CIVIL AIR PATROL

L3 COMMUNICATIONS
CDR
T206H AFT BAGGAGE CAMERA PORTAL MODIFICATION
11/3/2011

Prepared by Jason Labonte

Project Manager: Ernie Smith
Designer/Draftsman: Jason Labonte
Structural DER: Venkat Ramachandran
Structural Engineer: Eric Lewis
 Slide 1

MODIFICATION
PROGRAM
1. Aft baggage area camera portal Design 4. Master Drawing List (MDL)
-Flight control cable dwgs 5. Certification
-Structure design (Eric Lewis) Analysis
-Equipment shelf relocation dwgs
2. Belly Door dwgs
3. Electrical Modifications
-Power Outlet at portal design
-Belly Door controls/ indication in cockpit panel design
11-3-2011
 Slide 2
STC
CERTIFICATION 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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 Slide 3

DESCRIPTION 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.

11-3-2011
 Slide 4

Major Drawing Tree Divisions

Aft Camera Portal Modification
(Cessna Aircraft, Stationair Model T206H, N176CP)

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

D = DWG CREATED
M = MODEL DEFINED
P = IN PROTOTYPE STAGE

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 Slide 5

First Look At The Aircraft Modification

Side Profile View

DETAIL

First Discussion of the Modification

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 Slide 6

First Look At The Aircraft

Power outlet

Camera Hole

Equipment
Shelf
Cable
Routing

DETAIL VIEW
Belly Door

Aircraft Pre Modification

(Model Created using AUTOCAD Inventor 2012)

11-3-2011
 Slide 7

AFT BAGGAGE CAMERA PORTAL

Structure Modification

POST CAMERA HOLE

PRE MODIFICATION MODIFICATION
Removable front plate
& Mount plate to allow installation
Of G3’s RCM P/N# TBA

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 Slide 8
EXPLODED CAMERA PORTAL INSTALLATION

Mount Plate

Top Plate

Aft Doubler Doubler

Intercostal

Fwd Plate
Fwd Doubler

Cut Out OEM Frames

Structure 11-3-2011
 Slide 9
EQUIPMENT 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 provided

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 Slide 11
TOP VIEW OF CABLE ROUTING

6 ASSEMBLY 4 ASSEMBLY
5 ASSEMBLY 3 ASSEMBLY 2 ASSEMBLY 1 ASSEMBLY

FWD
ORIGINAL ROUTING
ORIGINAL ROUTING

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 Slide 12
CABLE ROUTING
Fwd bracket (F.S. 90.00-100.00)

ASSEMBLY 1

Install

3D Model

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 Slide 13
CABLE ROUTING
Fwd bracket (F.S. 100.00-112.00)
ASSEMBLY 2

Install

3D Model
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 Slide 14
CABLE ROUTING
Fwd bracket (F.S. 138.0-152.20)
ASSEMBLY 3-6

Install

3D Model

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 Slide 15

Belly Door

PRE Modification POST Aircraft Modification

TO Relocated

Install DWG provided

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 Slide 16

Belly Door

Install DWG provided

DOOR DRIVEN BY ANSI #35 CHAIN LINK
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 Slide 17

Belly Door
Limit switches

Views depict the aft limit switches

Sliding door with adjustable bolts

Install DWG provided

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 Slide 18
Belly Door
Fwd limit switches

Limit switches
Limit switch angles

Sliding door Install DWG provided

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 Slide 19
Belly Door
Gear motor (front fairing removed)

Brushless gear motor

Adjustable Idler
Sprocket
Chain Tensioner

Install DWG provided

11-3-2011
 Slide 20

Belly Door
Fwd gear motor
(TBD) MFG by DYNETIC

Install DWG provided

Brushless Gear Motor 100:1 with (9 tooth sprocket) 11-3-2011
 Slide 21

Belly Door

Mid section spring guide chain tensioning device

Install DWG provided

Chain Tensioner 11-3-2011
 Slide 22

Belly Door
Aft sprocket

Install DWG provided

Adjustable Idler Sprocket ( 12 tooth) 11-3-2011
 Slide 23

Belly Door
Track system

Install DWG provided

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 Slide 24

Belly Door

Explosion1_3.wmv

Double click

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 Slide 25

INSTRUMENT PANEL

OPEN OPEN

CLOSED

IN
TRANSIT

CLOSE

2” x 2” H

Location of cockpit light and a Momentary switch

11-3-2011
 Slide 26
28 VDC POWER OUTLET

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

11-3-2011
 Slide 27
15
Master Drawing List (MDL)
Names and numbers below are (REF) only

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 Slide 29

Cessna 206 CDR

Structural Analysis
Nov. 3, 2011

29
 Slide 30

FEM

„ Software used: FEMAP & NX NASTRAN

„ 2” elements used except at new cutout
„ Shell and beam elements used
„ Compare original and modified fuselage designs

Constraints 
applied at 
Load applied  forward edge
near horizontal 
tail

30
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 Slide 31

FEM side view

54”

144”

31
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 Slide 31

FEM internal features

32
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 Slide 32

Original Design

33
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 Slide 33

Modified Design
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

34
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 Slide 34

Stiffness/Stress Comparison
„ Three individual load cases:
• 2,500 lb down load
• 2,500 lb lateral load
• 80,000 in-lb torsion moment (2500 lb x 36 in.)

„ Compare deflection of loaded node

• Down and lateral deflection is lower => stiffness is

higher
• Torsion deflection is higher => stiffness is lower
35
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 Slide 35
Stress Comparison
Original Design: down load

7‐8 ksi 4‐5 ksi
36
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 Slide 36
Stress Comparison
Modified Design : down load

Majority of 
region has 
stresses in 
the 1‐3 ksi
range, with 
peak at 
cutout of 9 
ksi

37
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 Slide 37
Stress Comparison
Original Design : lateral load

Majority of 
region has 
stresses in 
the 2‐5 ksi
range, red 
region 9‐10 
ksi

38
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 Slide 38
Stress Comparison
Modified Design: lateral load

Majority of 
region has 
stresses in 
the 1‐4 ksi
range, with 
peak at 
cutout of 
10 ksi

39
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 Slide 39
Stress Comparison
Original Design: torsion load

Majority of 
region has 
stresses in 
the 4‐5 ksi
range, with 
peak of 9 
ksi

40
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 Slide 40
Stress Comparison
Modified Design : torsion load

Majority of 
region has 
stresses in 
the 1‐4 ksi
range, with 
peak at 
cutout of 
12 ksi

41
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 Slide 41

Conclusion

„ The modified design is:

• A stiffer fuselage in down/lateral
bending (4% stiffer)
• A softer fuselage in torsion (2% softer)
• The peak stresses at the 5” radius
cutout are slightly higher than the
original stresses

42
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 Slide 42

Future Work

„ Future Analysis Work

• Modify FEM per actual aircraft
installation
• Look at going to 0.032 inch doubler
• Cable Routing Analysis
• Structural Analysis Report

43
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 Slide 43

Certification Status

„ Original Certification Plan Submitted July 2011

• Approximately 50 comments received
• All comments worked
„ Rev A of Certification Plan Submitted Oct 2011
• Three Additional Unit Members Added
„ Acoustics

„ Flutter

„ Lightning

„ Awaiting Approval of Certification Plan

44
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 Slide 44

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

11-3-2011