This paper presents the development and use of digital tools in the maintenance processes and ergonomics of work systems in the aerospace industry. The Industry 4.0 strategy aims to ensure the reliability of the human factor throughout the entire lifecycle of the maintenance process in the aerospace industry. Based on the requirement placed on the digital model of the working environment obtained from the 3D scanner data, an advanced software solution from TECNOMATIX, namely the TX JACK software 16.1.0 module, was used. The investigated digital ergonomic model, with two variants of workers with anthropometrically different weights, is the subject of analysis and simulation of the maintenance work process in an aerospace organization. Furthermore, the research also shows how the workers of maintenance and repair organizations are willing to develop their own knowledge and skills. The aviation industry should invest in the development of reliable software and hardware, improve safety at the level of digital ergonomics and the quality of jobs involving digitalization, and offer appropriate training for safety and quality personnel. The aim of this paper is to ensure the reliability of the human factor in the maintenance process and, consequently, to ensure technical safety by means of innovative tools in practice. The findings suggest that the investigated TESTER-STEND model with high-end adjustable pistons will improve ergonomics, worker performance, and work safety as a whole.

The use of a predictive approach in the aviation industry is an important factor in aircraft maintenance. The main goal of this study was to create a new method for stress prediction during the operation of parts and to apply it on an aircraft torque tube (ATT). The method operates in real time during taxiing, takeoff, and landing using a neural network (NN). The stress calculated by the proposed method can be used in the future to calculate fatigue life and to save maintenance costs related to ATTs. This can play an important role in the evaluation of tests, such as unobserved crack failure. The main contribution of the presented methodology is in the fourth part of this study, where a new method of mechanical-stress prediction using a NN is described. The method essentially replaces finite element methods (FEMs), which require large amounts of time. The new method is much faster than commonly available methods, as the NN predicts the mechanical ATT stress in 0.00046 s, whereas the solution time using FEM is 1716 s for the same load step. In total, 36 regimes were calculated by FEMs in 17 h, 9 min and 36 s, whereas the novel method calculated the ATT stress for 36 regimes in 0.0166 s. The accuracy was also high, with R above 0.99. The main innovation presented in this study is the development of a method that can predict ATT stress in a very short time with a high percentage of accuracy and that can be used for stress and life prediction during the operation of parts. The partial results from the experimental tensile tests are also presented, and they are used for FEM calculations. The FEM results are used as inputs for the stress prediction by the NN.

Aircraft maintenance has always been a significantly important area as it ultimately deals with the safety of all passengers and cargo traveling in the aircraft. Aircraft mechanics that handle such operations have always been in danger concerning their safety. This study concerns with the impact of maintenance workers in an aircraft chassis maintenance. The main aim of the study is to find out whether it has a positive or negative impact on mechanics. This paper summarizes the literature outline and evidence of the relationship between certain exposures important to the maintenance of the aircraft's chassis on the health of mechanics and the causes of this. This part of the studies consisted of relevant chemical components, individual company health danger reports, and limited case study notes documenting symptoms of exposure intoxication, which may have been a result of the database and search form that was used. This study will thus result ultimately in the safety of aircraft mechanics and the methods that have to be followed in order to do so. The overall study is a summarized overview of the data collected from the company Roder Component Service Center s.r.o Airport Košice Slovak Republik.

Aircraft emergency hydraulic pumps are safety-critical units whose intermittent operation complicates condition assessment and reduces the diagnostic value of conventional bulk physicochemical oil properties. This study evaluates the applicability of tribotechnical oil analysis for monitoring degradation of the NP-27T emergency hydraulic pump under controlled bench conditions. Four NP-27T units were tested on a dedicated hydraulic bench, and oil samples were collected at defined intervals during operation and after test completion. The diagnostic methodology combined elemental spectrometry (ICP-OES), particle counting interpreted with reference to ISO 4406, and analytical ferrography. The results showed that flow performance deterioration was accompanied by measurable changes in oil-borne wear indicators, although the sensitivity of the individual diagnostic channels varied among the tested units. In several cases, the coarse particle fraction (>15 μm) exhibited the clearest response to degradation, while Fe and Cu concentrations provided useful but not uniformly monotonic trends across all pumps. Using a pragmatic early warning criterion based on the first exceedance of 100 particles/mL in the >15 μm fraction, the coarse particle signal provided lead times of approximately 13–345 min before the flow-based rejection limit was reached in the four tested units. Ferrographic analysis identified cutting and fatigue debris, together with larger wear particles, in units approaching or reaching the flow-based rejection limit. Overall, the findings demonstrate that the combined use of elemental analysis, particle counting, and ferrography provides a practical multi-indicator framework for relating oil-diagnostic signals to functional degradation of the NP-27T hydrogenerator. Under the present bench conditions, flow proved to be a more sensitive degradation indicator than pressure. The proposed approach therefore represents a useful complementary tool for maintenance decision-making and for integration with vibration-based condition monitoring of aircraft hydraulic systems.