ESAEagle Star Aviation

Pylon for installation of a PW305A engine on a CRJ700 aircraft

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TEAM ORGANIZATIONPROJECT SCOPEThe team was divided into six departments depending on the project requirements and on the team members’ experience and interests. The team’s small size forced ESA’s structure to be very dynamic. Human ressources had to be reallocated depending on the workload of different departments at different phases.

Eagle Star Aviation (ESA) had the mandate to design a pylon to allow the installation of a Pratt & Whitney PW305A turbofan engine onto a Bombardier Aerospace CRJ700. With a development budget of 670,000$, ESA had to go through a full product development process, from requirements definition to final certification compliance.

ESA is composed of 11 graduate and undergraduate engineering students from five Québec universities. This project is supported by engineering professionals from Pratt & Whitney Canada, Bombardier Aerospace and Bell Helicopter. Industrial technical support was also provided by l’École Nationale d’Aérotechnique and Dassault Systèmes. The industrial partners guided the students through the project by sharing their great experience and knowledge of the aerospace industry.ESA would also like to thank École Polytechnique de Montréal and the CAMAQ for their support.

Wilton Zapata

Stepherd Kishore Raj

Nicolas Latrémouille Sowndhar Salaman

Larabi KdiderBrieuc Queffelec

Mehdi Ben Henia

Michael Kuan

Philippe Prézeau Sreenath Menon

Alan Padron

Eagle Star Aviation Eagle Star AviationEagle Star Aviation

Testing

ManufacturingSystems

Structures Systems

StructuresStructures

CertificationConfiguration

Asst. ManagerManager

Product DevelopmentSystems Integration

2014-2015

New powerplant installation

Existing powerplant installation

Team ESA

PYLON COMPONENTS1-Front engine mount2-Aft engine mount3-Firewall4-Bleed air duct5-Fuel lines6-Hydraulic lines

1

910

11

2

3

4

8

5

6

7

12

7-Fire entinguishing system8-FADEC cable9-Main power cable10-Fire detection system11-Trailing edge12-Leading edge

STRUCTURES DESIGN

SYSTEMS DESIGN

PROJECT MANAGEMENT MANUFACTURING

TESTING

CERTIFICATIONCONFIGURATION

The project was successfully completed under cost and on schedule. The labor cost per task was tracked weekly using the earned value methodology. The risks associated with schedule cost and weight of the product were identified and mitigation plans were developped and implemented.

Compliance to structural strength and deformation requirements was shown by analysis substantiated by test. A static bench test was performed on a prototype of the front engine mount under representative load cases. The test validated that ESA’s finite element analyses are conservative.The qualification of the FireX systems will be shown through a full scale FireX test for which a request for test was developped.

The certification basis was defined by ESA and agreed upon with the certification authorities represented by Bell Helicopter. The means of compliance were determined by ESA’s certification department in close collaboration with other relevant departments and tracking of the compliance status was done throughout the entire project. The final design and compliance methods were agreed upon with the certification authorities.

Eagle Star Aviation

Finite element analysis was used to optimize the design of the structural components: front engine mount, aft engine mount, skins, leading edge, trailing edge and spars. The design complies to all applicable certification requirements, such as rotor burst and fire protection. Changes to the aircraft structure were minimized to allow for an easy retrofit process.The systems components comply with all

certification and client requirements. To achieve this, different analyses, such as bleed air pressure, touch temperature, evaluation of fireX agent concentration and voltage drop were performed. An accessibility analysis was completed to validate that all systems and critical structural components are accessible for visual inspection and maintenance.

Detailed production planning was completed to ensure ESA’s capability of delivering the pylons required for the production of 60 aircrafts and to perform 4 retrofits per year. This

was achieved by preparing a complete manufacturing strategy including make/buy strategy, an optimized shop floor layout, preventative maintenance strategies, detailed manufacturing plans and assembly plans.

The design processes, product configuration and maturity status were controlled through a structured configuration management process which guaranteed the integrity of the product definition. These processes allowed ESA to successfully release all 305 pylon components.