Luxury Aircraft Doors

When designing the interior of an aircraft, lightweight and sturdiness are the key factors to consider. This was certainly the case for Hiller Inc., an established manufacturing company for almost 40 years, who has carved out a reputation of excellence by providing superior solutions in a full assortment of aircraft – such as Learjet, Cessna, Beechcraft, Bombardier, and Air Force One.

In one recent design situation, Hiller engineers encountered issues with the upgrade of a lavatory door design. Looking for a sturdier and more reliable linear guide product, Hiller began collaborating with PBC Linear to produce a more efficient linear motion solution. The original linear guide for the lavatory door did not perform up to Hiller's high standards that coincide with luxury aircraft. The weight of the door put too much load on the slide, causing it to sag over time, which results in misalignment and improper operation. As the problem progressed, the door would be unable to latch – causing further maintenance issues.

Hiller identified PBC's Low Profile Redi-Rail (LPRR) linear guide system as a viable improvement. LPRR is a compact (19mm) cam roller system equipped with high performance, double row bearing rollers for increased load capacity and rigidity. It also features steel inserts embedded within the lightweight aluminum rail to ensure durability and long life. However, to adapt the LPRR into the Hiller application, PBC needed to make some custom refinements to the standard design to further decrease weight while maintaining strength. To lighten the LPRR, Hiller proposed designing air pockets along the rail. This achieved the goal of reducing the weight without sacrificing load capacity or performance. After testing the first prototype, Hiller asked if PBC could machine for higher volume production. Equipped with a 150,000ft² manufacturing floor, PBC Linear can provide several unique machining capabilities and had no problem mass machining the custom rail.

Initial testing of the linear guide system proves to be successful. On static pull tests, the LPRR is able to perform at two-and-one-half times the specified weight (around 300 lb) without bending or misalignment. Pleased with the performance, Hiller is using the door with the new linear guide system in their upcoming aircraft designs.

PBC Linear Roscoe, IL
pbclinear.com

Hiller Inc. Wichita, KS
hillerinc.com