SSV 2014 S8A2 - Handling of Flight Safety at Saab Flight...

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HANDLING OF FLIGHT SAFETY AT SAAB

FLIGHT TEST DEPARTMENT IN GENERAL

AND EXAMPLES FROM GCAS FLIGHT TEST

Anders Erlandsson

Björn Rubensson

August 2014

COMPANY UNCLASSIFIED - NOT EXPORT CONTROLLED

- - - - Anais do 7º Simpósio de Segurança de Voo (SSV 2014) - Direitos Reservados - Página 558 de 843 - - - -

AGENDA


General Introduction

SAAB

Gripen Fighter

GCAS (GCAS - Ground Collision Avoidance System) in Gripen

Flight test Safety approach at SAAB in general and ”hands on” GCAS TEST

Authority Cooperation

Process

Education

Summary and Lessons Learned

Questions/Discussion

General Introduction Flight Safety Approach at SAAB Summary and Lessons Learned Questions/Discussions


WORLD MAP

~10 700 km




SAAB DEFENCE AND SECURITY

World-leading solutions, products andservices for military defense and civilsecuritySales 2013: MSEK 23,75014,000 employeesLocal presence in 33 countries andcustomers in 100 countries worldwideSaab’s B-share listed on NASDAQOMX Stockholm’s Large Cap listsince 1998 (SAAB B)

Sales

distribution

2013

Geographic markets, %

Sweden, 41

EU excluding Sweden, 17

Rest of Europe, 3

Americas, 13

Asia, 18

Africa, 4

Australia, etc., 5

Market segments, %

Air, 45

Land, 27

Naval, 10

Civil Security, 8

Commercial Aeronautics, 7

Other, 3




SAAB HISTORY




Group

Functions

Market Areas

CEO

ORGANISATION

Aeronautics ElectronicDefenceSystems

Dynamics

Security andDefenceSolutions

Support andServices

Combitech*

*Independent subsidiary reported as a business area

Business Areas

Nordic& Baltic

AmericasEurope& Greater

Middle East

India Sub-SaharanAfrica

AsiaPacific




AERONAUTICS EXPERIENCE

More than 70 years in business

More than 4000 aircraft manufactured

Among them 500 airliners

15 different types of aircraft




AERONAUTICS PRODUCT

AREAS

The Gripen Fighter System

Commercial Aeronautics

Unmanned Aerial Systems (UAS)

Airborne Mission Systems

Training & Support systems

Future Air Systems

Saab 340/2000 and derivates

SK 60, Trainer




AERONAUTICS TECHNOLOGY AND COMPETENCE

Flight Test and

Verification

Aeronautical

Engineering

Airborne & Gd. Based

Computer Systems

Vehicle

Systems

Human-Machine

Interaction

Tactical

System

Weapons

Integration

Structural

Technology

Structural and Systems

Installation Design

Simulators

and Training

Production

Systems

Maintenance

Systems

Engineering Methods & Tools

SYSTEMS INTEGRATION

Overall Design and Architecture

Survivability

Systems Safety and Reliability

ILS, Availability and Maintainability




FLIGHT TEST AND VERIFICATION


~ 230 employees

• Test Pilots• Mechanics • Test Engineers (flight, ground, lab)

Flight Test Wing

”Makes The A/C fly” Test Engineers”Defines & conducts testing”

Support

” Tools & equipment”

• Soft- and hardware engineers

Management”Lead and inspire”

• Management• Staff and controllers• Planning



TEST VEHICLES

GripenSAAB 340 / 2000 and derivativesNH90 TMSSKELDARSK60

System tests in rigs and simulators

Flight Test




INTRODUCTION TO THE GRIPEN

FIGHTER SYSTEM

Multi-role and Swing-role capability

Advanced Mission Support System

Weapons

High maintainability and low operating costs

Data Links

Upgradability

Training system




GRIPEN CONTINUOUS DEVELOPMENT

System upgrades every 3rd years




GRIPEN NG DEVELOPMENT

Increased Thrust

HMI and

Decision Support

Improved

Communication

More weapon

stations

Target Aquisition

Airframe upgrade

External Sensors

General Systems

upgrade

New Avionics

Architecture

Electronic Warfare

MAW & MFS

Increased Range

Eth ern et Switch

‘Commer cia l’

‘ASL’

Serial Link

Tact ica l Mi ssi on C omputer(TMC)

Fli ght Management Computer

(FMC )

GECU

I NS, GPS

R ALT

OBOGS

B-EC U

Simula tedCSMU (PC)

WTU

BOY

FPU/RAU

FADEC

Gun BOY

FTU/FAU

BOYBOY

Pylon 1L Py lon 2L Pylon 3L Pylon 5L Pylon 4 Pylon 5R Py lon 3R Py lon 2R Pylon 1R

Elec tronicW arf are U nit

Avionics S ystem LA N 1 (ASL)

AECU

1553B N etwor k

Simulated

HUD(PC)

Anti-g

AD C-1

AD C-2

R S-422

UC P

RS-422

TAP

IFF

Radar

SMU

1553B

Digit izer (TBD )

AIU

Analog video

LCP

GTA

ACP

Di gi tiz er (TBD )

Digital video

RS -485 / AR INC-429Emergency Mode

C ommercial E thernet

1553B

WAP

Cockp it sw itches(including HOTAS)

Cockp it indica tors

DiscreteInput/Output

Discrete I/O

FC S

APEC U

ILS, VOR

DME

SSR

H DD HD D H DD

AMU

V/UH F2

V/UH F1

FMC-1

HS1 | 2 | 3 | 4

1553B

FMC-1

HS1 | 2 | 3 | 4

1553B

FMC-2

HS1 | 2 | 3 | 4

1553B

FMC-2

HS1 | 2 | 3 | 4

1553B

“Bus 1”

“Bus 2”“Bus 3”

“Bus 4”

Avionics System LA N 2 (ASL)

Eth ern et Switc h

‘Comme rcial’

‘ASL’

TMC-1

HS1 | 2 | 3 | 4

1553B

TMC-1

HS1 | 2 | 3 | 4

1553B

TMC-2

H S1 | 2 | 3 | 4

1553B

TMC-2

H S1 | 2 | 3 | 4

1553B

VideoProcessing

Module

DTU

Mass

MemoryUni t(PC)

2 8V

2 8V

28V28V

28V

115 V

F LIR/LDP




Why GCAS?

Increase flight safety

Prevent ground collisionControlled flight into terrain

G-induced loss of conscientious

Target fixation

Joint researchUS Air Force ResearchLaboratory

Saab

INTRODUCTION TO GCAS – GROUND

COLLISION AVOIDANCE SYSTEM




SYSTEM OVERVIEW

SCAN

Ground profile

from terraindatabase

WRN

Audio &visualwarning

AFU

AutomaticFly-Up

ARM

Flight pathprediction

AFU ARM

PredictedAutomatic Fly-Up

GPW ARM

Predicted GroundProximity Warning

FCS SC

Actual

flight

path




FLIGHT SAFETY CHALLENGES IN

FLIGHT TESTING

New, unproven products/w, h/w, etc.

Envelope expansion

New external store, in new envelopeSafe separation?, Engine impact?

Stall test

What are the risks? How can we decrease the risks? Shallwe do the test?




FLIGHT TEST SAFETY APPROACH AT SAAB

IN GENERAL AND ”HANDS ON” GCAS TEST


ProcessEarly test involvement

Flight Safety steps

Test teams

Education




MILITARY FLIGHT TEST IN SWEDEN–

REGULATIONSFLYGI

Swedish Military AviationSafety Inspectorate

RMLSwedish Rules ofMilitary Aviation

Authorization oforganizations

according to RML

Periodical Audits

Requires:• Adequate and safeprocesses• Competence, education• Resources in balance

Issue Flight Test Permit(FTP)

Maintain authorization toperform:- Design and production- Aircraft maintenance- Flight Operations

Apply and follow RMLin all operations

Apply for FTP fortest aircrafts etc.

Requires:• Adequate and safeprocesses• Descriptions• Product according todesign

Authority

SAAB Aeronautics




PROCESS WITH EARLY TEST

INVOLVEMENT


Flight Test

Design

Define TestTask andTest Team

PrototypingDesign, Implementation

VerificationReport

“Design forTest” issue

Plan, PerformAnalyze test

TestReport

Cooperation



EARLY TEST INVOLVEMENT - GCAS

APPLICATION


DesignFormal systemVerification

Flight Safetyand confidencetest

Flight Test

Design for test Performed in collaboration withsystem design

Verify implementation andrequirements

Performed incollaboration with systemdesign (Flight Testresponsible)

System robustness

Affect on other functions

System confidence

Main responsible for flighttest activities

System test rig and simulators Test a/c



FLIGHT TEST SAFETY PROCESS

Flight Test and Verification

Airworthiness

Review Board

Test Evaluation

BoardFlight Safety

Review Board

Preparation Flight Tests AnalysisTest

Report

Flight Safety

Assessment

Flight Test Plan Test Cards

” NO VOTE!”



MANDATORY OPTIONAL

MANDATORY OPTIONAL


ACTIONS REGARDING FLIGHT TEST

PLAN

Flight Safety Assessment

Test Team

Test engineer, pilot,system engineer etc.

• What is new in the test?

• Is there any earlier experience?

• Are other systems affected?

• Will there be an expansion of the envelope?

• Do the tests involve difficult flight conditions /maneuvers?

• Deviations from Regulations / Flight Manual /Line Maintenance Instructions?

• Can the third party be affected?

Flight Safety Review

Flight Safety Review Board

Chief Test Pilot,Chief Test Engineer,

Line Maintenance etc.

• Test plan

• Test point

• The event/risk

• Cause?

• Affect of event?

• Probability?

• Suggest measures

• Risk index

Process step

Who

What




RISK MANAGEMENT GCAS

Flight test main partsLogicDive towards fictive groundLow level tactical flying

Identified risksLogic or system failureMissed test condition during dive

Handling risksExtensive testing, GCAS off manuallySensitivity analysisProcedures, build-up, backup planMindset of personnel




ABORT CRITERIA DURING FLIGHT TEST

Altitude margin

Abort altitude

Min altitude, pilot pull-up

Minimum Descent Altitude

Ground

Altitude whereAFU is expected

Max altitude loss AFU

Altitude loss, pilot pull-up.Using minimum performance attainable

Altitude loss due to reactiontime

Alti

tud

e




ON-LINE MONITORING AND

EVALUATION

Ensure flight safety

Test efficiency

Quick evaluation

2D and 3D tool




EDUCATION OF TEST ENGINEERS


Organized education giving authority

Uniformed education leading to uniformed working methods

Support fulfillment of authorities request of formal education

Increase SAAB competence

Support personal development



Test Teqniques

Customer knowledge

System/product

Knowledge

Personal

development

Test Engineer First Test Engineer Senior Test Engineer

Test

Engineer

Program

First

Test

Engineer

Program

Senior

Test

Engineer

Program

Job Rotation

ThesisJob Rotation

ThesisThesis

TEST ENGINEER AUTHORIZATION

PRINCIPLES




0 1 2 3 4 5 6 7

År

Application

Admission/planning

Education

Authorization

Working experienceWithin SAAB Testprocess

PTEP

TEP

FTEP

STEP

AUTHORIZATION OVERVIEW




Flight Test Safety is enhanced by


Follow a Process including flight safety:

Early test involvement

Flight Safety steps involving experienced people

Teamwork

”No vote approach”

Formal education giving authorityIncluding:

Make flight safety discussion a natural part of theeveryday work

Encourage the mindset of asking oneself, what can I do toensure flight safety?


SUMMARY AND LESSONS LEARNED



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