2. Needs
General
All systems must operate in same ambient environment as the
platform and aircraft
Day or night operation
VFR (Visual Flight Rules) for maintenance flights
IFR (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
operations
Reliability of 99.9999%
3. 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
4. Needs
Operators
Able to be flown manually for maintenance by a pilot
Manual flight controls should not be generally accessible to
passenger occupants
5. 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
8. 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
9. Needs Data
Detailed maintenance plan of control systems
Cannot be out of service more than 10 minutes per
day
No specialty tools not found in standard mechanic
tool box
External data research supporting designs and assumptions
Illustrated parts breakdown and parts list and part numbers
10. 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
11. Available pilot at time of operation
Our trained professionals will be doing the
land based maintenance
Safe mode only pertains to flight controls
Standard instruments will be used
Icing is an airframe issue
Assumptions
12. This Rv-10 has a Carburetor not fuel
injection.
Assumptions
13.
14.
15. House of Quality Analysis
Design 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
16. 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.
31. 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.
32. 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%
33. 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%
34. 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
Servo
Servo
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
35. 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
Disconnecte
d 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
39. 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
40. 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.
41. 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
42. 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= $0
Basic tools required.
Sunlight or lighting
Can be done by anyone
43. 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 month
Lighting and electrical power
All tools on the tool list required
A & P Mechanics
44. 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.
45. 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.
46. 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.
47. 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
