Presentation is loading. Please wait.

Presentation is loading. Please wait.

777 Freighter First Flight Preparation and Conduct Van Chaney, Boeing 777 Deputy Chief Pilot Paul Bolds-Moorehead, Boeing 777 Stability & Control Senior.

Similar presentations


Presentation on theme: "777 Freighter First Flight Preparation and Conduct Van Chaney, Boeing 777 Deputy Chief Pilot Paul Bolds-Moorehead, Boeing 777 Stability & Control Senior."— Presentation transcript:

1 777 Freighter First Flight Preparation and Conduct Van Chaney, Boeing 777 Deputy Chief Pilot Paul Bolds-Moorehead, Boeing 777 Stability & Control Senior Lead Engineer Flight Test Safety Workshop – Europe Vienna, Austria 12 November, 2009 P

2 777F First Flight - FTSW Europe 2009 2 …… following Capt. Cashman 14 years later, much is the same 6 th generation of 777 Confidence built on past success Not a new airplane Pressure to do less (time, conditions, money) “Keep it simple” V

3 12 November, 2009 777F First Flight - FTSW Europe 2009 3 Agenda 777F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary V

4 12 November, 2009 777F First Flight - FTSW Europe 2009 4 Agenda 777F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary V

5 12 November, 2009 777F First Flight - FTSW Europe 2009 5 777 Freighter First Flight V

6 12 November, 2009 777F First Flight - FTSW Europe 2009 6 777 Introduction Family Evolution 535,000-lb TOW 74k-84k Thrust 777-200 1995 777-200LR 2006 766,000-lb TOW 110k & 115k Thrust 777-300ER 2004 775,000-lb TOW 115k Thrust 777-200IGW 1997 632,500-lb TOW 84k-90k Thrust 777-200ER 1998 648,000-lb TOW ≤ 90k Thrust 777-200ER 2000 656,000-lb TOW ≤ 94k Thrust 777-300 1998 660,000-lb TOW 84k-98k Thrust 777F 2009 766,000-lb TOW 110k & 115k Thrust P

7 12 November, 2009 777F First Flight - FTSW Europe 2009 7 MTOW 766,800 lb(with revised c.g. envelope) MLW 575,000 lb(a 17% increase) Addition of Maneuver Load Alleviation (MLA) function in Primary Flight Computers Summary of Changes: 777-200LR to 777F No aerodynamic changes -Same wing -Same fuselage -Same empennage V

8 12 November, 2009 777F First Flight - FTSW Europe 2009 8 777F Airplane Description Flight Envelope P

9 12 November, 2009 777F First Flight - FTSW Europe 2009 9 777F Airplane Description GW/CG Envelope V

10 12 November, 2009 777F First Flight - FTSW Europe 2009 10 Maneuver Load Alleviation (MLA) Purpose: Reduce wing bending loads due to positive maneuver conditions Function: Symmetrically deflects some lateral control surfaces as a function of normal load factor Benefit: Forward CG expansion without additional structure Application: 777F unique to-date. 777F Airplane Description Maneuver Load Alleviation P

11 12 November, 2009 777F First Flight - FTSW Europe 2009 11 777F Airplane Description MLA Details Design Intent: a) Handling Qualities unchanged during normal maneuvers b) Handling Quality changes during elevated “g” maneuvers to be imperceptible P

12 12 November, 2009 777F First Flight - FTSW Europe 2009 12 Agenda 777F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary P

13 12 November, 2009 777F First Flight - FTSW Europe 2009 13 777F First Flight Preparation Predicted Flight Characteristics document Very thorough, rigorous evaluation of many different maneuvers and characteristics Mapped across entire flight envelope Less breadth than for a new airplane Pilot training in engineering simulator Procedure review/modification Flight condition reasonableness/attainability Familiarization with handling Crew Resource Management development Establish or refine abort/safety criteria P

14 12 November, 2009 777F First Flight - FTSW Europe 2009 14 777F First Flight Preparation (cont’d) Control law issues MLA/HOSP interaction (HOSP = Hardened Overspeed Protection) First flight dry run Simulator used with most test participants Treated as actual flight Ground testing System specific component tests “Gauntlet” Flight test tools in use at BCA Engineering CAB / Fixed Based Simulator Flight Emulation Test System (FETS) LabVIEW Airplane Display System (LADS) Airborne Data Acquisition & Monitoring System (ADAMS) P

15 12 November, 2009 777F First Flight - FTSW Europe 2009 15 777F First Flight Preparation (cont’d) Developed Contingency Plans Plan A:  Full first flight profile with a landing at Boeing Field test center Plan B:  In case of telemetry failure or other mechanical problems  only do low and med risk test conditions (no high risk)  return landing at origination base (Paine Field manufacturing center) Added a temporary limitation to prevent activation of MLA function  turned out to be very wise as we essentially chose the time and place to do battle with any “discoveries” V

16 12 November, 2009 777F First Flight - FTSW Europe 2009 16 Agenda 777F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary V

17 12 November, 2009 777F First Flight - FTSW Europe 2009 17 777F First Flight Day 14 July, 2008 At the airplane Final prep activities Taxi testing Telemetry (control) room activities Anticipating reception of telemetry data Successes Airplane flew exactly as predicted (simulator) and the same as the parent model (777-200LR pax airplane) Failures or “Opportunities” Telemetry failure – followed “Plan B”, e.g. aborted and returned to origination field (PAE) V

18 12 November, 2009 777F First Flight - FTSW Europe 2009 18 Agenda 777F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary V

19 12 November, 2009 777F First Flight - FTSW Europe 2009 19 777F First Flight – Part Two 16 July, 2008 Completed what had been planned for first flight profile Telemetry repeater van local for this test attempt Arrived at primary Boeing test facility (Boeing Field, Seattle) (originally planned for completion of first flight) Planned layup and inspections followed V

20 12 November, 2009 777F First Flight - FTSW Europe 2009 20 Agenda 777F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary V

21 12 November, 2009 777F First Flight - FTSW Europe 2009 21 777F Aileron Vibration Major discovery on third flight: Significant aileron vibration present with MLA function active Occurs at 1.8-2.0 g with a specific aileron deflection Could have encountered on first flight without TM had the limitation not been present V

22 12 November, 2009 777F First Flight - FTSW Europe 2009 22 Aileron vibration discovery flights Flutter-type testing 2 altitudes and increasing Mach numbers  Manual controller “kicks”  Elevator frequency sweeps  Roller Coasters and “kicks” in turns (elevated g) Aileron vibration occurred with trailing edge up deflections of ailerons. Ailerons had never been used previously at these speeds due to aileron lock-out function. With additional MLA g bias applied (e.g.- PFC thinks it’s under a 1.8 G load): column kicks, shallow bank turns exhibited vibration Without MLA g bias: 60 deg bank turns and roller coaster maneuvers to higher g levels showed vibration V

23 12 November, 2009 777F First Flight - FTSW Europe 2009 23 Aileron Vibration Details Pilot comments on Aileron Vibration: “Alarming.” “Feels like driving over a washboard road.” “Feels like something is going to come off.” “Distracting and you naturally want to unload and slow down” Causal factor unknown. Potential contributing factors include: 1.Aileron deflection angle for vibration corresponds to approximately zero hinge moment 2.A “scoop” is created between the mass balance tower and the lower surface of the wing when the aileron is deflected V

24 12 November, 2009 777F First Flight - FTSW Europe 2009 24 Aileron Vibration Video V

25 12 November, 2009 777F First Flight - FTSW Europe 2009 25 Aileron Vibration Data P

26 12 November, 2009 777F First Flight - FTSW Europe 2009 26 Aileron Vibration Mapping P

27 12 November, 2009 777F First Flight - FTSW Europe 2009 27 777 Outboard Aileron Balance Tower P

28 12 November, 2009 777F First Flight - FTSW Europe 2009 28 Aileron Vibe - Potential remedies Aerodynamic modifications External wing treatments Aerodynamic sealing Internal flow diversion Flight control software modifications Change to basic MLA aileron travel schedule Addition of aileron “No-Dwell zone” function P

29 12 November, 2009 777F First Flight - FTSW Europe 2009 29 Re-test flights : MLA Aileron “No Dwell” Zone P

30 12 November, 2009 777F First Flight - FTSW Europe 2009 30 Agenda 777F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Lessons Learned Summary V

31 12 November, 2009 777F First Flight - FTSW Europe 2009 31 777F Lessons Learned Thorough checkout of ALL systems for the test program is crucial Although telemetry is not a flight critical system, it is necessary for test success Past success doesn’t guarantee future success Fly-By-Wire airplane control laws present opportunities to remedy issues such as this Team approach to problem solving is required Especially when pilot opinion and engineering data differ The “right thing” will still prevail once thorough communication occurs Important to capture lessons learned on specific technical “discoveries” to share between programs Pilot distraction needs to be considered as certification issue Contingency planning (“Plan B”) is a necessary step Envelope expansion for new functionality (MLA limitation) is required V

32 12 November, 2009 777F First Flight - FTSW Europe 2009 32 Agenda 777F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary P

33 12 November, 2009 777F First Flight - FTSW Europe 2009 33 Summary Never assume that a test program will escape problems, no matter how seemingly “minor” the effort is ! P

34 12 November, 2009 777F First Flight - FTSW Europe 2009 34 Questions? P


Download ppt "777 Freighter First Flight Preparation and Conduct Van Chaney, Boeing 777 Deputy Chief Pilot Paul Bolds-Moorehead, Boeing 777 Stability & Control Senior."

Similar presentations


Ads by Google