NASA HU-25A ACTIVATE Program – Aircraft Crown Modification

Project Overview:
Performed all design and structural analysis engineering tasks for the NASA ACTIVATE aircraft crown modification.  

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.

Structural Analysis and  FAA DER Approval:

  • Generated system level finite element model
  • Calculated instrument drag loads
  • Performed quasi-static analysis for aero loads, internal pressure, and limit maneuver loads 
  • Performed global and detailed stress including mechanical joints (bolted and riveted)
  • Provided DER review and approval via FAA Form 8110-3

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