Even with no guarantees of involvement, Eaton made the decision to embed its engineers with Boeing’s team in Seattle, Wash., in the earliest stages of program development.

“In a composite structure, all the rules change for systems inside the aircraft,” said Geoff Reed, Eaton’s account director for Boeing. “Our relationship with Boeing was strengthened by physically being part of the team. Eaton employees embraced Boeing’s culture and were fully integrated on the design team from start to finish."

Solution

Working closely on-site with Boeing’s team, Eaton engineers developed new fuel systems components that were not only compatible with composite structures, but were also compliant with stringent new Federal Aviation Regulations.

Eaton brought high-level competencies to the fuel and pump package design process through mastery of sophisticated tools for spatial integration. Eaton’s design scope had to factor in a significant increase in fuel tubes in addition to basic installation and 3D modeling of components.

Eaton was able to perform high-level analyses and modeling of fuel system performance, measuring such variables as pressure flow rate, tube sizing, and the performance of pumps and valves at various temperatures, pressures, altitudes and conditions.

“Eaton was involved a step above being just a component supplier to a much higher level of intellectual input,” Reed said. “Our work covered hardware installation in addition to the analysis and modeling of the fuel system. We brought a lot of competency to the system level from our history of component expertise.”

Results

By designing smaller, lighter and more efficient components, Eaton helped contribute to weight-savings on the 787 that contribute to the airplane’s improved fuel efficiency. The 787 uses 20 percent less fuel than similarly sized jets in operation.

Eaton’s diverse product portfolio is also used extensively across 787 sub-systems, including the aircraft’s fuel inserting equipment. The 787 is the first commercial transport to include the fuel inserting system in the baseline design.

“Eaton’s decision to embed with Boeing’s team in the earliest stages positioned our team to be responsive to customer needs and work our way through problems and challenges quickly, without causing schedule delays or setbacks,” Reed said. “Our team experienced very little turnover, which was an important advantage in creating a stable relationship with Boeing and providing project continuity.”

Additional Eaton content includes components for the aircraft’s power electronic cooling system and cabin pressurization, as well as emergency equipment such as the ram-air turbine and power assist system that opens aircraft doors in the event of power loss. Eaton also manufactures the Dreamliner’s landing gear hoses and the hydraulic motor for the high-lift system used for takeoff and landing; motor controllers; engine feed, override, and jettison fuel pumps; APU fuel pumps and actuators; ball valves, float valves and check valves; jet pumps, pressure relief valves, pressure switches, orifices and flame arrestors.