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



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%





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


Seized Linkage


Junk Data Sent from Computer

Excessive Vibration



Controller Fails

Seized Linkage


Seized


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


Seized

Hinge Fails

Rust

Dirt

Push Button Fails to Activate Safe Mode


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

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

Minutes/Works Cited

Questions?

request for proposal rv-10 presentation

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