By embedding IoT sensors right across its product lines and manufacturing facilities, the global engineering giant has come to view data — and the services it can deliver — as a strategic asset. Is Rolls-Royce an engineering company that generates lots of data or a data-rich company that produces market-leading engines? Data generated by IoT sensors — aggregated and analyzed in the cloud — is providing Rolls-Royce with unprecedented insight into the live performance of its products — from jet engines and helicopter blades to power generation systems and marine turbines. And that data capability is rapidly evolving beyond just predicting equipment issues and maintenance requirements to providing customers with valuable aftermarket services that range from showing airlines how to optimize their routes to keeping a survey ship in position in heavy seas. A modern passenger jet such as a Boeing generates an average of GB of data per flight and several terabytes on long-haul routes.
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Can a homemade plane revolutionise manufacturing in India?
Rolls-Royce is using Microsoft Azure IoT to target use cases in predictive maintenance and fuel efficiency. Maintaining the aircraft on the ground can add hundreds of dollars per hour. Although fuel costs have been falling, airlines are still pursuing ways to reduce running expenses. Some areas being pursued include increasing fuel efficiency of jet engines, optimizing flight paths, and improving maintenance. Rolls-Royce is well-known for its luxury cars, but its most vibrant business is aircraft engine manufacturing.
In fact, the company has more than 13, engines for commercial aircraft in service around the world, and for the past 20 years, it has offered customers ongoing engine maintenance services. Machine data, however, can create headaches for any company trying to analyze it. A typical aircraft engine is loaded with sensors that generate thousands of real-time signals, covering everything from fuel pump wear-and-tear to fuel efficiency.
A Trent series engine on an aircraft. Photo: Rolls-Royce. Rolls-Royce addressed these growing data analysis challenges by building a monitoring solution into its TotalCare Services , which oversee responsibility for engine reliability and maintenance. As documented by Microsoft, the types of data processed include:. The company is also using Microsoft Cortana Intelligence Suite to analyze datasets and perform data modeling at scale to accurately detect operational anomalies and help customers plan relevant actions.
In that respect, one area being explored is predictive maintenance. By analyzing detailed data from each specific pump and comparing it to data models and other pumps in the fleet, it is possible to provide an alert that indicates that a specific pump might not be performing well and should be replaced sooner than its soft life.
Aircraft fuel efficiency is another area being targeted. By analyzing new data against existing forecasts, reference tables, and historical trends, Rolls-Royce will be able to help airlines understand exactly which factors—including flight plans, equipment maintenance, weather, and discretionary fuel—have the most impact on fuel performance.
Rolls-Royce sees the ability to provide a wider swath of operational data as a way to expand its services to customers, the Microsoft case study reports. The company is also moving to solve different problems through machine learning and analytics. Another benefit is that Rolls-Royce has gained a clearer understanding of how it should structure its support contracts, how it can better manage risk, and product development needs. Source: Microsoft. Engine photo by Rolls-Royce. Rolls-Royce wanted to analyze that data to help reduce delays and fuel consumption.
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Triumph Group Inc. Phase 1 of the contract will use Triumph's structural engineering resources to provide airframe design and analysis support. As part of the contract, Triumph Aerospace Structures will design portions of the aircraft structure to optimize weight, cost, and producibility in support of the program. Triumph offers multiple engineering disciplines, including trade studies, finite element modeling, structure sizing and detail components, and stress analysis. The company serves the global aviation industry, including original equipment manufacturers and the full spectrum of military and commercial aircraft operators.
List of turbofan manufacturers
GAMA's nine month industry update showed aggregate business jet and piston airplane deliveries continued experiencing increases in compared to last year, whereas the number of turboprops and rotorcraft deliveries declined. Aircraft owners need to make informed decisions about how to comply with emerging and existing regulatory mandates. Read more about worldwide modernization activities by clicking above. Click above to watch our video series about working in the general aviation industry, including how you can get a job and the growth opportunities for your career. This includes promoting a better understanding of general aviation manufacturing, maintenance, repair, and overhaul and the important role these industry segments play in economic growth and opportunity, and in serving the critical transportation needs of communities, companies, and individuals worldwide. Read more.
Microsoft customer stories
An engine is the heart of a vehicle's operating system and ultimately what makes the vehicle a successful form of transportation. Without the engine, a vehicle is just another big piece of stamped out metal appearing in various shapes and sizes. In addition to being manufactured for vehicles, engines are also built for aircraft and large machinery equipment, such as Caterpillar excavators and dozers. They are also used in trailer manufacturing for the hydraulic systems.
Mumbai, India - When a commercial pilot in India announced in that he would build a plane on top of the roof of his home, most people thought he was joking because he had no aeronautical engineering experience. Yadav, who works as a senior commander with Jet Airways and flies twin-engine turboprop planes, said it was his longtime dream to build aircraft. Despite the fact his family's construction business was running a significant loss that year, they decided to fund his "dream" project. His mother used her Mangala Sutra necklace as collateral for a loan from a local jeweller. Amol built a workshop and spent four years constructing a six-seat aircraft. Unlike his previous attempt, the plane was operational. A few years later, Amol landed the job at Jet Airways. He began flying planes but his dream of building India's first indigenous aircraft still weighed heavily on his mind. Amol had a decent job, so it made him think why shouldn't I give it another try," said his brother Rashmikant Yadav.
How IoT is turning Rolls-Royce into a data-fuelled business
For airliners and cargo aircraft , the in-service fleet in is 60, engines and should grow to , in with 86, deliveries according to Flight Global. A majority will be medium-thrust engines for narrow-body aircraft with 54, deliveries, for a fleet growing from 28, to 61, GE Aviation , part of the General Electric conglomerate, currently has the largest share of the turbofan engine market. On the military side, GE engines power many U. Rolls-Royce and General Electric were jointly developing the F engine to power the Joint Strike Fighter, however, due to government budget cuts, the program has been eliminated.
Over the past decade, aero engine manufacturing processes have increased in complexity to meet advanced design requirements and evolving customer demands. Engine configurations today must reach peak performance standards while maintaining controlled maintenance costs. Low noise and emissions coupled with high fuel efficiency, are the key parameters to meet aero engine design requirements. Cyient supports turbine engine OEMs in deploying innovative technology solutions for aircraft engine components and modules. Our expertise lies in the design and ownership of actions, bearings, rotors, cases, lube systems, dynamic loads, and electric propulsion systems for aircraft.
Triumph to support next-gen commercial aircraft program
Rolls-Royce is using Microsoft Azure IoT to target use cases in predictive maintenance and fuel efficiency. Maintaining the aircraft on the ground can add hundreds of dollars per hour. Although fuel costs have been falling, airlines are still pursuing ways to reduce running expenses.
Manufacturing is no longer simply about making physical products. Changes in consumer demand, the nature of products, the economics of production, and the economics of the supply chain have led to a fundamental shift in the way companies do business. Customers demand personalization and customization as the line between consumer and creator continues to blur. As technology continues to advance exponentially, barriers to entry, commercialization, and learning are eroding.
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