Flight Test Instrumentation System Integration
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1 Flight Test Instrumentation System Integration Suzanne Shipp Nova Defence Aerospace Operational Support Group Nova Aerospace Pty Ltd
2 Background Nova formed in 1999 as an independent, experienced provider of T&E and certification services to Commonwealth Aerospace Operational Support Group (AOSG) provider of specialist services to support Army Aviation and Royal Australian Air Force Nova Aerospace Pty Ltd
3 Background My Role Project Systems Engineer and Avionics Design Engineer to develop a Flight Test Instrumentation System (FTIS) for Black Hawk - DANGER ARMY Nova Aerospace Pty Ltd
4 Project Echidna BAE Systems Enhance the Electronic Warfare Self Protection System for Black Hawk + Includes: Countermeasures missile warning system Nova Aerospace Pty Ltd
5 Systems Engineering Framework CONCEPTUAL DESIGN & ADVANCED PLANNING PHASE PRELIMINARY DESIGN PHASE DETAILED SYSTEM DESIGN & DEVELOPMENT PHASE MANUFACTURE, TEST & CALIBRATION PHASE OPERATIONAL USE & SYSTEMS SUPPORT PHASE Task Initiation User Requirements Stakeholder Requirements Technical Requirements Management Requirements Logistics Considerations Risk Analysis Plan Verify Implement Functional Analysis Allocation of Requirements Trade-off & Optimisation Synthesis List Design Requirements Technical Performance Measures Assign Design Activities Design Prototype Development Drawing Production Manufacture Installation Calibration Requirements Verification Acceptance Testing EMI/EMC Testing Non-Standard Mod Orders ARDU Aircraft Configuration Certificate (AACC) Safety of Flight Test Airborne System Test Data Collection Data Analysis Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 Product Baseline EDR Documents Safety Program Functional Design Baseline meets 'Build-to' Baseline Product Baseline 'Design-to' Specification. Baseline Product meets Design. Statement of Requirement Project Engineering Management Plan System Verification Plan Adverse Effect Review Hazard Assessment Safety Analysis Conceptual Design Review Critical Design Review (Systems Requirements Verification) Technical Specification Design Proposals Test Plans Calibration Procedures OR Preliminary Design Review Design Reports Stress Analysis Electrical Loads Analysis Design Drawings As Specified, as Designed, as Maintained (Requirements Validation) (Verify Adequacy & Producibility of Design) Installation Orders Test Reports Configuration Audits Design Certificate System Certification Review (Product Validation) (Lessons learned) REQUIREMENTS FUNCTIONAL ANALYSIS DESIGN DEVELOPMENT, REVIEW & APPROVAL MANUFACTURE Experience & Knowledge CERTIFICATION Independence & ACCEPTANCE ANALYSIS Nova Aerospace Pty Ltd 2007 INSTALLATION ACCEPTANCE 5
6 Step 1: Requirements Development Statement of Requirements Conduct System Requirements Review Conduct Conceptual Design Review Present Options Nova Aerospace Pty Ltd
7 Flight Test Instrumentation System Option 1: Resurrect previous system (ADARS) Option 2: Resurrect previous system (GDAS) Option 3: Utilise Hornet FTIS (CDAU + D20) Option 4: Utilise ACRA Control Technology Nova Aerospace Pty Ltd
8 Camera System Option 1: High Speed Digital Camera Option 2: Cine High Speed Camera Option 3: Handheld High Speed Digital Camera Nova Aerospace Pty Ltd
9 Step 2: Functional Design Functional Breakdown Technical Specifications System Specification Reviews Preliminary Design Review Design Proposals Nova Aerospace Pty Ltd
10 Functional Breakdown 1.0 FTIS 1.1 Data Acquisition 1.2 Data Storage 1.3 Power Management 1.4 Software 1.5 User Interface 1.6 Flight Line Support System 1.7 Time Synchronisation Nova Aerospace Pty Ltd
11 F1.1 Data Acquisition Data Acquisition - core function acquire the data from various sensor systems, aircraft systems Consists of: Data Acquisition Chassis Modules Interface Aircraft Systems and Sensors Nova Aerospace Pty Ltd
12 F1.2 Data Storage Data Storage stores the data from data acquisition function Consists of: Data Storage Hardware Interface Nova Aerospace Pty Ltd
13 F1.4 Software ACRA KSM Nova Aerospace Pty Ltd
14 F1.5 User Interface Option 1 : Eurocopter Option Laptops Nova Aerospace Pty Ltd
15 Nova Aerospace Pty Ltd
16 TSPI Rack Laptop Rack Assy System ACRA Chassis System Camera System Nova Aerospace Pty Ltd
17 Step 3: Detailed Design Design Analysis Draft Calibration Procedures Draft Test Procedures Conduct Bench Level Tests Produce Drawings Judgement Of Significance and Review Flight Test Ground Test Bench Level Testing Analysis Nova Aerospace Pty Ltd
18 Step 4: Manufacture Raytheon ARDU is contracted to perform the manufacturing of items Use documents (work orders, drawings, development) from Engineering to perform tasks Nova Aerospace Pty Ltd
19 Step 5: Installation and Test Raytheon is contracted to perform the installation to the aircraft Use the approved calibration and test procedures to conduct the verification activities with System Engineering oversight Flight Test Ground Test Bench Level Testing Analysis Nova Aerospace Pty Ltd
20 Step 6: Rectification Request for Design Changes (RDCs) Approval of Designs and drawings Nova Aerospace Pty Ltd
21 Step 7: Modification Issued Non Standard Modification is reviewed and approved Includes: Modification Order Flight Manual Supplement Maintenance Event Sheets Installation and Removal Procedures Photographic Record Attribute Records Nova Aerospace Pty Ltd
22 Step 8: Systems Acceptance Review whole system incorporating any external designs Provide Technical Airworthiness recommendation at the Flight Test Readiness Review Produce a Aircraft Configuration Certificate Nova Aerospace Pty Ltd
23 Ready to FLY!! LFP (18000lbs) Referred Torque Unmodified (A25-210) BHIE (A25-101) BHIE (A25-101) Unmodified (A25-210) Flight Manual (ISA) Indicated Airspeed Nova Aerospace Pty Ltd
24 Progress Taken approximately two years to complete the Systems Engineering process Completed the performance and handling testing, acceptance testing activities, and stores clearance Many lessons learned. Nova Aerospace Pty Ltd
25 Outcomes Key Lessons learned include: Requirements Communications Flexibility Hazard / Risk program Technical Issues Nova Aerospace Pty Ltd
26 Summary Successful FTIS Program SAFE On budget On schedule Why: Good communications Good teamwork Good support Remained flexible and motivated Nova Aerospace Pty Ltd
27 Flight Test Instrumentation System Integration Suzanne Shipp Nova Defence in conjunction with Aerospace Operational Support Group Details PO Box 19, RAAF Base Edinburgh, South Australia, 5111 Telephone: Facsimile: Address: suzanne.shipp@originenergy.com.au Nova Aerospace Pty Ltd
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