AmSafe Airbag Systems Overview

AmSafe Airbag Systems

• Mature technology derived from the automobile industry.• AmSafe is the first and only company to design, certify and

manufacture airbags specifically for the aviation market.• AmSafe Airbag is modular, retrofitable and does not interface

with other aircraft systems.• In service since 2001— millions of flight hours of service and

over 100,000 airbags delivered• Flying on over 80 airlines• Standard equipment on 90% of single engine GA aircraft

AmSafe Aviation Airbag

• The airbag is stored in the lap belt or shoulder harness portion of the seatbelt and deploys away from the seat occupant.

• Airbag system consists of the following components:– Airbag Assembly– Cable Interface Assembly– Inflator Assembly– Electronics Module Assembly

“16G” Rule

• Enacted in 1988 in response to several aircraft accidents that could have been survivable if the seat stayed attached to the floor.

• Originally would require all aircraft to meet new 25.562 standards.

• Finally agreed only aircraft TC’d after 1988 must meet standard.

• 10 years to comply – Jetstream 41 was first aircraft to meet standards.

“16G” Rule Updated

• All transport category airplanes manufactured on and after October 27, 2009 used in part 121 passenger carrying operations must comply with current improved crashworthiness standards.

• FAA has adopted, waiting for EASA.

• Economy Seats at Bulkhead / Partitions: Rock Solid Monuments• Type 3 Exit Rows: Larger Pitch, Stiffened Seatbacks• Offset Seats: Impact between seats, back of armrests.• Angled Seats: Impact on walls or forward monument• Close Pitch Premium Seats: Impact on solid forward structure• Life Raft Bustle locations

Every airbag system is custom designed for the seat and interior strike hazard.

Interior Design Regulatory Obstacles

AmSafe Airbag Installations

Airbus A330, A340 & Boeing 777 Economy Class

Full Class of Service

Airbus A330, A340 & Boeing 777Business Class

Full Class of Service

AmSafe Airbag Installations

Boeing 777 Business Class Front Row

Boeing 777 BusinesEliteFull Class of Service

AFTER DYNAMIC IMPACT EVENT……• Seconds after crash event, airbag is deflated and pliable for easy access to belt

buckle• No egress or trip hazard

BEFORE DYNAMIC IMPACT EVENT ……• AAIR System enabled when all electrical connections are connected

DURING DYNAMIC IMPACT EVENT ……• AAIR System sensors detect serious dynamic impact (function of acceleration

and impact energy)• Approximately 45 to 50 milliseconds into dynamic event, airbag inflates through

a tearable seam on the airbag cover away from occupant cushioning head (and upper torso) from impact injury while also reducing the occupant rate of acceleration moving forward

System Operation

Airbag Deployment – Real Time

Wedge Airbag Used for setbacks approximately 37” or longer

Barrier Airbag Used for setbacks closer than 37”

Wedge Airbag – Life Raft Bustle

26G Forward Impact: 4-Point Restraint

16G Side Impact: 3-Point RestraintStandard Restraint Tubular Airbag Restraint

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Structure Mounted Airbag Systems

Armrest Mounted

Static Deployment

• AmSafe designed and certified the first structure mounted airbag system in 2012.

• Installed on angled seat for HIC compliance

• Entering service in 2013

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Structural Conforming Airbag

• Deploys close to monument structure, final shape conforms to monument structure.

• Airbag module is surface mounted to monument.

• Module dimensions: 8” wide x 11” tall x 0.50” thick

• Inflator remotely mounted, gas ducted through gas hose

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Structure Mounted Airbag

Design and Certification Requirements

• HIC

• Safe Deployment for Range of Occupants

• Safe Deployment of Out-Of-Position or Brace Position Occupants

• Safe Deployment for children restrained on the parents lap or in child seats.

Aircraft Accidents with AAIR Installed• Boyceville, WI

– August 2006: Plane stalled during training maneuver, left wing touched ground sending plane cart wheeling. • “Fortunately the plane had a number of safety features,

the inflatable shoulder harness airbag probably saved his brother’s life”

• Switzerland:– July 2006: Crashed in mountainous terrain, airbag

attributed to reducing injury or saving life.• “I have one broken vertebra and had an operation

Tuesday. No other injuries thanks to Cirrus safety features and airbag”

Aircraft Accidents with AAIR Installed

Airbag Systems

Design and Certification Requirements

• HIC compliance for full range of setbacks and +/- 10 degree yaw positions at 16G’s

• Safe Deployment for Range of Occupants• Safe Deployment of Out-Of-Position or Brace Position Occupants• Operational Restrictions: There should not be any operational

restrictions for the seats.– The full range of occupants must be allowed– Children restrained on the parents lap or in child seats.

• HIC compliance for impacts under the deployment threshold of the crash sensor

Certification Considerations•Brace Position

AAIR V23 System

Airbag Belt

InflatorAxial Inflator Fitting

Electronics Module Assembly

Diagnostic Connector

Interface Cable

2-Point Airbag Belt

• TSO C22G two-point restraint.• User operation is the same as standard

restraint.• Lift latch buckle with magnetic enabling

switch.• Airbag attached to lap belt, covered with

leather shroud• Airbag-Belt designed to fit specific

aircraft interior configuration to maximize occupant protection.

• Demonstrated to protect occupant range from 2 year old to 95th percentile male.

• 6250 PSI inflator assembly required for each seat position

• ACH: Compressed helium / argon • Threaded inflator to hose connection• Full DOT/UN/FAA/EASA qualification• If in aircraft fire, will self-deploy at

230 deg C• Ten year service life

Inflator Assembly

ACH 2.2 Mole

ACH 3.0 Mole

Electronics Module Assembly (EMA)

• Lithium Battery supports EMA operation for seven (7) years

• Tested to ELT, DO-160 and windmilling vibration standards

• A single EMA can support up to three (3) inflators.

• Inadvertent Deployment System Reliability: Above catastrophic level reliability requirements at 1x10-10.

• System design does not allow any single point failures to result in an inadvertent deployment.

• Failure to Deploy System Reliability: Above hazardous requirements at 1x10-8.

Acc

eler

atio

n (G

)

Time (s)

0.010 0.050 0.100

High G,

Low Energy

No – Fire

High Energy, Low G

Must – Fire

Crash Sensor Threshold

Maintenance Considerations

• System diagnostic check at installation, every 4000 flight hours

• Cleaning, visual inspection of belt essentially the same as standard belt

• V23 EMA – refurbish at 7 years• NexGen EMA – No maintenance.

Replace at 10 years• Inflator – No maintenance. Replace at

ten (10) years• All other components have no life limits

Operational Considerations

• Pax briefing in accordance with company procedures• Passenger operation same as standard belt.• Works with passenger in brace position.• AAIR can be used from two-year olds and up.• AAIR Belt Extender use: Only for child safety seats and passengers

that need extra seatbelt length.• Lap-held children are not restricted.• Unoccupied seats should not be buckled.• Seat or seat group placarded as “Inoperative AAIR” should not be

used.

Certification Considerations• Airbag System Special Conditions (SC) and Certification Review

Items (CRI) exist for all major airframes.

• Core Certification Approved Once – Good for All Programs– EMI, HIRF, Flammability, Environmental, SSA, Gas Toxicity,

Noise, Twisted belt, Incorrect buckling, Inadvertent deployment, Egress, Operation after fuselage separation, System verification and maintenance, Brace position, loose belt, pregnant women, range-of-occupant girth, 2-year old, lap held children, child seats

Certification Considerations• Program specific testing needs to be performed

– Dynamic HIC– Dynamic Structural (active system with wedge airbag)– 95%tile height with barrier airbag– Threshold Test– Vibration Testing (DO-160 and Windmilling)– Egress (maybe)

• 95%tile Compliance: Dynamically test at installed setback and pitch.– Barrier Airbag: Static Inflation MOC– Wedge Airbag: Consistent means of protection per AC 25.562 1B.

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