Systems Integration Evaluation Remote Research Aircraft

SIERRA

Airworthiness and Flight Safety Review Board

(Flight Readiness Review for Flight Testing)November, 2006

Code SGE

Randy Berthold650.604.43408

AFSRB Goal;To obtain authorization to commence flight test

program for the SIERRA

SIERRA AFSRB 3

Package Contents• Overview

– AFSRB presentation philosophy– Background– Features, Options, and Projected Performance Objectives

• Mission Objectives• SIERRA Subsystems

– Airframe– Power plant – Avionics

• Testing/Validation Plans– Ground Test Program– Flight Test Program

• Success Criteria • Risk Assessment• Operations• Attachments,

– Compliance Matrix, Ground Test Plan, Flight Test Plan, Drawing Package

SIERRA AFSRB 4

Overview

SIERRA AFSRB presentation philosophy;

• APR 1740.1, Airworthiness and Flight Safety, 9 September 2005 is currently undergoing reviews and updates. The procedural requirements, as defined, are not yet fully developed for UAS, nor for new UAS AFSRBs. Hence this review will deviate from the outlined format and bridge those open items with a Compliance Matrix which will summarize requirement actions based on AFSRB Package, Ground Testing or Flight Testing elements.

• Because an AFSRB is a prerequisite for Flight Testing this review will serve as an Flight Readiness Review for Flight Testing

• The SIERRA AFSRB is focused on first flight authorization. • Early development concepts were supported by Ames Aircraft

Management Office

SIERRA AFSRB 5

OverviewAFSRB Element AFSRB

PackageGround Testing

Flight Testing

Post First Flight

Ground Procedures

1 Mission Objectives X

1.1 Integrated systems testing X X X

1.2 Evaluate handling qualities and tune flight control parameters All

1.3 Flight envelope expansion to mission objectives: X

1.3.1 Flight Plans All

1.4 Success Criteria X X

1.4.1 Proven stability through tested envelope All

1.4.2 Hours of flight X

1.4.3 Altitude X

1.4.4 Duration X

2 Airframe X

2.1 Design heritage X

2.2 Design characteristics X

2.2.1 Stability X

2.2.2 Fuel tank balance X X

2.3 Materials X

2.3.1 Locking Fasteners X

2.4 Fabrication Protocols X

2.5 Predicted flight characteristics X

2.5.1 Cloudcap Simulator X X X

2.6 Structural testing X

2.6.1 Wing loaded to 6 Gs X

3 Powerplant X X X X

3.1 Engine X X X X

3.2 Electrical system X X X X

3.3 Fuel system X X X X

SIERRA Compliance Matrix

SIERRA AFSRB 6

OverviewSIERRA Compliance Matrix

AFSRB Element AFSRB Package

Ground Testing

Flight Testing

Post First Flight

Ground Procedures

4 Avionics X X X

4.1 Cloudcap Piccolo Plus Autopilot X X X

4.2 Actuators X X X

4.3 Systems Health X X X X

4.4 Ground Support equipment X

4.5 Communications links X X X

5 Risk assessment X

5.1 Failure modes and effects, Probability/Severity matrix X

5.1.1 Collision avoidance, including radar reflectivity X

5.1.2 Flight termination X X X

5.2 Reliability Testing5.2.1 Engine X

5.2.2 Cloudcap systems reliability X X

5.2.3 Actuators5.2.4 Communications systems X

5.2.5 Flight termination System X

5.3 Engineered risk mitigation X

5.4 Procedural risk mitigation X

6 Operations6.1 Area of Operation X

6.2 Team roles and responsibilities X X

6.2.1 Pilot certification X

6.2.2 Range Officer X X

6.3 Collision avoidance X

6.4 Communications Procedures X

6.5 FAA COA X

6.6 Emergency Procedures X

6.7 Inspections6.8 Log book

SIERRA AFSRB 7

Overview

Background • SIERRA is a utility UAS, designed for testing, evaluating, and demonstrating

developmental payloads and supporting associated missions. Its configuration and operation is highly versatile and adaptable to different payloads.

• SIERRA has proven design heritage• Airframe designed by the Naval Research Labs • Manufactured by recognized airframe manufacturer• Components and control elements are designed for airframes by

aircraft part manufactures• Materials and fasteners, etc., where applicable use parts designed and

manufactured to aircraft specifications• Specifications and subsystem designs are base lined

SIERRA AFSRB 8

Overview

Features, Options, and Projected Performance Objectives

• Payloads up to 100 pounds• Currently pusher (Can be re-configured as tractor)• Engines 25.5 HP, gasoline fuel• Flight control:

• RC pilot-in-loop • Auto-stabilized manual (control stick steer)• Autonomous GPS waypoint navigation

• Large payload volume 15” 15” 30”• 2.5 hour endurance with 100 pound payload• 55 kts. cruise speed• 12 mile line-of-sight communications range

SIERRA AFSRB 9

Overview

• Features, Options, and Projected Performance objectives SIERRA is an utility UAS for testing, evaluating, and demonstrating

developmental payloads and supporting associated missions. Its configuration and operation is highly versatile and adaptable to different payloads.

• Payloads up to 100 pounds• Currently pusher (Can be re-configured as tractor)• Engines 25-38 HP, gasoline fuel• Flight control:

• RC pilot-in-loop • Auto-stabilized manual (control stick steer)• Autonomous GPS waypoint navigation

• Large payload volume 15” 15” 30”• 2.5 hour endurance with 100 pound payload• 55 kts. cruise speed• 12 mile line-of-sight communications range

SIERRA 3-View and Specifications, Pusher Configuration

Wing SpanLengthHeight

Wing AreaEmpty WeightGross Weight

Max SpeedCruise Speed

Stall Speed (clean)L/D

Rate of ClimbCG Position

20 ft.11.8 ft.4.6 ft.42.4 sq. ft.215 lbs.345 lbs.79 kts.55 kts.30 kts.11:5545 ft./min.30% Chord

SIERRA AFSRB 10

Overview

Operating Limits• Maximum gross weight: 330 lbs.• Limit bank angle to 30° for autopilot operation• Limit all flight conditions to 2.0 G maximum• Maximum wind conditions, 20 kts. steady, 15 kts. gusting• No operation in worse than light precipitation or icing conditions

SIERRA AFSRB 11

Overview

Mission Objectives• First Order

To validate and certify the SIERRA as a functional UAS • Second Order

To support a variety of research, first responder, Homeland Defense, applications with unique remote sensing payload capabilities in environments where UAS’s with SIERRA performance capabilities are advantageous

• Example mission,San Bernabe Vineyard Airborne Thermal Imaging ProjectScience objective is to demonstrate airborne thermal imaging systems as a means to mitigate frost damage to agricultural crops. Sensors, micro bolometer array camera, hyper spectral push-broom sensor to evaluate crop stress. Include are PC104+ data systems with supporting wireless modem, wireless network, GPS and INU subsystems to support remote operation, real time data downlink, and metadata infusion.

Aircraft requirement(1) Altitude requirement in 3000 to 10000 ft range(2) Duration 4 to 8 hours(3) Payload 2 to 10 Kg(4) Cruise speed 20 to 40 m/sec

SIERRA AFSRB 12

Overview

Flight Envelope Elements

• Addressed in flight test program • Hours of flight

• Altitude

• Duration• Proven stability

SIERRA AFSRB 13

SIERRA Subsystems

Airframe– Design heritage and characteristics

• Dakota II (400+hours) and GHOST(25+hours)– Airfoil utilized on numerous NRL and vendor UAS

– Materials• Aircraft grade hardware and materials wehere applicable

– All fasteners are A/C grade

– Fabrication performed by recognized UAS manufacture

– Predicted flight characteristics

• Base on Dakota and GHOST heritage

SIERRA AFSRB 14

SIERRA Subsystems

Power plant • Engine, Herbrandson Dyad 290B• Electrical system

• Designed and built by certified avionic technician, design concepts reviewed by Ames Flight Management Team

• Fuel system, • NASA designed, Flight Management Team contributions

Avionics • Cloud Cap Piccolo II Autopilot• Actuators

• HiTec digital, 1/4 scale

• R/Cats• Honeywell Digital Compass

SIERRA AFSRB 15

SIERRA Subsystems

Systems health• RCATS and Piccolo II

• RCATS covers:– RPM– 4 currents – left aileron, left ruddervator, fuel qty., outboard flap– Power bus voltage and current– 4 temperatures – left and right CHT, left and right EGT– Airspeed and altitude

• Piccolo II– Fuel flow– RPM– Airspeed and altitude

Communications links• Micro Hard, imbedded in Piccolo II AP

– bidirectional– Up-command and control– On Data:AC systems information and positional location

» Payload data

SIERRA AFSRB 16

Testing/Validation PlanGround Test Program (encompasses integrated systems testing)• Testing Philosophy

• Static testing of all subsystems to verify system integrity, control, connectivity

– Bench, static run ups, ground controls– Range check

• Subsystems tested• Structural wing testing, loaded to 4.4 Gs

– Successfully demonstrated the ability to support a positive 4.4 g flight load. – Performed by RnR Products Inc.

» Approximately 1,232 lbs of sand was placed along the entire length of the wing to simulate a 4.4 g flight load. At full load, each tip deflected approximately 5.5 inches. The wing supported the total load for several minutes before sand removal commenced.

» The wing recovered to its original position.

– Reference Plan

SIERRA AFSRB 17

Testing/Validation PlanFlight Test Program

• Testing Philosophy• To systematically evaluate and validate handling qualities and tune flight control

parameters– Test Plan will be implemented by certified team at Crow’s Landing– Test Plan will address ALL subsystem– Exercise all subsystems as designed to established operational boundaries

• Test Plan has compliance matrix of systems to be validated against AFSRB elements• Example: AFSRB, Element; 4 Avionics, 4.1, Cloud Cap Piccolo II Autopilot, Section

XXXXXXXFlight Test Plan– Piccolo II –Test Cards (from Cloud Cap)

» Datalink validation» Turn rate control validation» Airspeed control validation» Pitch damper validation» Altitude control validation» Tracker control validation» Yaw damper control validation

– Reference Plan

SIERRA AFSRB 18

Testing/Validation Plan

Flight Test Program• Overview

• Pilot-in-loop operation• Fail safe mode to terminate flight with loss of link• 5 gallons maximum fuel load• Inspection at conclusion of each test day.• At 10 hours flight time, conduct full airframe inspection• Test plan is progress, e.g., base on successful accomplishment of

sequences

SIERRA AFSRB 19

Risk Assessment

Failure Modes and Effects Table

Probability/Severity Table

• See pages 18A &18B

SIERRA AFSRB 20

Risk Assessment

Reliability Testing• Engine, COTS with proven historical applications • Actuators, COTS aircraft rated parts

• Servos used on NRL SPIDER autonomous helicopter• As of July 6, 2006: 147 flights, 27.5 hrs and no problems with

servos• Cloud Cap systems, COTS with proven historical applications

• Communications– Micro Hard has significant flight time

• Flight termination system

SIERRA AFSRB 21

Risk Assessment

Engineered Risk Mitigation• Extra braking capability• Over engineered landing gear• _____flaps for reduced take off and landing operations• Implementation of dedicated NASA/FAA assigned command and control

frequencies• Fail safe mode to terminate flight with loss of link • Inspection at conclusion of each test day

Procedural Risk Mitigation • Adherence to defined operational limits• Utilize only trained, current, flight team personnel

Pilot-in-loop operation 5 gallons maximum fuel load At 50 hours flight time, conduct full airframe inspection Test plan is progressive, e.g., base on successful accomplishment of

sequences

SIERRA AFSRB 22

Risk Assessment

VERY LIKELY "A"

LIKELY SEVERAL TIMES

DURING PROGRAM "B"

LIKELY SOMETIME

DURING PROGRAM"C"

UNLIKELY BUT

POSSIBLE "D"

EXTREMLEY IMPROBABLE

"E"

CATEGORY 1: DEAT H, LOST TIME INJURY, PROPERTY DAMAGE

2, 3, 10

1, 4, 6

CATEGORY 2: LOSS OF OR SIGNIFICANT DAMAGE TO VEHICLE, LOST TIME INJURY

5

CATEGORY 3: SYSTEMS DEGRADE, LOSS OF MISSION

7, 8, 9, 11

CATEGORY 4: SAFE

FUNCTIONAL HAZARD ASSESSMENT MATRIX

SIERRA AFSRB 23

ACCEPTED RISKS

INDEX PROBABILITY CATEGORY 1. E 1, 2 FIRE / EXPLOSION 2. D 1 GROUND CREW MEMBER CONTACTING THE TURNING

PROPELLER. 3. D 1, 2 LOSS OF CONTROL DURING TAXI, TAKEOFF OR LANDING 4. E 1, 2 LOSS OF CONTROL IN FLIGHT 5. D 2 LOSS OF ENGINE POWER IN FLIGHT 6. E 1, 2 MID-AIR COLLISION 7. D 3 LOSS OF RADIO UP-LINK, IN FLIGHT 8. D 1, 2 LOSS OF ALL VEHICLE ELECTRICAL POWER, IN FLIGHT 9. D 3 LOSS OF GROUND STATION POWER

SIERRA AFSRB 24

RISK MITIGATIONINDEX # 2 - GROUND CREWMEMBER CONTACTING THE TURNING PROPELLER

- Only trained, qualified and required crewmembers allowed around a running vehicle

INDEX # 3- LOSS OF CONTROL DURING TAXI, TAKEOFF OR LANDING- All controls and backups verified functional and in correct configuration prior to taxi, takeoff or landing.- Vehicle maximum wind speed and crosswind component will not be exceeded.- Operating area will be free of RF hazards.

INDEX # 5- LOSS OF ENGINE POWER INFLIGHT- Proper maintenance, preflights and crew briefs.- Flight activity within glideback range.

INDEX # 7- LOSS OF RADIO UPLINK IN FLIGHT- If in the system is in manual mode, after the designated pilot timeout time, the system will switch from manual to autopilot mode and will continue to the currently selected waypoint within the current flight plan.- If in the system is in autopilot (autonomous) mode, after the designated communication timeout time (usually longer than the pilot timeout), the system will switch to the lost communication waypoint (loss link routine) and continue with that flight plan from that point.- The pilot and communication timeouts are set within the autopilot control software.- During loss of communication, payload and system monitoring data will not be received or available on the ground.

INDEX # 8 LOSS OF ALL VEHICLE ELECTRICAL POWER INFLIGHT-Proper maintenance and preflight of the alternator, batteries and electrical systems.

INDEX # 9 LOSS OF GROUND STATION POWER-The portable ground station contains a backup battery in the event of loss of shore power. If both power systems fail, then this is equivalent to loss of radio unlink and that procedure will be followed.

SIERRA AFSRB 25

Risk Assessment

Actions taken during integration that have resulted in design modifications– Landing gear– wheels– Thermal plastic deformation…….– wiring

power

SIERRA AFSRB 26

Operations

Area of Operation

• Within boundaries and defined operational parameters of Crow’s Landing for all test flight activities

• All operations conducted per base lined flight plan and procedures

• All activities performed by trained, certified, and current flight team

SIERRA AFSRB 27

Operations

Team roles and responsibilities• Flight/Test Director (S. Dunagan)

• Responsible for development and implementation of fight plan

• Directs flight sequence, management of flight cards

• ATC interface

• Go-No-Go responsibility

• Pilot (L. Monforton)

• Full authority for platform operation during take off and landings

• Responsible for platform flight safety

• Responsible for performance/meta data interpretation and actions

SIERRA AFSRB 28

Operations

Team roles and responsibilities• RSO (One of Certified SGE RSO Cadre)

• Air space and airstrip management. • Early identification of potential airspace conflicts• Direct communications to pilot

• Ground Station (B Lobitz) • Responsibility for flight activities during autonomous control• Direct interface to pilot• Monitors meta data and responses to commands develop action

recommendations• Crew Chief (R Kolyer)

• Responsible for platform maintenance and airworthiness• Provide preflight operations support to pilot

SIERRA AFSRB 29

Operations

Collision avoidance• Utilize SVADS See and Avoid

Communications Procedures• Implement defined roles and responsibilities, and communications plan

FAA COA• Operate under Moffett Field COA for Crow’s Landing

Emergency Procedures• Implement procedure for personnel safety, i.e., location of medical facilities/capabilities, POCs• Implement NASA Ames Emergency Contact/Incident Reporting Policy, as required

Inspections• Perform test site inspections and verify equipment readiness via established protocols

Log book (airframe, engine, propeller, avionics)• Perform accurate and timely entries of activities • Verify compliance with all required maintenance elements