Crash Dummies and Robot Arms: Testing Airline Seats.
In a quiet town in Northern Ireland, a robotic arm is tirelessly opening and closing an airplane meal table. This task, seemingly simple, has been programmed to repeat a staggering 28,000 times, day and night, over the course of more than a week. The robot performs this mundane duty without any reward, not even a bag of peanuts.
Gerald King, the head of engineering at Thompson Aero Seating in Banbridge, explains the intricacies of this process. “We can measure the force that the robot’s having to apply to that,” he notes. An increase in force indicates rising friction, a critical factor in ensuring smooth operations. This attention to detail is essential in the aerospace industry, where precision is paramount.
Thompson Aero Seating specializes in crafting first-class and business-class aircraft seats, the luxurious options typically found at the front of passenger planes. These seats come equipped with privacy-enhancing enclosures, built-in entertainment systems, and ample legroom, catering to the needs of discerning travelers. The company’s commitment to quality is evident in its rigorous testing processes.
Among the various machines used for testing the durability and safety of aircraft seats is a state-of-the-art facility that cost £7.5 million, which opened last autumn. Here, crash test dummies are strapped into seats and propelled down a short track at incredible speeds. This testing ensures that both the seat and its occupant can withstand a brief exposure to forces of up to 16 g’s.
Surprisingly, Northern Ireland produces just under one-third of the world’s aircraft seats, according to Invest NI, an economic development agency. Thompson, acquired by a Chinese company in 2016, is one of the few businesses in the region specializing in this niche market. The company currently manufactures approximately 1,500 seats each year.
Another key player in the Northern Ireland seat manufacturing sector is Collins Aerospace, located in Kilkeel. Additionally, Alice Blue Aero, based in Craigavon, contributes to the region’s reputation as a hub for high-quality aircraft seating solutions. These companies collectively play a vital role in the global aerospace supply chain.
On the global stage, one of the largest aircraft seat manufacturers is Safran, which operates facilities across six continents. This extensive network allows Safran to meet the demands of airlines worldwide, providing a wide range of seating options to enhance passenger comfort and safety.
However, the COVID-19 pandemic has dramatically affected the demand for aircraft seats, causing significant fluctuations in the industry. As the pandemic unfolded, the aerospace manufacturing sector experienced a sharp decline, leading to widespread layoffs and financial difficulties. Companies like Thompson Aero Seating were forced to halve their workforce in response to the changing landscape.
The impact of these changes has been profound, with many businesses struggling to navigate the uncertainties brought about by the pandemic. As the industry begins to recover, companies are reassessing their strategies to adapt to the new market conditions and ensure their long-term viability.
In summary, the story of Thompson Aero Seating and the broader aircraft seat manufacturing industry in Northern Ireland highlights the challenges and innovations within this specialized field. As the world gradually emerges from the pandemic, the resilience and adaptability of these companies will be crucial in shaping the future of air travel.
Thompson can bypass this issue with its in-house testing facilities, according to Colm McEvoy, the vice president of corporate accounts. He states that the company can currently meet its customers’ needs, but adds, “We’re having to be very strategic with regards to the new customers.”
There are over 650 people employed at Thompson’s sites in Northern Ireland, but the company had more than a dozen job vacancies listed on its website at the time of writing. “We’re in competition with other manufacturing companies to try and secure the best talent,” says Mr McEvoy.
Despite this challenge, Thompson has a five-year plan to multiply its annual output of seats. Mr McEvoy shows the factory floor at the firm’s Portadown site, where workers are busy riveting aluminium seat parts together and checking the complex wiring for the entertainment systems in these expensive structures – each seat costs “tens of thousands” to make, says Mr McEvoy.
“This seat in front of you is the most complex seat we make,” adds Eoin Murray, operations manager. It takes around 100 hours for the highly skilled workers here to assemble it in full.
Mr Murray is determined to boost the rate of production on this factory floor. He shows off a jig, developed in-house, upon which a seat can be mounted and angled so that workers can easily access the sides or underside. “This allows us to hit like a rate 14,” says Mr Murray – 14 seats produced in one shift. “I need to get to 18. To 20,” he adds.
To that end, there’s another even more capable version of the jig in the room next door, a prototype that staff here hope will be even better. Mr Murray and his colleagues are also developing new working practices – such as utility belts with tools arranged in the sequence they are required.
