SwRI Mature Aircraft Systems Support Flyer

Mature Aircraft Systems Support

As the nation's military and commercial aircraft fleet matures, problems frequently develop with a system or subsystem assembly or component. Southwest Research Institute (SwRI) provides extensive engineering and technical support for the maintenance of mature aircraft. The Institute's re-engineering services may be required when a drawing package of a component is unavailable or a change in the component design is necessary. If a component design is available but no longer manufactured or the client needs alternate vendors, SwRI re-engineers the component with an updated production drawing package. Institute engineers and scientists create new sources of supply through a detailed process that includes:

Analyzing existing design criteria

Reviewing available documentation

Re-engineering existing design

Establishing manufacturing process

Building prototypes for verification

Validating the design through operational and environmental tests

Generating a complete technical data package to document the design

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The C-5 landing gear gearbox (shown at the left) was re-engineered to develop a new supply source. The Pro/ENGINEER™ models in the center and on the right are a part of the technical data package generated to establish reprocurement drawings.

The Aerospace Electronics and Training Systems Division at SwRI redesigns a component when it has a high failure rate, is no longer supported, is difficult to maintain, or requires enhanced functionality. Using state-of-the-art technology, techniques, and tools, Institute engineers support a wide range of redesign efforts.

Combining dimensional and metallurgical information to create solid models, engineers test virtual prototypes in SwRI laboratories before the actual parts are manufactured.

To support the Institute's mechanical redesign program, the following equipment, software applications, and procedures may be used:

Coordinate measuring machines to determine dimensions

Optical, scanning, and Auger microscopes to provide metallurgy information

Pro/ENGINEER™ to create virtual prototypes

ANSYS™ to provide stress and thermal modeling

ADAMS™ to provide dynamic modeling

Stereolithography to produce rapid prototypes

Temperature, humidity, vibration, and electromagnetic interference and compatibility (EMI/EMC) tests to evaluate the prototype

Using a coordinate measuring machine, SwRI engineers obtain precise dimensions to serve as inputs for the three-dimensional models.

Complex printed circuit cards are designed, modeled, manufactured, and tested in the SwRI laboratories.

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The SwRI electrical redesign efforts may include the following:

PSPICE™ to model electrical circuits

ACCEL™ and Tango™ to lay out printed circuit boards

ABEL™ and WARP™ to generate embedded software

Automatic Test Equipment (ATE) and Test Programs Sets (TPS) to support new components

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Engineers redesigned the F-16 landing gear control assembly, solving numerous system mechanical and electrical problems.

Formerly the highest failure rate item in the AWACS radar monitoring system, the video card was redesigned to resolve reliability problems and incorporate new technology.

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After the military's sole source of supply for this component was no longer available, the actuator arm of the C-5 landing gear was re-engineered to qualify new vendors.


(a)	(b)	(c)	(d)
The components shown from left to right detail the rapid prototype process. (a) Dimensional and metallurgical data are obtained from the original component. (b) Using Pro/ENGINEER™ files, a stereo lithographic part is generated. This plastic stereo lithographic component becomes the positive casting model for the aluminum casting shown in figure (c). (d) The casing is then machined back to the dimensions of the original component, and the process is documented.

This flyer was published in June 1997. For more information about mature aircraft systems support, please contact Christopher E. Camargo, Aerospace Electronics and Information Technology Division, Southwest Research Institute, P.O. Drawer 28510, San Antonio, Texas 78228-0510, Phone (210) 522-2095.