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Balancing Engineering Resource with Demand
Mike Costen
ASR Principal Engineer Analysis Group


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ASR Corporation would like to congratulate Honeywell and Electroid Co. for FAA certification of 737 and 747 Nitrogen Generating Systems. ASR is proud to have provided structural analysis and design support to Electroid Co. for this effort.

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Honeywell Receives Second Nitrogen Generation System Certification

 

NITROGEN GENERATION SYSTEM REDUCES RISK OF FUEL TANK FIRE

 

ASIAN AEROSPACE, Feb. 21, 2006 -- Honeywell (NYSE: HON) annouced today that it has received FAA Certification for its Nitrogen Generation System (NGS) for Boeing's 737 airplanes. The certification comes less than two months after the company received similar approval for the inerting system on Boeing 747 airplanes.

The Honeywell NGS reduces the risk of flammability of an aircraft fuel tank by injecting nitrogen-enriched air into it. Using micro fibers, nitrogen-enriched air is produced by separating oxygen from conditioned engine-bleed air through components supplied by Parker Aerospace.

The nitrogen displaces the oxygen in the fuel tank, thereby reducing the risk of an explosion or fire.

"Honeywell is committed to providing innovative products for commercial aviation," said Tim Mahoney, President, Air Transport & Regional, Honeywell Aerospace, "One of our highest business priorities is ensuring the safety of customers who use our products. It's a natural extension of our expertise in thermal management and systems integration to develop an inerting system for use in the fuel tanks of a variety of aircraft. We will continue to work with suppliers and customers to provide similar protection for other air transport airplanes, as well," he added.

"We have completed flight testing of the nitrogen generation system with outstanding results and have entered full-scale production," said Eric Wendling, NGS Program Manager. "We are performing an In-Service Evaluation with the NGS System installed in four commercial airplanes currently in service. Our next steps will be to pursue certification for additional applications," he added.

 

From 'Out of the Blue,' SATOP COMES TO THE RESCUE

 

Obviously, when it comes to aircraft parts, quality and safety are always top concerns. No one knows this better than the folks at Aeronautical Components, Inc. a Long Island based manufacturer of military aircraft parts. When the US Government tightened the standards on an oil pressure transmitter manufactured by Aeronautical Components, company officials knew they would have to make some changes for the part to be included on the updated Qualified Parts List (QPL).

Michael Dantona, marketing and engineering manager at Aeronautical Components, was a part of the team challenged with making the necessary changes to the part. "The part in question is a rather complicated pressure bellows located inside a transmitter that senses air pressure inside the aircraft," said Dantona. "Our existing design did not meet the QPL's new performance parameters, so we needed a new design."

Fortunately, Dantona attended the Long Island Forum for Technology and was introduced to SATOP. "We didn't know a thing about SATOP and were scratching our heads about how to resolve the bellows issue, when out of the blue SATOP came to the rescue." he said.

Dantona filled out a Request for Technical Assistance (RTA) and was matched with ASR Corp., a premier mechanical engineering services company, Mike Costen, a principle engineer and Keith Frerichs, an analyst with ASR, agree to tackle Aeronautical Component's RTA.

"Although the part had failed with the new specs, Aeronautical Components wanted to make the necessary changes to become a qualified supplier," said Costen. "Keith and I decided to start with a comprehensive stress and fatigue analysis."

ASR ended up examining three to four different bellows configuration, ultimately offering one design with a high degree of confidence that it would pass the test. "Aeronautical Components did not have the expertise to create the re-design required to pass the newest performance parameters," explained Costen, "but this is exactly the type of work we do at ASR." Dantona has taken the new bellows design to a manufacturer and is optimistic that it will meet the new performance requirements.

"The whole process of working with SATOP was painless and rewarding," said Dantona. "It was remarkable that we could be associated with ASR's level of engineering technology, and we didn't have to pay for it. I would gladly recommend the program to other manufacturers."

"Even though I've answered more than a dozen SATOP requests, I haven't gotten tired of the challenges," said Costen. "They are usually interesting projects, that have short and sweet solutions. There is something deeply satisfying in solving clearly identifiable problems."

SATOP New York Director Ryan McLaughlin said that the Aeronautical Components RTA clearly illustrates the need for a program like SATOP. "Here is a successful company facing a technical challenge that could have a negative impact on their business," he said. "Through SATOP, they were able to access the high-level technical expertise of Mike and Keith at ASR and receive a cost-effective solution. That's why SATOP exists - to help small businesses succeed and grow."

SATOP Makes Beautiful Music with Bassesloaded


Industry:
Arts

Category:
Materials

Location:
Philadelphia

Referred by:
SATOP Publicity

Background:
Designs novel musical instruments including "Bipolar", a multistringed, multi-tunable instrument.

Challenge:
Needed a better material for the neck of this instrument, as the original stainless steel neck would bend during tuning.

Alliance Partner:
ASR Corporation


Solution:
Analyzed different materials, and recommended switching from steel to carbon fiber rods, which are cost-effective and durable.

Result:
"I was treated with the same respect and diligence as a scientist would be. Tapping into SATOP's resources has been a phenomenal experience for Bassesloaded."
-Al Powell, Owner


Al Powell has immersed himself in the world of music for as long as he can remember. Powell, 46, has worked as a sound engineer, an entertainment venue production manager, and as the owner and operator of sucessful Philadelphia-based Columbus Rehearsal Studios, formerly known as 1020 RPM.

"I have been learning how to play bass since I was 14, and in 1981 I built my own acoustic guitar," said Powell. "I have always had a profound interest in exceeding the limits of present-day musical instruments."

On a mission to transform this pursuit into a reality and prototype his own musical instruments, Powell founded a business he christened "Bassesloaded" in the summer of 2001. Over the years, he has developed three instrument modifications.

Bassesloaded's most recent project is an instrument Powell describes as "a multi-stringed, multi-tunable instrument in which each string is its own universe." Dubbed "Bipolar," it stands apart from other instruments in that it is simplified, indestructable and extremely versatile.

Last year, however, Powell faced a technical roadblock that threatened to slow the instrument's development. He found that the force of tuning his creation would bend the neck of the instrument, which consisted of a steel rod. The bending of the neck moved the strings too far from the surface, making it nearly impossible to play.

Powell had tested different tuning mechanisms, but all threatened the instrument's simplicity, because each would require the addition of other parts.

Uncertain of how to proceed, Powell came across a SATOP success story while paging through magazines in the waiting room of a doctor's office. Unsure of whether Bassesloaded would qualify, he contacted SATOP and spoke with Madi Kalibala, Project Engineer at SATOP New York.

"I was my only employee, and I didn't really think that Bassesloaded would be considered for help from SATOP. I had so many questions, but Madi helped me identify the problem and assigned me to an Alliance Partner," said Powell.

SATOP promptly initiated contact between Powell and Mike Costen, Principal Engineer at Aerospace Structural Research Corporation (ASR Corp.), a Bronze Alliance Partner in Milford, CT.

ASR Corp. Analytical Engineer Cezar Moisiade was assigned the request for technical assistance (RTA). "Al was looking for a material in rod form that would be cost effective and durable, all while maintaining Bipolar's structural integrity," said Moisiade. "The new material also had to be of the same thickness and length as the stainless steel Al had been using. Otherwise, all integral parts would have to be redesigned."

Drawing from experience, Moisiade studied materials that he thought might fit all of the qualifications. From that research, Moisiade produced a design matrix that provided the thickness, weight, deflection and cost of the finest materials Powell could use to optimize the instrument's design.

After studying the information provided, Moisiade was able to determine that the perfect material for Bipolar would be carbon fiber. Additionally, ASR Corp., informed Powell of where he could obtain the carbon fiber rods.

"There is a tremendous value added from the work we are able to do through SATOP. Al was able to save several years in development and a lot of money. Looking for a material with limited scientific knowledge and resources was like walking in the dark," said Costen. "As it turns out, Bipolar will gain a great deal of structural integrity from switching to carbon fiber."

Powell said that SATOP is a fantastic resource for enterpreneurs. "I was treated with the same respect and diligence as a scientist would be," Powell said. "It pleases me to know that my tax dollars make this research available to small business owners like myself. Tapping into SATOP's resources has been a phenomenal experience for Bassesloaded."

 

LOCAL INVENTOR RECEIVES NEEDED BOOST FROM NASA OUTREACH PROGRAM

 

NEWBURGH, N.Y. (April 16, 2003) - With help from the NASA-funded Space Alliance Technology Outreach Program (SATOP) and Aerospace Structural Research Corp. (ASR), local inventor Joel LePore is ready to manufacture and sell his innovative “VibPro” vibration resistant wire terminal.


LePore, a former trucker, knew first-hand that wire terminal failure was often the cause of delays on the road. Because trucks and heavy machinery all endure extreme vibrations under the hood, wiring can break and/or come loose. Seeking a solution, LePore invented the VibPro - a vibration resistant wire terminal that is 30 times stronger than a regular terminal.


“For 13 years I drove heavy equipment for the transportation industry. In this business, time is everything,” said Lepore. “Frequently, wiring would short out in our trucks due to intense engine vibrations and eventually the battery wouldn’t take a re-charge. A lot of heavy equipment has this problem since current battery construction involves soldering a thin wire to a cheap terminal.”


LePore figured if he could develop a stronger terminal, able to endure continual vibration, he could sell the device to the trucking industry. He tinkered in his garage and came up with what he felt sure was the right design. However, “garage tested and approved” would not cut it in today’s business environment.


Fortunately, LePore learned about SATOP and the free engineering advice the program offers to small businesses and inventors when he attended the Orange County Chamber’s 2002 Business Expo. Joel stopped at SATOP's table and was so intrigued by the program he filled out a Request for Technical Assistance form on the spot.


SATOP paired LePore with Mike Costen, a principle engineer with ASR, a high tech company providing engineering support services to commercial industry and government agencies. “Joel had an innovative mechanical concept that he wanted to commercialize, but the design wasn’t supported with CAD drawings or research,” said Costen. “I knew that if he wanted to present this product to manufacturers and buyers he would need more stringent tests and analysis.”


This is where ASR was able to help. Costen slightly modified the original design, as well as provided the CAD drawings and detailed analysis that LePore needed when presenting the VibPro to manufactures and trucking industry representatives. ASR also conducted a finite element stress analysis, using state of art tools. “We were able to confirm that Joel’s original design was viable -- in fact, the VibPro can handle over 100 g’s of acceleration and still have an infinite life,” noted Costen.


Lepore has a provisional patent on the VibPro and the prototypes he built and installed have so far operated flawlessly. “I installed one on a farm tractor in Warick, New York and this vehicle takes a beating,” said Lepore. “I can’t think of a better field test than that!”Mike Costen enjoyed working with LePore and SATOP. “This was my first SATOP assignment, but I understand from my colleagues that you never know what you’ll get -- sometimes it’s a tough technical challenge and at other times we simply give advice,” said Costen. “In this case we were able help an inventor who had a sound idea but needed the presentation materials to convince an audience of its viability.


“SATOP is a well organized, well run operation. Ryan McLaughlin [SATOP - NY Engineering Services Manager], my point of contact, was very good at following up and making sure we were communicating at every point along the way,” said Costen.


LePore also has ample praise for SATOP. “I can’t say enough good things about SATOP,” said LePore. “As an inventor, I don’t have the capital to conduct all the research and testing ASR did, so it was a blessing. I’m now one of SATOP’s biggest supporters.”

 

AWARDS

 

ASR Corporation received the "Alliance Partner of the Year" award on May 15, 2007. Lynne Costen representing ASR Corp accepted the award in Washington DC. US Senator Joseph Lieberman also extended his congratulations to Mike Costen and ASR Corporation.

 

The National Aeronautics and Space Administration (NASA) presents a Certificate of Recognition to Michael K. Costen for the creative development of a scientific contribution which has been determined to be of significant value in the advancement of the space and aeronautical activities of NASA and is entitled: Lightweight, Low-cost Solar Energy Collector.

The award was presented to Michael K. Costen on May 16, 2006

 

The National Aeronautics and Space Adminstration (NASA) presents the Public Service Group Achievement Award to ASR Corporation (Microwave Limb Sounder Gas Laser Team) for outstanding accomplishment in the development of a 2.5 terahertz laser local oscillator for critical atmospheric measurements on the Aura mission.

The award was presented to ASR on March 29, 2005 by Frederick D. Gregory, Deputy Administrator, NASA

 

PATENTS

 

A US Patent was awarded to Michael K. Costen on February 7, 2006 for his Lightweight, low cost solar energy collector.

A US Patent was awarded to Michael K. Costen on January 31, 2006 for his Heat Exchanger with Header Tubes.






 





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