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Helicopter Modifications and Upgrades

Helicopter Modifications and Upgrades

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Published by asmrmel
Summary of helicopter modification and upgrade design and certification process
Summary of helicopter modification and upgrade design and certification process

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Published by: asmrmel on Apr 13, 2009
Copyright:Attribution Non-commercial

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03/07/2013

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Pag.1
HELICOPTER MODIFICATIONS AND UPGRADES
 
Pag.2
FOREWORD
The operational life of helicopters and aircrafts is usually over 20 years; some models exceedthis period by far (CH-47 Chinook, DC-3, etc.). During those years, many changes occur inlegislation, operation requirements and, for military helicopters/aircrafts, mission scenariosand threats.Many excellent books have been written covering most disciplines involving helicopterdevelopment (aerodynamics, structures, performance, hydraulic systems, fuel systems, etc).Most of them focussed, as mentioned above, on the development phase, that is, they providevaluable information to design a new helicopter, and although that information is perfectlyvalid to achieve any modification, I haven’t found a book specifically orientated to helicoptermodifications and upgrades.This book is intended to be a guide for those small and mid size companies that carry outmost of the modifications and upgrades that any helicopter will undergo during its operationallife. These companies are not the helicopter manufacturer; therefore most of the helicopterengineering data is not available to them, often none at all. In most of the cases, onlymaintenance manuals and the helicopter itself are available.I hope this book can solve similar problems, at least a few of them, to those my co-workers(and friends) and I have had to face for many years when coping with many helicopters’modifications.Madrid, August 2006.Adolfo Sanchez Manso
 
Pag.3
TABLE OF CONTENTS
1. OBJECT.............................................................................................................................4  2. DEFINITION.....................................................................................................................5  3. RELATIONSHIP WITH CUSTOMER.............................................................................6  Documentation:......................................................................................................................6  4. CERTIFICATION............................................................................................................13  5. MATERIAL PROCUREMENT AND LOGISTICS........................................................19  6. MODIFICATION DESIGN.............................................................................................20  6.1 SAFETY ASSESSMENT..............................................................................................20  6.2 STRUCTURAL DESIGN..............................................................................................22  6.2.1 Geometrical definition.............................................................................................22  6.2.3 Actual stress distribution.........................................................................................23  6.2.4 Material selection and documentation.....................................................................28  6.2.5 Weight and balance.................................................................................................31  6.3 ELECTRICAL DESIGN................................................................................................32  Pin to pin diagrams...............................................................................................................32  Harness routing.....................................................................................................................33  Electrical load analysis.........................................................................................................34  6.4 AERODYNAMIC AND PERFORMANCE DESIGN..................................................35  6.5 SYSTEMS DESIGN......................................................................................................39  6.5.1 Fluid systems (hydraulic, air conditioning, antiicing, fuel, etc.).............................39  6.5.2 Mechanical systems.................................................................................................40  6.6 NOISE............................................................................................................................40  6.7 ADDITIONAL DOCUMENTS FOR CERTIFICATION.............................................41  6.8 MANUAL SUPPLEMENTS..........................................................................................43  7. PROTOTYPE INSTALLATION.....................................................................................48  7.1 SERVICE BULLETIN...................................................................................................49  7.2 WORK ORDER.............................................................................................................50  8. PROTOTYPE TESTS......................................................................................................52  8.1 FUNCTIONAL AND GROUND TESTS......................................................................52  8.2 EMI/EMC TESTS..........................................................................................................58  Equipment level tests............................................................................................................58  Interoperability test...............................................................................................................58  Allowable radiation level.....................................................................................................65  8.3 FLIGHT TESTS.............................................................................................................65  9. ENTRY INTO SERVICE.................................................................................................72  10. SUMMARY.................................................................................................................73 

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Dear asmrmel, do you also conduct training of the same subject of your book. please mail me at sam@mycopteraviation.com.my
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