Executive Summary:

Triumph, a global leader in overhauling aerospace systems, contracted HD to provide detailed design services to their actuation system division. Triumph needed a new actuation gear box that had been robustly designed, with manufacture considered from the offset.

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Using HD’s proven design process allowed Triumph to deliver a solution that had a significant weight reduction and met additional performance requirements. The solution was designed for manufacture from the offset, and also included FEA and mechanical engineering calculations. Extensive tests were carried out by Triumph on HD’s design, all of which passed without issue before proceeding to vibration and climatic testing, prior to being fitted to the aircraft. Considering DFM from the outset is part of HD’s design ethos, and as such, Triumph were able to achieve all of their project objectives by working with us.

Triumph selected HD from previous experience of their test design capability. They rose to the challenge of our schedule and technical requirements producing a first-class design. In addition, they worked closely to our methods and processes so it was like having an extended design team. – Triumph

Haughton Design have a history of working in highly regulated sectors with specific specialist test rig expertise so, we were able to apply a range of specialist skills to achieve the requirements of this brief.

Haughton Design were contracted to develop a refined concept for an aircraft wing flap drive unit. The client had established an outline concept that needed to be significantly developed to a working concept. The outline concept was overweight, unable to achieve space requirements, unable to achieve performance requirements, unsealed and unable to be assembled. The main challenges of this development were achieving the required output performance whilst; Being below 3.6 kg (This was revised down to 2.4kg during the project); Fitting within a supplied space envelope; Being designed for efficient manufacture and assembly at a lower cost than typical products of this nature; Sealing the unit without increasing its overall weight and footprint; Selecting materials, gears and bearing designs to achieve performance and lifecycle requirements.

To achieve these requirements, HD needed to develop a design that had several novel features that would allow the unit to be assembled efficiently. HD worked alongside the clients in house electrical team to ensure the mechanical design and casing design was appropriately engineered to endure the environments for use. We conducted FEA on all of the components for strength and fatigue analysis.

The project moved through most of our development stages but due to the nature of the product and value of its materials and components, no interim prototypes were built. The first off components were machined and assembled as a working prototype that underwent performance testing at Triumph’s plant in Deeside. Once this was tested and approved, HD engineered the full gearbox receiving excellent feedback from the client.

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