Past Successes

From decades of new product development and testing work, and investigating and resolving various kinds of field failures, with 100% success rate, our Consultant is adept at helping clients in expediently arriving at the root of their long standing problem.

In all of our past projects and cases, the accuracy of our analysis was proved by the fact that the results of our analysis matched the observed behavior or empirical data. In some cases it even predicted vulnerabilities that showed up as field failures that were not revealed before hand. This kind of success is very satisfying.

After delving into a wide variety of problems, disciplines and applications, we have arrived at a method that works consistently in all cases, including the very important human factors that come into play whenever we’re dealing with products, systems or interactions that are created by humans.

Contact us especially if you’re struggling with a long-standing issue that has a substantial impact. We’d like to help you out.

Listed below, are some of the tasks and problems that were handled and solved by the consultant in his career in different applications, and the descriptions are kept brief here. For details, see the resume.

Failures and Undesirable Phenomena:
    • Journal bearing failure, ball bearing failure, spline wear, wear-debris, etc.
    • Pressure spikes and pulsations in landing gear sub-system, overheating from internal leakage in pumps, adverse effect of air in hydraulic system,
    • o-ring failure, shaft-seal wear, surface finish issues causing leaks at metal-to-metal sliding interfaces of high pressure hydraulic components,
    • cavitation in pumps.

Testing (Systems, Structural and Aerodynamic):
    • Prototype development testing, qualification testing, endurance testing, functional testing, testing of systems and components,
    • Glass fiber reinforced plastic (GFRP) composite wing destructive testing,
    • Wind-tunnel testing to measure thrust of propeller driven by model-airplane engine.

Analysis:
    • GDT tolerance stack-up analysis.
    • Journal and ball bearing sizing analysis.
    • Spline sizing and contact stress analysis.
    • Hydraulic system flow demand analysis, line sizing calculations and pressure-drop analysis, pump sizing;
    • Heat exchanger sizing, orifice sizing, o-ring sizing, reservoir sizing,
    • Analyses for experimental and kit airplanes: preliminary design, aerodynamic design, stability analysis, and detailed structural analysis (by manual calculations of loads and internal stresses).
    • Structural analysis and testing of certificated airplane structures, using FEM analytical software (including CAD modelling). FEM analysis and investigation of fatigue cracks in structural parts: airplane wings, nose landing gear drag-brace bracket, horse/stock-trailer framework.

Hydraulic Components:
    • Hydraulic system, engine driven hydraulic pump, DC-motor driven hydraulic pump, hydraulic motor driven generator, power transfer unit / PTU;
    • Power transfer switching valve, pressure relief valve, landing gear control valve, flight control actuators.

Airplanes:
    Experimental kit airplanes, multi-engine amphibian airplane, glider, certificated production airplanes, business jets, propeller airplanes, novel free-wing airplane, remotely piloted / unmanned air vehicle (UAV).

Types of Structures:
    Aluminum monocoque shell structure, fiberglass plastic monocoque structure, fabric covered steel-tube truss airframe.

RESUME of Consultant, Rajeev Pandit

Major Root Cause INVESTIGATIONS:

For US navy, Bell Helicopter & Vickers Aerospace:
--Failure investigations, root cause analysis and resolution of technical problems in V-22 Osprey tilt-rotor aircraft. Solved decade-long problem in 5 months.

--Troubleshooting of pressure spikes and instability in AH-1Z upgrade helicopter hydraulic system:

for Gulfstream Aerospace Corpn & Vickers Aerospace:
--Root cause analysis / Troubleshooting of elusive field-failures of the GV aircraft main hydraulic pump. Solved a 2-yr long problem in 5 months.

Design Verification TESTING;
Performance & Functional Testing:

for Raytheon-Beech & Vickers Aerospace:
Complete Hydraulic System for
Hawker-4000 business-jet development

--Conceptualized, planned & guided the setup of an Integrated Test Facility.
--Developed detailed test plans and instrumentation,
--Conducted tests, Interpreted results.
--Resolved various challenging problems / shortcomings that arose.
--Similarly with Aircraft Flight Testing
--Expediently troubleshot elusive, intricate problems and in-flight failures, including malfunctioning in the flight control system.

Development of NEW PRODUCTS:

for Cessna Citation X business-jet:
Hydraulic Control System development.

Project co-ordination and complete analysis and testing (ground and flight).

for Light Aero, Inc:
Structural Analysis and Development of Explorer, a large custom-built amphibious airplane.
--Work recognized in Sport Aviation magazine, Aug. 1991, pp 40-47.
• Performed all aerodynamic analysis, LG loads, stability calculations, etc.
• Performed all detailed classical structural analysis of the airplane fuselage, wings, etc.

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