Why it matters
Without AI, maintenance decisions rely on manual readings and scheduled checks, risking AOG events, delayed landings, missed AD compliance, and safety occurrences due to late or incomplete data interpretation.
From design to safety
Design
AI-supported design of shock struts
In design, AI analyzes test data from oleo strut assemblies, nitrogen charge specs, and seal layouts to influence selection, tolerances, and servicing interval planning, and it validates compatibility with service bulletin SB-XXXX for future updates.
- oleo strut assembly
- nitrogen charge valve
- seal kit
Build
AI checks during build and acceptance
During build, AI reviews hydraulic fluid reservoirs, strut extension sensors, and documentation to verify installation accuracy and servicing chart alignment before release to service. It cross-checks torque data, seal fit, and valve clearances against project spec.
- hydraulic reservoir
- strut extension sensor
- servicing charts
Operation
In-service monitoring and planning
Operation uses AI to correlate readings from strut assemblies and hydraulic levels with flight profiles to predict service windows and avoid threshold breaches. It factors landing gear loads, cycle counts, and expansion chamber temperature trends.
- oleo strut assembly
- strut extension sensor
- seal kit
Maintenance
Predictive maintenance signaling
Maintenance relies on AI trend analysis of hydraulic fluid levels, nitrogen charge, and seal conditions to generate pre-emptive service work orders and recompute intervals. It integrates historical maintenance logs and regulatory calendars for AD and SB alignment.
- hydraulic reservoir
- nitrogen charge valve
- seal kit
Safety
Safety-driven monitoring and compliance
Safety uses AI to flag anomalies, trigger corrective actions, and ensure CAMO notes, ADs, and service bulletins are reflected in the maintenance records. The system synthesizes SMS inputs and auditor access traces.
- servicing charts
- seal kit
- oleo strut assembly
Part by part
- 1
oleo strut assembly
- Watch for
- rapid extension or retraction irregularity, oil seepage, or external corrosion at the strut body.
- AI action
- detect abnormal position/velocity patterns and trigger pre-emptive inspection or replacement order.
- 2
nitrogen charge valve
- Watch for
- nitrogen loss or charge drift beyond tolerance, leading to reduced damping.
- AI action
- alert for replenishment and verify pressure with scheduled logbook entry.
- 3
hydraulic reservoir
- Watch for
- hydraulic fluid level drift, air ingress, or contamination.
- AI action
- raise service reminder and schedule fluid top-up and filter check.
- 4
strut extension sensor
- Watch for
- sensor drift or failure causing incorrect extension readings.
- AI action
- calibrate or replace sensor; update maintenance record.
- 5
seal kit
- Watch for
- seal wear or leakage indicating reduced damping performance.
- AI action
- prompt leak check, replace seals, log service action.
- 6
servicing charts
- Watch for
- out-of-date servicing charts or missing sign-offs.
- AI action
- audit and alert on chart version mismatch with current maintenance plan.
Worked example
AI-Driven Shock Strut Health and Leak Surveillance
Illustrative scenario with sample data.
A large-cabin business jet operator scales AI monitoring of shock struts across its 12-aircraft fleet to reduce unexpected strut failures and ensure compliance.
Signal in
aircraftId: G550-07, phase: SIL, oleoStrutStatus: nominal, nitrogenCharge: 1900 psi, hydraulicLevel: 72%, strutExtension: 12.3 cm, sealCondition: intact, servicingChartVersion: v3.2, lastInspection: 2026-10-02, torqueValues: nominal
System out
alert: left gear strut extension drift detected; action: schedule NDT inspection and replace seals if needed; log: TSN 2100; WO: 98214; correctiveAction: tighten mounting bolts if wear is found.
Human sign-off: Director of maintenance approves work order and CAMO signs release to service after parts available and torque values verified.
How to roll it out
Phase 1
Weeks 1 to 2
Baseline data collection across fleet and threshold tuning for strut sensors and nitrogen charge.
Phase 2
Weeks 3 to 6
Pilot implementation with one maintenance base and one line station, refining alert rules and reporting.
Phase 3
Weeks 7 to 10
Full deployment with standard operating procedures updated and maintenance teams trained.
Where people stay in charge
- Decisions about parts replacement and service intervals must stay with a certified Part-145 engineer or CAMO manager, who signs off all work orders.
- The AI may not authorize airworthiness-directive-required actions; only qualified personnel can approve modifications and release to service.
- All data influencing airworthiness decisions must be traceable in the aircraft maintenance log and CAMO records.
Questions owners and crews ask
What data does AI review for shock strut servicing and leak detection?
AI reviews oleo strut assembly readings, nitrogen charge status, hydraulic fluid levels, strut extension data, seal integrity, and servicing chart versions to determine maintenance needs and documentation.
Who approves actions generated by the AI system?
A Part-145 certifying engineer or CAMO manager approves work orders and release-to-service decisions, with the accountable manager signing off on the operation plan.
Will AI trigger unscheduled maintenance?
AI flags abnormal readings or trend deviations, creating work orders that prompt mechanic inspection; final decision rests with the authorized maintenance authority.
How are changes recorded after AI-detected issues are addressed?
All actions, parts, and readings are logged in the maintenance records, with servicing charts updated and AD compliance checked by CAMO.