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Goodrich Engine Controls, Control of the skies

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Manufacturing in Action, Source : The Manufacturer
Published : October 2005

Julia Smith gets a handle on Goodrich Engine Controls, one of the world’s leading suppliers of engine control systems

The aerospace industry is well and truly airborne again. After a turbulent start to the 21st century, confidence in air travel has returned. The travelling public are taking to the skies more frequently than ever before.

Goodrich Corporation, a Fortune 500 company, is currently riding the crest of a wave. It is one of the world’s biggest suppliers of systems and services to both the aerospace and defence industry. The company’s transformation into one of the largest aerospace companies has been driven by strategic acquisitions and internal growth, supported by innovation and quality.

If there’s an aircraft in the sky, Goodrich technology is likely to be involved somewhere in helping it take-off, land or simply keeping it up there in the sky. From aerostructures and actuation systems to landing gear, engine control systems, sensors and safety systems, there will be a Goodrich product to meet OEM demand. Headquartered in Charlotte, North Carolina, the corporation employs more than 21,000 people worldwide in over 100 facilities across 16 countries.

Modern aircraft are highly sophisticated and complex assemblies, requiring many different technologies. To make sense of the industry, Goodrich has organised its business vertically by product group. A modern engine control system, for example, comprises the electronic control unit, engine actuation, fuel pumps and fuel metering unit. Each of these functions has its own dedicated division within the organisational structure and operates as a distinct business unit.

Within this framework, the engine control systems division of Goodrich has emerged as one of the world’s leading independent engine control suppliers. Engine control systems perform a number of critical functions. They must provide the correct fuel flow, air bleed and vane position for all operating conditions. Control systems are also tasked with automatically protecting the aircraft from excessive speeds and temperature fluctuations.

The work of the division covers a comprehensive range of applications for civil aerospace engines, large and small, helicopters and all forms of military aircraft including trainers, transporters, and fighters. The product portfolio includes fuel metering controls, fuel pumping systems, electronic controls (software and hardware), variable geometry actuation controls, and engine health monitoring systems.

The high end of Goodrich’s work is undoubtedly engine control systems for military applications. Fighter jets operate under much more challenging conditions than civil aircraft and their heightened performance criteria demands different technologies and a number of additional features.

It is a big operation. Over 1600 people are employed at six facilities in North America and Europe. The UK has traditionally been an important manufacturing centre and there is a major manufacturing plant at Hall Green, in Birmingham.

As a market leader, Goodrich is committed to building lighter, smarter systems that last longer. The engine controls sector must satisfy many different demands that sometimes seem to conflict. Safety, high reliability, low weight, low lifecycle cost, protection against obsolescence, and ease of dispatch and maintenance are just some of the issues that must be addressed. Goodrich can build on its extensive experience of developing high reliability electronic engine controls with safety critical software.

The company can point to many successes, the award winning Trent 500, for example. This system has the most efficient fuel pump in its sector, with a relight flow at 4.3 per cent of maximum fan speed. For greater reliability and obsolescence protection the LAe 2000 microprocessor, with its 32-bit RISC processor, was developed. It offers the ultimate benefit of enhanced performance at reduced cost.

Goodrich is also the driving force behind the engine control system for the EJ200 engine on the pan European consortium that is developing the Eurofighter Typhoon. By designing safety and maintainability into the systems architecture, the system Goodrich has designed offers reduced risk and lifecycle costs. Quality has been a prime consideration at every stage of the design, development and manufacturing process. The programme has also allowed Goodrich to demonstrate its management skills in reconciling the diverse interests and demands of the various consortium members.

Equally importantly, Goodrich has kept to its pledges on lead time. Delays on projects such as this cost thousands of dollars and getting it right first time is a big priority. Goodrich can offer customers the benefit of a world-leading systems test facility that is capable of simulating the entire control loop.

Goodrich is now playing a part in most of the world’s military and civil aerospace programmes.