Unison Industries specializes in manufacturing electrical and mechanical components for industrial aircraft. Our goal was to design a protective housing for the electrical parts inside an airplane engine’s ignition exciter box, while also reducing the total cost of creating the housing and decreasing the time to build the assembly.
The current design features a stainless steel square housing with the electrical components glued in place. This adhesive takes 24 hours to harden and can be messy and difficult to use. The lengthy time needed for the adhesive curing slows down the assembly process and makes repairs difficult. The housing may undergo changes in temperatures and environmental conditions, and experience many vibrations during flight.
We tested the model to ensure the design can support the temperature changes and the material will not fail during operation. We used a tight-fit molding design to account for the small amount of space inside the box. This compact design provides a specific location for each electrical component in the housing. Once each part is in its correct position, a second molding fits on top, enclosing the parts. This tight-fitting design helps to lessen vibrations. We added durable foam in between the top and bottom moldings for extra support.
The new design decreases the total time and cost needed to build the housing. Components can now be easily lowered into position and the box shuts with little effort or extra hardware needed.