CIVIL AIR PATROLCIVIL AIR PATROL L3 COMMUNICATIONSL3 COMMUNICATIONS

CDRCDRT206H AFT BAGGAGE CAMERA PORTAL MODIFICATIONT206H AFT BAGGAGE CAMERA PORTAL MODIFICATION

11/3/201111/3/2011

Prepared by Jason LabontePrepared by Jason LabonteProject Manager: Ernie SmithProject Manager: Ernie Smith

Designer/Draftsman: Jason LabonteDesigner/Draftsman: Jason LabonteStructural DER: Venkat RamachandranStructural DER: Venkat Ramachandran

Structural Engineer: Eric LewisStructural Engineer: Eric Lewis

MODIFICATION PROGRAM

1. Aft baggage area camera portal Design-Flight control cable dwgs-Structure design (Eric Lewis) Analysis-Equipment shelf relocation dwgs

2. Belly Door dwgs3. Electrical Modifications

-Power Outlet at portal design-Belly Door controls/ indication in cockpit panel design

Slide 1

11-3-2011

4. Master Drawing List (MDL)5. Certification

STC STC CERTIFICATION PATHCERTIFICATION PATH

Straight Flight has engaged support from the ARINC ODA to assist in the issuance of a new FAA STC for the FAA Part 23 Cessna Aircraft single engine T206H/206H to prevent delay in FAA ACO processing.Straight Flight has assigned a Managing DER responsible for all coordination of DER subsets and report generation.

The ARINC ODA shall assist in the following specific areas related to obtaining STC:

Act as the interface to the FAA in conjunction with SF's Managing DER Provide guidance, when requested for showing compliance with the applicable regulatory requirements Provide guidance, when requested for test plans, test reports, and analysis reports in order to show compliance to federal regulations Collaborate with SF's Managing DER to create relevant certification documentation

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DESCRIPTION OF WORKDESCRIPTION OF WORK

The new Camera Portal STC will encompass the following items:

Actual one 18" wide x 19.8” long rectangular camera portal open to the atmosphere in the fuselage belly centerline at station FS 130.00 or centered in the aft baggage area.28VDC power port near new portal rated for 30 Amps.Electrically driven belly door with controls and indication in cockpit. Dwg provided.New cable routing. Dwg provided.Aft equipment shelf. Dwg provided.

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Major Drawing Tree DivisionsMajor Drawing Tree Divisions Aft Camera Portal ModificationAft Camera Portal Modification

(Cessna Aircraft, (Cessna Aircraft, StationairStationair Model T206H, N176CP)Model T206H, N176CP)

Slide 4

Top level install drawings

• Removal of structure, OEM Flight control cables and wiring. M• Installation of camera portal assembly structure. M• Installation of Motor driven sliding Belly Door. D• Installation of 28 VDC power port. P• Installation of cockpit controls for Power/ Belly Door and lights. D• Installation of equipment shelf. D• Installation of cables. D

D = DWG CREATEDM = MODEL DEFINEDP = IN PROTOTYPE STAGE

NOTE: many of the assemblies called out in drawings are created.

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Slide 5

First Look At The Aircraft ModificationSide Profile View

First Discussion of the Modification

DETAIL

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Slide 6

First Look At The Aircraft

Aircraft Pre Modification(Model Created using AUTOCAD Inventor 2012)

Power outlet

Camera Hole

Cable Routing

Belly Door

Equipment Shelf

DETAIL VIEW

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AFT BAGGAGE CAMERA PORTALAFT BAGGAGE CAMERA PORTAL

PRE MODIFICATIONPOST CAMERA HOLE

MODIFICATION

Slide 7

Structure Modification

Removable front plate& Mount plate to allow installationOf G3’s RCM P/N# TBA

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Slide 8

EXPLODED CAMERA PORTAL INSTALLATION

Structure

Fwd Doubler

Fwd Plate

Intercostal

Doubler

Top Plate

Mount Plate

Aft Doubler

Cut Out OEM Frames

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Slide 9EQUIPMENT SHELF

All equipment under the aft baggage area and empennage equipment interfering with new cable routing will be relocated to the new shelf. The shelf transitions across the empennage and between frame 145 to 165

Larger view next slide

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Slide 10

Install DWG provided11-3-2011

Slide 11TOP VIEW OF CABLE ROUTING

FWDORIGINAL ROUTINGORIGINAL ROUTING

1 ASSEMBLY2 ASSEMBLY3 ASSEMBLY4 ASSEMBLY

5 ASSEMBLY6 ASSEMBLY

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Slide 12CABLE ROUTING

Fwd bracket (F.S. 90.00-100.00)

3D Model

Install

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ASSEMBLY 1

Slide 13CABLE ROUTING

Fwd bracket (F.S. 100.00-112.00)

3D Model

Install

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ASSEMBLY 2

Slide 14CABLE ROUTING

Fwd bracket (F.S. 138.0-152.20)

3D Model

CABLE ROUTINGFwd bracket (F.S. 138.0-152.20)

Install

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ASSEMBLY 3-6

Slide 15

Belly Door

PRE Modification POST Aircraft Modification

Relocated

Install DWG provided

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TO

Slide 16

Belly Door

Install DWG providedDOOR DRIVEN BY ANSI #35 CHAIN LINK

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Slide 17

Belly Door

Install DWG provided

Views depict the aft limit switcheswith adjustable bolts

Limit switches

Sliding door

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Slide 18Belly Door

Install DWG provided

Fwd limit switches

Limit switchesLimit switch angles

Sliding door11-3-2011

Slide 19Belly Door

Install DWG provided

Gear motor (front fairing removed)

Brushless gear motor

Chain Tensioner

Adjustable Idler Sprocket

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Slide 20

Belly Door

Install DWG provided

Fwd gear motor(TBD) MFG by DYNETIC

Brushless Gear Motor 100:1 with (9 tooth sprocket) 11-3-2011

Slide 21

Belly Door

Install DWG provided

Mid section spring guide chain tensioning device

Chain Tensioner 11-3-2011

Slide 22

Belly Door

Install DWG provided

Aft sprocket

Adjustable Idler Sprocket ( 12 tooth) 11-3-2011

Slide 23

Belly Door

Install DWG provided

Track system

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Slide 24

Belly Door

Double click

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Explosion1_3.wmv

Slide 25

INSTRUMENT PANEL

2” x 2” H

OPEN

CLOSE

Location of cockpit light and a Momentary switch

OPEN

CLOSED

INTRANSIT

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Slide 26

28 VDC POWER OUTLET

POWER OUTLET FOR CAMERA EQUIPMENT WILL BE MOUNTED IN THIS AREA. (TBA)

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Slide 15Master Drawing List (MDL)

Names and numbers below are (REF) only

Slide 15Slide 27

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Cessna 206 CDRCessna 206 CDR Structural AnalysisStructural Analysis

Nov. 3, 2011Nov. 3, 2011

29

Slide 29

FEMFEM

Software used: FEMAP & NX NASTRANSoftware used: FEMAP & NX NASTRAN22”” elements used except at new cutoutelements used except at new cutoutShell and beam elements usedShell and beam elements usedCompare original and modified fuselage designsCompare original and modified fuselage designs

Constraints 

applied at 

forward edgeLoad applied 

near horizontal 

tail

30

Slide 30

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FEM side viewFEM side view

31

144”

54”

Slide 31

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FEM internal featuresFEM internal features

32

Slide 31

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Original DesignOriginal Design

33

Slide 32

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Modified DesignModified Design

34

0.040”

skin doubler

0.040”

side wall

1.5”

x 0.75”x 0.09”

c‐channel

Skin cutout is 19”

x 18”

with a 5”

radius

Slide 33

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Stiffness/Stress ComparisonStiffness/Stress Comparison

Three individual load cases:Three individual load cases:•• 2,500 lb down load2,500 lb down load•• 2,500 lb lateral load2,500 lb lateral load•• 80,000 in80,000 in--lb torsion moment (2500 lb x 36 in.)lb torsion moment (2500 lb x 36 in.)

Compare deflection of loaded nodeCompare deflection of loaded node

•• Down and lateral deflection is lower => stiffness is Down and lateral deflection is lower => stiffness is higherhigher

•• Torsion deflection is higher => stiffness is lowerTorsion deflection is higher => stiffness is lower35

Slide 34

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Stress ComparisonStress Comparison Original Design: down loadOriginal Design: down load

36

4‐5 ksi7‐8 ksi

Slide 35

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Stress ComparisonStress Comparison Modified Design : down loadModified Design : down load

37

Majority of 

region has 

stresses in 

the 1‐3 ksi

range, with 

peak at 

cutout of 9 

ksi

Slide 36

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Stress ComparisonStress Comparison Original Design : lateral loadOriginal Design : lateral load

38

Majority of 

region has 

stresses in 

the 2‐5 ksi

range, red 

region 9‐10 

ksi

Slide 37

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Stress ComparisonStress Comparison Modified Design: lateral loadModified Design: lateral load

39

Majority of 

region has 

stresses in 

the 1‐4 ksi

range, with 

peak at 

cutout of 

10 ksi

Slide 38

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Stress ComparisonStress Comparison Original Design: torsion loadOriginal Design: torsion load

40

Majority of 

region has 

stresses in 

the 4‐5 ksi

range, with 

peak of 9 

ksi

Slide 39

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Stress ComparisonStress Comparison Modified Design : torsion loadModified Design : torsion load

41

Majority of 

region has 

stresses in 

the 1‐4 ksi

range, with 

peak at 

cutout of 

12 ksi

Slide 40

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ConclusionConclusion

The modified design is:The modified design is:•• A stiffer fuselage in down/lateral A stiffer fuselage in down/lateral

bending (4% stiffer)bending (4% stiffer)•• A softer fuselage in torsion (2% softer)A softer fuselage in torsion (2% softer)•• The peak stresses at the 5The peak stresses at the 5”” radius radius

cutout are slightly higher than the cutout are slightly higher than the original stressesoriginal stresses

42

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Future WorkFuture Work

Future Analysis WorkFuture Analysis Work•• Modify FEM per actual aircraft Modify FEM per actual aircraft

installationinstallation•• Look at going to 0.032 inch Look at going to 0.032 inch doublerdoubler•• Cable Routing AnalysisCable Routing Analysis•• Structural Analysis ReportStructural Analysis Report

43

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Certification StatusCertification Status

Original Certification Plan Submitted July 2011Original Certification Plan Submitted July 2011•• Approximately 50 comments receivedApproximately 50 comments received•• All comments workedAll comments worked

Rev A of Certification Plan Submitted Oct 2011Rev A of Certification Plan Submitted Oct 2011•• Three Additional Unit Members AddedThree Additional Unit Members Added

AcousticsAcousticsFlutterFlutterLightningLightning

Awaiting Approval of Certification PlanAwaiting Approval of Certification Plan

44

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Engineers / Managers:Engineers / Managers:

•John May - ARINC ODA, Administrator - 719.574.9001 •Ernest Smith - Straight Flight, Project Manager – 303.867.9777•Jason Labonte - Straight Flight, Designer / CAD Draftsman - 303.867.9775•Venkat Ramachandran - Structures DER / Managing DER - 303.514.1882•Mike Gukich - Flight Test DER - 303.752.0468•David Barnes - Flight Analyst DER - 303.666.8266•Karl Jones - Electrical DER - 303.404.3856•Chuck Goodard - Mechanical Systems DER - 336.602.2159•Robert Husted - Program DAR - 303.550.6507•Ralph Rissmiller – Flight Test Pilot DER – 316.253.6182•Brian Gothan – Sheet Metal Lead – 303-799-8906

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