NASA HU-25A ACTIVATE Program – Aircraft Crown Modification


Project:
Perform all engineering tasks for the NASA ACTIVATE aircraft crown modification.  

Customer:
SSAI for NASA Langley

Services Performed:
PEI provided design, analysis, DER approval, and manufacturing support for development of the HU-25A crown modification and instrument suite mounting for the HU-25A aircraft..

Structural Analysis and  FAA DER Approval:

  • Generate system level finite element model
  • Calculation of instrument drag loads
  • Quasi-Static analysis for aero loads, internal pressure, and limit maneuver loads 
  • Global and Detailed Stress including mechanical joints (bolted and riveted)
  • FAA DER review and approval
  • Generation of FAA Form 8110-3 for approval of modifications

Engineering Design:

  • Two site surveys to measure and document HU-25A aircraft
  • Create solid models of five instruments and four pylons mounting to the aircraft crown aft of cockpit
  • Modeled local aircraft structure (Frames 9 through 13, stringers 1-5)
  • Designed preliminary reinforcements for instrument mounting
  • After structural evaluation, completed detail design of reinforcing structures
  • Conducted Preliminary and Critical Design Reviews at NASA Langley
  • Generated all detail part and assembly drawings
  • Coordinated with fabrication vendor and provided NASA with reinforcement components