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Intro

This document provides an introduction to flight testing. It discusses reasons for flight testing such as complying with regulations, developing products, and safety. It outlines FAA regulations and advisory circulars for different types of aircraft. The document also discusses the order of prototype and certification testing, flight test instrumentation, controlling aircraft configuration and loading, weight and balance terminology, ballasting, flight cards, flight test tolerances, data collection methods, data reduction sequence, and characteristics of the atmosphere.

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68 views

Intro

This document provides an introduction to flight testing. It discusses reasons for flight testing such as complying with regulations, developing products, and safety. It outlines FAA regulations and advisory circulars for different types of aircraft. The document also discusses the order of prototype and certification testing, flight test instrumentation, controlling aircraft configuration and loading, weight and balance terminology, ballasting, flight cards, flight test tolerances, data collection methods, data reduction sequence, and characteristics of the atmosphere.

Uploaded by

bigfootted
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 27

Introduction to Flight Testing

Ralph D. Kimberlin, Ph.D.


Professor, College of Engineering
Reasons for Flight Testing

• To comply with Regulations, Specification, or


Mission Requirements
• To develop Products
• Safety
• Research

2
FAA Regulations and Advisory Circulars

• FIXED WING AIRCRAFT


Small Aircraft FAR 23 & CAR 3
AC 23-8C
Transport Aircraft FAR 25 & CAR 4B
AC 25-7C
• ROTARY WING AIRCRAFT
Small Rotorcraft FAR 27 & CAR 6
AC 27-1B
Transport Rotorcraft FAR 29 & CAR 7
AC 29-2C

3
FAA Regulations and Advisory Circulars

• NOISE FAR 36

• AIRCRAFT ENGINES FAR 33


AC 33-2C

• PROPELLERS FAR 35

4
Military Specifications

• MIL-C-5011B Performance Specification


• MIL-F-8785D Stability and Control Specifications
• MIL-1797 Flying Qualities
• MIL-M-7700D Handbook Specification
• Requirements of the Contract

5
Order of Prototype Testing

1. Shakedown Flights
2. Airspeed System Calibration
3. Stall Speed Measurement
4. Flight Envelope Expansion
a) Airspeed and G
b) Center of Gravity
5. Performance Measurements
6. Spins
7. High Speed Dives
8. Certification Testing

6
Suggested Order of Certification Testing

1. Certification Flight Test Plan Approved


2. Applicant Flight Test Report Reviewed
3. TIA Issued
4. Conformity Inspection Performed
5. Familiarization Flights
6. Airspeed System Calibration Flights
7. Stall Speed Measurement Flights
8. Engine Cooling and other Engine Related Flights
9. Performance Flights

7
Suggested Order of Certification Testing

10. Forward C.G. Stability and Control Tests


11. Aft C.G. Stability and Control Tests
12. Spins
13. Dives to the Dive Speed
14. Special Tests
a) Performance
b) Noise
c) Avionics
d) Other Systems
e) Function and Reliability

8
Flight Test Instrumentation

• TYPES OF INSTRUMENTS
– Air Data
– Power
– Acceleration
– Fuel Flow and Fuel Consumed
– Control Position and Force
– Gyros, Attitude and Rate
– Flow Angles (Alpha & Beta)

• CALIBRATION REQUIREMENTS
– All Calibrations Traceable to NBS
– Zero Check each Flight
– All Instruments Calibrated every 6 months
– Critical Instruments Calibrated every 60 days Maximum
Reference FAR 21.39 & ACs 23-8, 25-7, 27-1 & 29-2

9
Control of Aircraft Configuration and Loading

• Aircraft Configuration Log


• Aircraft Loading Log
• Reasons for Controlling Configuration and Loading
1. Knowing what was tested
2. Test Safety

10
Weight and Balance Terminology

• Maximum Takeoff Weight or Standard Weight (Ws)


• Empty Weight (We)
• Minimum Weight
• Fuel Weight (Wf)
• Test Weight (Wt)
• Center of Gravity (C.G.)
• Center of Gravity Range or Envelope
• Moment
• Mean Aerodynamic Chord (M.A.C.)

11
Weight and Balance Terminology

• Ramp Weight
• Landing Weight
• Maximum Zero Fuel Weight
• Maximum Taxi Weight
• Fleet Weights (Production)
• Fleet Weights (Operations)
• Datum
• Arm

12
Empty Weight and C.G.

• Empty Weight
(a) Must be determined by weighing with:
1. Fixed Ballast
2. Unusable Fuel
3. Full Operating Fluids (except water)
(b) Conditions must be well defined and easily repeatable.

– Note: These requirements apply to the determination of the empty


weight for production aircraft before a fleet weight is established.

– Reference: FAR 23.29 and 25.29

13
Development of the Weight and C.G. Envelope

• Structural Envelope (Airframe Group Responsibility)


• Flight Test Envelope (Flight Test Responsibility)
• Tolerances for Weight and Center of Gravity During
Flight Tests:
– Weight:
• Performance Testing: +5% to -1%
• Other Testing: +5% to -10%
– C.G.: + or – 7% of total travel
– Note: FAR 25 contains extrapolation limits.

14
Determination of Aircraft Weight

• Methods for Determining Weight


– Actual Weighing (Required before start of FAA Flight Tests)
– Computation
– Computation based upon actual weighing
• Types of Scales
– Platform
– Electronic
• Reference AC 65-9 and AC 91-23

15
Weighing Techniques

• Leveling the Aircraft


– Longitudinally
– Laterally
• Determining Tare Weight
• Determining Weight and C.G.
• Determining the Vertical and Lateral C.G.

– Reference AC 65-9 and AC 91-23

16
Significance of Weight Requirements

• From a Flight Test Standpoint the Maximum Takeoff


Weight is usually set by a Performance Parameter.
• However, even if Performance is adequate, the
Maximum Takeoff Weight cannot exceed that Weight
to Which the Aircraft’s Structure has been tested.
• Minimum Weights obtained from their possible
combinations should be paid particular attention.
Especially on STC Programs, as the Additional Weight
of the Modification may not allow the modified aircraft
to meet the Regulation.

17
Weight and Balance

• Piper Cherokee Six PA-32-260 N3736W

18
Ballasting for Flight Tests

• Selection of Ballast Types


– Solid – Lead Bars, Shot Bags, Sandbags
– Liquid – Water Tanks
• Safety Considerations
– Provisions for Jettisoning
• Solid – Shot Tanks
• Liquid – Water Tanks
• Methods to Simulate Vertical C.G.
– By Ballasting – Ballast Boxes, Shot Tanks, Water Tanks
– Calculation

19
Flight Cards

• Used to help the Pilot and Engineer organize


the flight efficiently, while collecting the
necessary data.
• Are personalized for efficient use by the Test
Pilot and Flight Test Engineer

20
Flight Cards
Should contain the following information:
1. Date
2. Type Aircraft
3. Tail or N Number
4. Flight Number
5. Configuration and Loading
6. Takeoff and Landing Times
7. Type of Test and Test Method Used
8. Trim Speed, Altitude and OAT
9. Position of Landing Gear and Flaps
10.Power Setting at Trim
11.Any Test Limitations
12.Test Specific Data
13.Comments about Specific Test or Data Point
14.Names of Personnel involved in the Test

21
Flight Test Tolerances
• Purpose – To allow for variations in flight test values from
which data are acceptable for reduction to the desired value
ITEM TOLERANCE
Airspeed 3 kts or + or – 3% whichever is greater
Power + or – 5%
Wind (TO & LDG) As low as possible but not to exceed 12%
of Vs1 or 10 kts at 6 FT above the runway

• In certain instances the tolerances should be less than is


stated by the rule
– References: FAR 23.2lb and 25.21d
AC 23-8A, 25-7, 27-1, and 29-2A

22
Flight Test Tolerances

• Tolerances are not to be used to circumvent


the regulation
• Consult Advisory Circulars 23-8C, 25-7C, 27-
1B, and 29-2C for Tolerance Information on
Specific Tests

23
Data Collection Methods

• Stable Equilibrium
• Non-Stable Equilibrium
• Non-Equilibrium

24
Data Reduction Sequence

1. Correction for Instrument Error


2. Correct for Position Error (Air Data)
3. Correct for Non-Standard Conditions
4. Presentation in Standard Conditions
5. Expansion to Non-Standard Conditions for
Pilots Handbooks

25
The Atmosphere

26
The Atmosphere

• Composition
– 21% Oxygen, 78% Nitrogen, 1% Other Gasses
– 0-4% Water Vapor in first 10 miles
• Limits – 400,000 Feet (NASA)
• Standard Atmosphere
– Seasonal Changes
– Daily changes due to weather patterns
– Aircraft performance varies with changes in the atmosphere
• 1962 Standard Atmosphere
– Assumptions – Perfect Gas, Dry Air, Tropopause occurs at 36,089 Feet.
– Tables

27

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