3. Design Situation
- Helicopter maintenance is a vital part in the Aviation industry. It is
implemented at various extents according to the airframe time.
- This requires an engineer to view the engine directly and work on it
effectively. This may mean that the engineer may need to stand on a ladder
to maintain the aircraft.
- As well as the practice being dangerous, it can be costly. Ladders can be
unstable if the ground is not flat. This may cause swaying which can
potentially damage the aircraft. Costs exceeding hundreds of dollars may
be induced by this practice.
- Helicopters are unlikely to be serviced inside an applicable area such as a
hanger or facility designed for helicopter maintenance when doing vital
tasks such as aerial firefighting
Design Situation
4. Primary research
What Equipment do you use to reach the engine and Transmission of the
helicopter?
If the recipients answered the previous question with “ladder” they were further
questioned whether they had ever hit or damaged an aircraft due to instability
from the ladders position:
Recipients were asked if they ever felt unsafe or vulnerable to falls when
performing maintenance or inspections on aircraft.
Pilot Engineer
Pilot Engineer
Pilot Engineer
Yes
No
Yes
No
Ladder
Nothing
Stairs
Ladder
Stairs
Nothing Yes
No
Yes
No
4. Recipients where asked about any safety concerns or issues that
they had when using the equipment identified in question 1.
Both Pilots and engineers shared answers that referred to the instability of
the equipment, lack of connection to the aircraft and the inability to move or
prevent themselves from falling due to the small surface area of their
standing equipment.
5. Primary research
Recipients were asked if they thought they thought if there was a need for a product
that improved the working conditions of aviation personnel.
Recipients were asked, that if a product were to be design for the
purpose of improving the working conditions of aviation
personnel, what should be a key area of focus
Yes
No
Yes
No
Safety of the personnel
Versatility of the product
Improving access to the engine bay
and transmission
All
Safety of the personnel
Versatility of the product
Improving access to the engine bay
and transmission
Pilot
Engineer
Pilot
Engineer
6. Design Parameters
Major Design Parameters
- The project must be completed, including the folio of the project by the end of August 2021.
- The entire cost of the project must be under $500.
- The project will be completed using both the tools found at school and if necessary, tools located outside of school.
- The resources of the project may either be sourced from the school collection of materials or from hardware and
stock retailers supplying the necessary materials.
Justification of the Need.
- Aviation personnel are likely to feel unsafe while working on Helicopters.
- It can be costly if the Helicopter is damaged from equipment used to help both Pilots and Engineers complete
maintenance.
Design Brief
The product must, to some extent, improve the safety of aircraft engineers as well as minimizing the risk of potential
damage to the aircraft with the use of ladders and other unstable frames hitting the helicopter. The project must cost
less than $500 to construct and fit within an 11-month period. The product must be portable to allow for use in remote
areas and airfields.
7. Areas of investigation Areas of
Investigation
Method of
Investigation
Justification of
Investigation
Techniques The investigation of techniques will
be an important part of the
development of the product. This
will allow for the product to achieve
its goals and fulfil its purpose.
The investigation of techniques
will primarily be conducted with
primary research such as
interviews and discussions made
with the class teacher.
Appropriate techniques will allow
the professional construction of
the project in the limited time
available that the project is
running.
Existing Design
Ideas
Existing Design Ideas will be an
appropriate area of investigation.
This may allow for inspiration as
well as informing me about designs
that have already met the need.
The investigation for this sector
will be primarily second-hand
including research online.
This will allow for inspiration and
exploration of ideas and
concepts.
Versatility The versatility of materials will
ensure the final product is able to fit
into a range of environments while
still being a functional product.
The method of investigation for
this area will include a range of
interviews and conversations with
the class teacher about
techniques and materials. It will
also include secondary research
completed online including the
research of materials and
techniques that are versatile and
strong.
The investigation of appropriate
materials will allow for the
product to fit into a range of
environments and still operate. it
will also allow the product to be
moved or transported with ease
to fit a variety of applications.
Areas of
Investigation
Method of
Investigation
Justification of
Investigation
Materials Materials that are strong and
light weight: suitable for
portability
The investigation of materials for
the design of the project will be
completed from a range of
secondary resources as well as
the introduction of primary
research and testing.
The investigation of materials for
the project is vital in the
development of the product. The
product must be portable and
durable, and the materials
selected for this must be able to
fulfil these requirements.
Tools Equipment that may be used in
development of my project
including welders, drills and
angle grinders.
The main source for information
on this element will be primary
research, sourced from the class
teach and workstation hand.
Secondary research may also
take place if needed to look for
more exotic and applicable
tools.
Effective use of tools will be vital
in the development of the
product to make the project
streamlined.
Safety Completing the project safely will
be something that will be
researched throughout the
course of the project. This also
includes the safety of the user
when using the final product.
The main source of information
sourcing when researching
safety will be via primary
research with the class teach on
the safest method to complete a
task.
It is of vital importance that both
i, and the people around me a
kept safe throughout the
development of the product. This
will ensure that the product is
successful, and no one will be
injured as a result of the project.
8. Criteria to evaluate success
Criteria Tests Justification
Safety
Testing the safety of the final product will include testing the stability of the product while it is in use.
This may include testing of the product while an engineer or pilot is using the product. The ability for
the user to fall off the product will also be tested and evaluated
The safety of the product is one of the primary focuses of the design. It must be able to improve the
working conditions of aircraft engineers and allow them to use the product safely. This is of highest
priority
Ergonomics
The ergonomics will be tested against existing product used in the aviation environment. A survey
may be implemented if the product is used by aviation maintenance personnel.
While the ergonomics of the design are of some importance, the product is not required to fit with the
environment or relate to the user. The projects primary focus if functionality for the product and
safety for the user.
Durability
The durability of the product will be tested by identifying the quality of the practical skills and
development of the final product. This includes the strength of the product and other factors that will
affect the product while it is being used.
The durability of the product of high importance. With regards to safety the product must be able to
do what it was intended to reliably and safely. In use, it will be transported several times and the
product must be able to withstand the day-to-day pressures of use.
Functionality
The functionality of the product will be determined after it has been tested in use by aviation
personnel who undertake maintenance and inspection of helicopters.
The functionality of the product is of high importance. The product must be able to do what it was
intended to do. The user must be able to use the product and its features to complete the task it was
design for.
Aesthetics
The aesthetics of the product will be determined with the professionalism of the product in its final
design. This includes the practical development of factors and components of the final design and
the quality of these components.
The aesthetics of the design are of low importance. While the design must look professional it is of
little concern to the final product.
14. Action Plan
Actions Material Tools Process
Action 1:
Identification of the Need and project proposal.
None - Adobe In-design
- Google Forms
- Internet Access
- Through access to the internet, research existing methods of helicopter engine maintenance.
- Research the dangers of helicopter maintenance and the most common equipment used for engine
maintenance as well as where it is used.
- Create a survey and send it to a business working in the aviation industry.
Action 2:
Action, Time and Finance plans.
None - Microsoft Excel
- Adobe In-design
The Initial and proposed Action, time and finance plans will be developed using Microsoft excel. These files will
then be placed into the Adobe In-design folio.
Action 3:
Design sketches and illustrations.
Innovation of design concepts. This includes access
to a helicopter airframe to make appropriate designs.
- Paper. - Pencil
- Ruler
- Eraser
- Access to an AS350
Squirrel airframe.
- Includes the inspection of a helicopter airframe to mark appropriate measurements and dimensions.
- Using the dimensions and innovation, begin to innovate on potential designs to meet the need.
- Refine these drawings until a final design is made which effectively meets the needs of the brief.
Action 4:
Research and experimentation of materials and
existing techniques.
Research of industry specific standards in Aviation.
- Ply-Wood
- Screws
- Aluminium and different
metal material plates.
- Drill
- Circular saw
- Jig Saw
- Pencil
- CAD software
- Create a CAD Model in Fusion 360
- Test the strength of a variety of materials as well as the durability.
- Research existing techniques used in the Helicopter industry as well as other industries.
- Develop a life size wooden prototype for dimensions.
Action 5:
Development of final design and product.
- Materials tested to be
implemented into the final
design in Action 4
- Drill
- Drill press
- According to the dimensions of the prototype and the dimensions of the Airframe recorded in Action 3,
Commence the development of the final design of the project with the use of the materials identified in Action
4.
Action 6:
Final Evaluation
- None - Adobe In-design - The Final evaluation of the project will be completed on Adobe In- design. This includes an evaluation of the
product which will be tested with interviews with aviation personnel who complete maintenance in the field.
15. Finance Plan
Component Proposed Cost Actual Cost Justification of difference
Materials for Testing and
and Experimentation
- Wood for prototype
- Hardware e.g. screws
- Different metals
Cost Total: $200
Materials for MDP Final
Final Design
- Metal used in the final design
- Hardware
Cost Total: $200
Tools Tools that may be needed to
complete the project tat may
need to be rented or paid for
Total Cost: $0
Materials for presentation of
presentation of MDP
- Paper
- Models
Total Cost: $50
Folio Printing Total Cost: $20
Sourcing of Finance:
- Under $500
- Sourced from own money.
- Relatively high budget to get the most
durable and functional materials suitable
to the design.
