Download - Request For Proposal RV-10 Presentation
RFP RV-10 FLIGHT CONTROLS
Chris Erman, Brandon Hart, Caleb Leuck, Nathan Nagel, and Chae Douglas
Needs General
All systems must operate in same ambient environment as the platform and aircraft
Day or night operationVFR (Visual Flight Rules) for maintenance flightsIFR (Instrument Flight Rules) is not required to be certified for
known icing conditions Critical systems shall not have more than 1 failure per 10,000
operationsReliability of 99.9999%
Needs Operation
Autopilot/Remote Control
Needs to be operational within 30 minutes of open container
Be ready to restore in container less than 2 hours
Expected 50 flights per year
Operation range of 650 statute miles with 2 passengers
Operation range of 1100 statute miles with 1 passenger
Needs Operators
Able to be flown manually for maintenance by a pilot
Manual flight controls should not be generally accessible to
passenger occupants
Needs Modifications
Secondary electrical power for flight systems and medical equipment
Combined modifications cannot add more than 150 lbs to aircraft
Launched using IsoLev Systems, 2800 Diharmonic Linowarp Accelerator System
Open Floor Space
Needs Safe Mode
Enter “safe mode” after landing, which means it must be safe for approach, open, secure, and in moving the aircraft.
Assume- Done by an electrical control lock that is engaged by
PAAEES to prevent control surface from hitting personnel- Will be locked in the neutral position. - Engine kill switch- Brakes engaged
Needs Data
Detailed maintenance plan of control systemsCannot be out of service more than 10 minutes per
dayNo specialty tools not found in standard mechanic
tool boxExternal data research supporting designs and assumptionsIllustrated parts breakdown and parts list and part numbers
Needs Maintenance Specifications
Guy on the rig- less than 10min per day, check corrosion on battery, check fluids, visual inspection, and a progressive maintenance plan
Available pilot at time of operationOur trained professionals will be doing the land based maintenance
Safe mode only pertains to flight controls
Standard instruments will be usedIcing is an airframe issue
Assumptions
This Rv-10 has a Carburetor not fuel injection.
Assumptions
House of Quality AnalysisDesign Options:Glass, Steam, Removable stick, Side Yoke, X-box Controller, Shortwave, Satellite,
Battery, Alt Needs
• 650 statute miles for 2• 1100 statute miles for 1• Autopilot• Manual Control• Unaccessible Controls• Secondary Electrical Power• 30min Operational• Turn around in 2hrs• 10 min or less maintenance• Minimal training• Less than 150lbs added• VFR conditions• 51 53 50 28
52 4 45 50 60
House of Quality Analysis
• Glass had a lower number (51) but had more Positives (5) vs. Steam (53) Positives (4)- Some of the reasons why it was lower, was because of negative numbers with low priorities on the HOQ. Example -7 for Glass on Secondary Power
• To control the aircraft we went with the X-Box Control, which had a higher number and higher pluses. -We didn't have to use traditional controls since this would be flown autonomously, most of the time.
• -Options like Short wave Radio scored low. This option could be thrown out.
House of Quality Results
Trade Study
Aileron Servo Motor
Servo Motor
No Servo
Aileron (2000)2001 Servo Motors
2002 Mounting Bolts
2003 Nuts
2004 Washers
2005 Brackets
2006 Brass Spacer
2007 Pushrod
Aileron Cont.
2001 Servo Motors
2002 Mounting Bolts
2003 Nuts
2004 Washers
2005 Brackets
2006 Brass Spacer
2007 Pushrod
Elevator (3000)
3001 Servo Motor
3002 Mounting Bolts
3003 Nuts
3004 Washers
3005 Brackets
3006 Brass Spacers
3007 Pushrod
Rudder Servo
Rudder (4000)4001 Servo Motor
4002 Mounting Bolts
4003 Nuts
4004 Washers
4005 Brackets
4006 Pushrod
6001
6004/6006/6007
6005
600360086001 Remote Controller
6002 Remote Controller Charger Kit
6003 Mount
6004 Mounting Bolts
6005 USB Charger Port
6006 Washers
6007 Nuts
6008 Wire Connector (Controller)
6009 Copper Wire 10 gauge
6009Controller
Glass Cockpit (7000)7001
7003
7002
7000 Glass Cockpit
7001 Glass Cockpit and installation
7002 Satellite Radio
7003 Headset
Engine Controls
8000 Engine Controls
8001 Servo Motors
8002 Mounting Bolts
8003 Washers
8004 Nuts
Safe Mode (9000)9001 Button
9002 Mounting Bolts
9003 Washers
9004 Nuts
9005 Brackets
9006 LED Colored Lights
9007 Hinge
9008 Aluminum Plate
9009 Push Button Latch
9010 Handle
9011 Hinge Pressure Switch
9012 Pull Switch
9013 Sticker
9009
9004
9008
9007
9010
9006
9001
Activates everything discussed in slide 8
Brake System10000 Brake System
10001 Electric Actuator
10002 Brackets
10003 Bolts
10004 Nuts
10005 Washers
10006 Wire
10007 Wire Connector10007
10006
10001
10002
10003/10004/10005
SHOW IPB
Sensitivity Analysis:200 Aircraft vs 5 Aircraft
200 Aircraft 5 Aircraft
Maintenance Dollars per Year
$3,085.22 $77.13
Spare Parts Dollars per Year
$14,316.78 $357.92
The life cycle cost of the fleet rose by $16,966.95 per year when the fleet size grew from 5 aircraft to 20 aircraft.
The cost drivers for the system grew together at a linear rate when the fleet size was increased.
When 200 aircraft are in the fleet we will be replacing servo motors, batteries and electric actuators more often than anything else.
Sensitivity Analysis:Failure Rate Decreased by 20%
Cost per Year for 5 Aircraft
Cost per Year for 5 Aircraft with Decreased Failure Rate
Cost per Year for 20 Aircraft
Cost per Year for 20 Aircraft with Decreased Failure Rate
Ailerons $18.75 $15.00 $749.31 $599.41
Elevators $20.12 $16.09 $804.04 $643.23
Rudder $18.37 $14.70 $734.36 $587.50
Miscellaneous $20.77 $16.62 $830.97 $664.78
Controller $9.59 $8.57 $383.62 $364.56
Glass Cockpit $299.27 $225.87 $11,970.86 $9,035.44
Engine Controls $24.60 $19.69 $983.69 $786.95
Safe Mode $10.59 $9.36 $415.34 $374.05
Brake System $13.25 $10.6 $529.83 $423.87
Total $435.05 $328.47 $17,402.00 $13,138.98
The life cycle cost of the fleet fell by $106.58 per year when the failure rate of a fleet of 5 aircraft was decreased by 20%. The life cycle cost of the fleet fell by $4,263.02 when the failure rate of a fleet of 20 aircraft was decreased by 20%
The cost drivers for the system grew together at a linear rate when the failure rate was decreased.
Servos, satellite radios, and batteries have the biggest cost impact when the failure rate is decreased by 20%
Sensitivity Analysis:Failure Rate Increased by 20%
Cost per Year for 5 Aircraft
Cost per Year for 5 Aircraft with Decreased Failure Rate
Cost per Year for 20 Aircraft
Cost per Year for 20 Aircraft with Decreased Failure Rate
Ailerons $18.75 $22.50 $749.31 $899.21
Elevators $20.12 $24.15 $804.04 $964.85
Rudder $18.37 $22.04 $734.36 $881.22
Miscellaneous $20.77 $24.92 $830.97 $997.16
Controller $9.59 $10.61 $383.62 $402.68
Glass Cockpit $299.27 $372.67 $11,970.86 $14,906.28
Engine Controls $24.60 $29.51 $983.69 $1,180.43
Safe Mode $10.59 $11.82 $415.34 $456.63
Brake System $13.25 $15.90 $529.83 $635.79
Total $435.05 $541.63 $17,402.00 $21,665.02
The life cycle cost of the fleet rose by $106.58 per year when the failure rate of a fleet of 5 aircraft was increased by 20%. The life cycle cost of the fleet rose by $4,263.02 when the failure rate of a fleet of 20 aircraft was increased by 20%
The cost drivers for the system grew together at a linear rate when the failure rate was decreased.
Servos, satellite radios, and batteries have the biggest cost impact when the failure rate is increased by 20%
FMECA (Fishbone Diagram): Flight Surface Movement
Flight Surface Movement
Flight Surface Over/Under Travels
Flight Surface Stuck in Neutral
Flight Surface Moves without Pilot Input
Flight Surface Stuck Deployed
Flight Surfaces are Out of Sync
Servo Out of Calibration
Linkage Fails
Flight Surface Fails to Respond to ServoServo
Fails to Respond to Input
Only One Servo Operates
One Servo Out of Calibration
Flight Surface Fails to Respond to One Servo
Flight Surface Fails to Respond to Servo
Servo Fails to Respond to Input
Flight Surface is not Connected with Servo
Servo Acts Without Pilot Input
Seized Linkage
Disconnected Linkage
Bad Electrical Connection
Controller Fails
Controller Fails
Junk Data Sent from Computer
Linkage Fails
Bracket Fails
Disconnected Linkage
Seized Linkage
Bad Electrical Connection
Junk Data Sent from Computer
Excessive Vibration
Bad Electrical Connection
Bad Electrical Connection
Controller Fails
Seized Linkage
Disconnected Linkage
Seized
Bad Electrical Connection
Disconnected
Excessive Vibration
FMECA (Fishbone Diagram):
Safe Mode
Safe Mode
Pull Handle Fails to Activate Safe Mode
Cable Fails
Wear From Pulley
RustHandle Stuck
Rust
Cable Pulley Seized
Door Fails to Open
Latch Fails
Disconnected Linkage
Seized
Hinge Fails
Rust
Dirt
Push Button Fails to Activate Safe Mode
Bad Electrical Connection
Failed Connector
Vibration Wears Wires
Button Does Not Depress
Button Breaks
Dirt in the Port
1.Servos2.Batteries3.Glass Cockpit Replacement
Top Cost Drivers
There is a battery to power electrical equipment.
Black box knows position with controls.
Parts Breakdown Assumptions
Tools
Maintenance Concept
Level 1 On wing Maintenance
Level 2 In Hanger
Level 3 Manufacturer’s Replacement
Flight Controls
balance flight control
surface
Avionics/Electronics
Inoperative G-1000
Safe Mode
LED Bulb and Sticker Replacement
Replace servo motor
Software Update
Replacement of Latch, Handle, pull switch cable or button.
Replace/Repair Wiring
Brakes/Miscellaneous
Battery Replacement
Replacement of Circuit Breaker , Actuator and Bleeding of Brakes
Inoperative Controller
Inoperative Controller Connector and Charger
Inoperative Satellite Radio
Inoperative Headset
Maintenance Concept Justification
Flight Controls - Maintenance can be done with the two levels. Balancing flight controls needs a hanger because any bit of wind can throw the balance off. Other maintenance can be done within a few hours and a hanger isn't always needed.
Safe Mode - Maintenance concept can be done within a few hours but if a part was to get broken it may take a little more time and a hanger would be nice to install the new part.
Avionics/Electronics - Since most of Avionics is computer based any problems with the avionics unit is going to have to be sent to a specialist or a manufacturer who knows a thing or two about avionics. Other maintenance concepts can be done on the plane or in a hanger if needed.
Brakes and Miscellaneous - If it can be done in a couple hours or less with minimum tool usage it
will be done on the plane. Anything that is a little more extensive will be done in the hanger.
Maintenance Concept with Cost
Level 1 On wing Maintenance
Level 2 In Hanger
Level 3 Manufacturer’s Replacement
Flight Controls
balance flight control
surface
Avionics/Electronics
Inoperative G-1000
Safe Mode
LED Bulb and Sticker Replacement
Replace servo motor
Software Update
Replacement of Latch, Handle, pull switch cable or button.
Replace/Repair Wiring
Brakes/Miscellaneous
Battery Replacement
Replacement of Circuit Breaker , Actuator and Bleeding of Brakes
Inoperative Controller
Inoperative Controller Connector and Charger
Inoperative Satellite Radio
Inoperative Headset
$25
$50
$80
Facilities: LEVEL 1 On Wing Maintenance
Within the maintenance concept, this “facility” is all maintenance that can be done on the plane out on the oil rig or tarmac.
Details:Cost= $0Basic tools required.Sunlight or lightingCan be done by anyone
Facilities: Level 2 Hangar
This facility is for Level 2 maintenance actions. Details:
Rented at nearby airport used for RV-10 operations for $2000 per monthLighting and electrical powerAll tools on the tool list requiredA & P Mechanics
Facilities: Level 3 Maintenance Manufacturer’s Replacement
This “facility” is where all top level avionic parts are sent to be replaced, repaired or inspected.
Details:Each facility will be sent the appropriate part via FEDEX after the part has been uninstalled. After the allocated action is done, FEDEX will ship the part back to where the plane is to be installed.
The price of each part and facility of will vary.
Hazmat and Environmental Disposal: Process
Recycle - Batteries will be boxed up with hazmat label and shipped via FeDEx to Battery Solutions in Mesa, AZ.
Scrap - All scrap parts will be stored in 55 gallon barrels before being shipped via FeDEx to HVF West LLC in Tucson, AZ.
Trash - All trash will be stored in 55 gallon barrels before being shipped via FeDEx to Waste Management
Send Back to Manufacturer - Any failures with the glass cockpit will cause the G1000 to be sent back to Garmin via FeDEx in Salem, OR.
Hazmat and Environmental Disposal: Issues
• Our waste and recycle barrels will need to be stored for extended periods of time before being shipped to their designated disposal experts.
• Space will have to be allotted in both the container and in the maintenance facilities for the waste and recycle barrels.
• The batteries will have to be shipped in hazmat labeled boxes before they begin to corrode. The batteries will have to be stored in a cool and dry environment until FedEx picks them up.
• If storage follows protocol, the environmental disposal issues will be covered by the individual disposal experts.
Environmental Impact on Operations/Retirement
• Offshore operations will force employees to keep components dry inside the container.
• Components will have to be secured properly when being shipped back to shore.
• Aircraft will have to be flown back to shore before being disassembled and retired
Reports and Records
Reports and Records
Reports and Records
Minutes/Works Cited
Questions?