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Tuesday - 1330-1400 (GL Noga Teleskopska Skorpion Mdm1)
Tuesday - 1330-1400 (GL Noga Teleskopska Skorpion Mdm1)
and Lessons Learned from
the “Scorpion” Aircraft
Development Program
Dave Sitz
Flight Test Engineer/Pilot
Textron Aviation
SETP Flight Test Safety Workshop
May 2015
What is the Scorpion Program?
Aircraft Description
Risk Reduction/Lessons Learned from 3 Scenarios:
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• Preparation for First Flight Company
Confidential and Competition Sensitive 2
- Spin Chute Taxi Test
• Initial Landing Gear Operations
Conclusion
• Condense our experiences into one unified safety approach or theme
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The Scorpion Program
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Price
Confidential and Competition Sensitive 3 Scorpion is
$20M designed to fill a
gap in the tactical
aircraft spectrum
$
Vast Majority of ISR/Strike
Missions
Capability
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Aircraft Description
* Design Targets
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Aircraft Description
Insert EXTRA
LARGE Flight Test
Instrumentation
Package HERE
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Aircraft Description
Aircraft Design
• Maximum Use of Existing Systems
- Engines
- Avionics
- Ejection Seats
- Sub‐Systems: Hydraulics, Electrical, Fuel,
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OBOGS, ECS, Flight Controls Company
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• New Composite Airframe
- New Main Landing Gear Struts
- Engine Inlet
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Aircraft Description
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MLG Axle
MLG Trunnion
Piston
Metering Pin
Stand Pipe
Torque Links
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Risk Reduction/Lessons Learned
Preparation for First Flight – At a “Macro” Level
• “Where Do You Even Start?”
• Cessna Engineering Flight Test
Processes and Procedures
- Quality/Configuration Control
- Test Planning 6/16/2015 9:47 AM Company
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- Independent Safety Reviews
- Flight Readiness Reviews
- Special Inspection (Pre‐First Flight)
• SETP Pilots Handbook
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Risk Reduction/Lessons Learned
Preparation for First Flight – At a “Micro” Level
• Aircrew involved in design process for over 1½ years before first flight
• Where are the “booby traps” due to unique configurations/interactions?
• The 4 Forces of Flight (what’s really important?):
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Event 1 ‐ Preparation for First Flight
First Engine Run – September 2013
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Event 1 ‐ Preparation for First Flight
Inlet: Aerodynamics and Airframe Location (behind Gear Doors)
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Event 1 ‐ Preparation for First Flight
Engine Inlet
• Natural Flow Visualization of Vortices
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Event 1 ‐ Preparation for First Flight
Inlet Risk Reduction
• “What Can You Do to Reduce Risk?”
• Pre‐Flight Taxi: Test “Worst‐Case” Gear Door Configuration
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Event 1 ‐ Preparation for First Flight
Landing Gear Availability
• “What Can You Do to Reduce Risk?”
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Event 1 ‐ Preparation for First Flight
SETP Handbook
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Event 1 ‐ Preparation for First Flight
December 12, 2013
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Event 1 ‐ Preparation for First Flight
Acknowledging the Team’s Efforts
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“Share the pilot’s exhilaration of a First
Confidential and Competition Sensitive 17
Pre‐Flight Taxi Testing
• Brakes/Steering
• Low/Moderate Speed Taxi Testing
• Elevator Control Power Evaluation (Aerodynamics: Rotation and Flare)
• Spin Chute Operational Test (Deploy/Jettison)
• Last‐Minute Aircraft Squawk
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• “Were We Ready?”Confidential and Competition Sensitive 18
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Event 2 ‐ Spin Chute Taxi Test
Spin Chute Controls
• Two Chutes, Fwd and Aft Panels
• Fwd: “Drive”, Aft: “Execute Test”
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Event 2 ‐ Spin Chute Taxi Test
Crew Resource Management in Action
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Event 2 ‐ Spin Chute Taxi Test
Was my “experience” working against me?
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Event 2 ‐ Spin Chute Taxi Test
What I expected:
“Deploy Confirmed” –or-
“No Chute, No Chute”
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Kinesthetic (Seat of Pants)
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Visual
Control Panel
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Event 2 ‐ Spin Chute Taxi Test
What I expected: What happened:
“Deploy Confirmed” –or-
Nothing (Com blocked)
“No Chute, No Chute”
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Kinesthetic (Seat of Pants) Nothing
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Visual Nothing
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Event 2 ‐ Spin Chute Taxi Test
What I expected: What happened (Pilot):
“Deploy Confirmed” –or-
Nothing (Com blocked)
“No Chute, No Chute”
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Kinesthetic (Seat of Pants) Nothing
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Visual Nothing
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Event 2 ‐ Spin Chute Taxi Test
Inadequate/misleading feedback led to delayed chute jettison
• Aircrew CRM saved the day
• Fortunately, the only consequence was a few extra thousand feet of FOD
walk for ground crew…
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Event 3 ‐ Initial Landing Gear Operations
Initial Gear Ops – Gear Up Attempt
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Event 3 ‐ Initial Landing Gear Operations
Under airloads, NLG doors overlapped
• MLG retract sequence did not complete
- Notice where MLG doors are…
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Event 3 ‐ Initial Landing Gear Operations
Initial Gear Ops – Gear Down Attempt (the one that counts…)
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Event 3 ‐ Initial Landing Gear Operations
Gear Down
• “What Would You Report?”
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Event 3 ‐ Initial Landing Gear Operations
Gear Down – Cockpit Indications
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Event 3 ‐ Initial Landing Gear Operations
Chase reported “apparent down and locked”
• No MLG “greens” due to incomplete sequence?
We did NOT declare an in‐flight emergency
• We were doing gear testing, after all
• Experimental License dictates initial takeoffs/landings from home field
Emergency Gear Extension?
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• Booby Trap: Continuous 3000 psi hydraulics vs. one‐shot pneumatics
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Airloads on MLG Drag Brace higher than anticipated
• Did not quite reach over‐center
• Gear locked over‐center during landing rollout
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Event 3 ‐ Initial Landing Gear Operations
Gear Down – After Landing
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Event 3 ‐ Initial Landing Gear Operations
∑ MLG Forces
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Event 3 ‐ Initial Landing Gear Operations
Troubleshooting and Changes
• For Gear Up: Adjust NLG Doors
• For Gear Down: Alleviate MLG Drag Loads
- Positive G and engine RPM (to assist “mechanical advantage”)
- Adjust airspeed (to reduce airload on MLG drag brace)
- Sideslip (to change airload direction from aft gear doors; “air dam”
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- Pulse braking on rollout to ensure load assists over‐center locking
• Additional Instrumentation
Next Attempt
• NLG closed but mains still didn’t completely lock over‐center
• This time we DID declare an emergency with McConnell Tower…
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Event 3 ‐ Initial Landing Gear Operations
Declaring an Emergency…
• We were “called to the principal’s office…”
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Event 3 ‐ Initial Landing Gear Operations
Declaring an Emergency…
• We were “called to the principal’s office…”
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“When you come to a fork in the
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Event 3 ‐ Initial Landing Gear Operations
More Troubleshooting and Changes
• Engineering “Tiger Team”
• More NLG Door adjustments, and new actuator
• Aerodynamic Fairing to reduce MLG Drag Loads
• New MLG actuator
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Final Success Confidential and Competition Sensitive 37
• Aircraft‐unique changes worked
• Procedural Lessons Learned
• Follow‐on improvements made
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Event 3 ‐ Initial Landing Gear Operations
Drag Brace Aerodynamic Fairing
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Event 3 ‐ Initial Landing Gear Operations
Final Gear Ops – Gear Up (watch for “special” signal…)
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Event 3 ‐ Initial Landing Gear Operations
Final Gear Ops – Gear Down
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Event 3 ‐ Initial Landing Gear Operations
Final Drag Brace Downlock Spring
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Conclusion
“The (Flight Test Safety) Theory of Everything”
• Theory of Relativity and Quantum Physics
There isn’t one (yet…)
MACRO: Proven Processes and Procedures
• Use of Cessna’s Established Methods
• SETP Guidance
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• Practice Good CRMConfidential and Competition Sensitive 42
• Ground Test before Flight Test
MICRO: Integration with Design; aircraft‐unique “Booby Traps”
• Inlet Risk Reduction
• Elevator Control Power Evaluation
• Initial Landing Gear Operations
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Questions?
Picture Placeholder
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Dave Sitz
Flight Test Pilot
Textron Aviation
(316) 831‐4252
dsitz@txtav.com
www.ScorpionJet.com
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Photo Gallery
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Photo Gallery
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Photo Gallery
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Photo Gallery
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Photo Gallery
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Photo Gallery
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Photo Gallery
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Questions?
Picture Placeholder
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Confidential and Competition Sensitive 56
Dave Sitz
Flight Test Pilot
Textron Aviation
(316) 831‐4252
dsitz@txtav.com
www.ScorpionJet.com
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