Air Line Pilots Association, International 50 th Annual Air Safety Forum EMBRAER 170/190 FLIGHT TEST DEVELOPMENT PROGRAM Washington, DC August 19 th, 2004
EMBRAER 170/190 Flight Test Development Program CONTENTS Embraer and the E170/190 Family E170/ 190 Flight Controls System Overview E170 Test and Certification Campaign E190 Ground and Flight Test Program Lessons Learned Conclusion
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Customer Global Assistance Embraer Embraer Aircraft Aircraft Corporation Corporation Fort Fort Lauderdale, Lauderdale, Florida, Florida, EUA EUA Weybridge Weybridge United United Kingdom Kingdom Embraer Embraer Aviation Aviation International International Le Le Bourget, Bourget, France France Embraer Embraer Maintenance Maintenance Services Services Inc. Inc. Nashville Nashville Tennessee Tennessee Beijing Beijing China China Singapore Singapore Embraer Embraer São José São José dos dos Campos, Campos, São Paulo, São Paulo, Brazil Brazil Embraer Embraer Aircraft Aircraft Corporation Corporation Melbourne, Melbourne, Australia Australia
Civil aircraft EMB 110 EMBRAER 170 ERJ 140 EMB 121 EMBRAER 175 EMB 120 ERJ 145 EMBRAER 190 ERJ 135 ERJ 135 LEGACY EMBRAER 195
Military aircraft EMB 111 EMB 312 TUCANO EMB 145 RS/ AGS SUPER TUCANO/ ALX EMB 145 AEW&C AMX-T P99
The 70 to 110 Seat Market The Seat Gap
EMBRAER 170/190 Family EMBRAER EMBRAER 170 170 70/78 70/78 Seats Seats 95% EMBRAER EMBRAER 175 175 78/86 78/86 Seats Seats 85% EMBRAER EMBRAER 190 190 98/108 98/108 Seats Seats 95% EMBRAER EMBRAER 195 195 108/118 108/118 Seats Seats
Two Views 98 ft 1 in Fwd Plug 33 in Aft Plug 33 in 85 ft 4 in 103 ft 11 in Fwd Plug 94.8 in Aft Plug 146.3 in 118 ft 11 in Fwd Plug 126.8 in Aft Plug 209.3 in 94 ft 3 in 126 ft 10 in
Range and MTOW 82,000 lb 2,000 nm 85,500 lb 1,800 nm 110,900 lb 2,200 nm 112,000 lb 1,800 nm
Engines EMBRAER 170 GE CF34-8E EMBRAER 190 GE CF34-10E Max TO Thrust ( SL, Static, ISA ) 14200lb Fan Diameter 46.2" Max TO Thrust ( SL, Static, ISA ) 18500lb Fan Diameter 53"
Cockpit
Overhead Panel Dark and Quiet 12 o clock philosophy
Sales Order Book *Commercial Proposal Signed
Main Differences 170 X 190 Forward Fuselage Plug Center Fuselage II with overwing emergency exits Aft Fuselage Plug Engine Horizontal Stabilizer Actuator Horizontal Stabilizer Flap actuators Main Landing Gear Wing and Flight Control Surfaces
Flight Control System Note: This configuration is not used for the Flaps/Slats, & Aileron controls.
Flight Control System Note: This configuration is not used for the Flaps/Slats, & Aileron controls.
FBW High Level Functions Elevator High Level Functions AOA Limit function Elevator Thrust Compensation (ETC) Column gain shaper adjust the pilot force Rudder High Level Functions Yaw Damper & Turn Cordination (via AFCS) Spoilers Speed brake/ Ground Spoiler function Roll Spoilers Spoiler Mixer combines speed-brake and roll spoiler actuation Horizontal Stabilizer System Automatic configuration trim compensates for spoilers deployment Elevator offload to stabilizer to reduce trim drag
The Angle of Attack (AOA) Limiting Function Stall warning is provided by the Auto-flight Control System (AFCS) by means of the Stick-Shaker function; AOA Limiting function is provided by the Flight Control Module (FCM) through a command to the elevators. It provides an elevator variable stop continuously set by an algorithm that takes into account key variables such as actual AOA, AOA rate, aircraft configuration etc. The Embraer 170/190 stall is defined by the pilot reaching the aft control column stop regardless of the aircraft center-of-gravity position and type of maneuver (straight, turning or accelerated stall); This leads to uniform, repeatable, and safe flight characteristics at the edge of the flight envelope.
AOA Limiting Function - Motivation AOA limiting X Stick Pusher Practical benefit - The AOA Limit allows 2 knots lower approach speed when compared to using a stick pusher This allows a 1000kg increase in payload for airports like London City
Simultaneous Development 2000 2001 2002 2003 2004 2005 2006 1Q/04 EMBRAER 170 3Q/04 EMBRAER 175 EMBRAER 190 3Q/05 EMBRAER 195 2Q/06
EMBRAER 170 Certification Simultaneous Certification Process CTA : 19 Feb 2004 FAA : 20 Feb 2004 EASA : 20 Feb 2004 Issue Papers and Action Items CTA: 83 FCAR s FAA: 44 IP s and 224 VAI s EASA: 86 CRI s and 60 CAI s 1252 Reports 250 Laboratory Tests Compliance Checklist Database with more than 5000 items 120 TSO s Hundreds of meetings (106 with JAA only).
EMBRAER 170 - Flight Tests 1 st Flight February 19 th, 2002 774 FH / 424 cycles 0001 0002 545 FH / 573 cycles 284 FH / 288 cycles 0003 523 FH / 732 cycles 0004 349 FH / 203 cycles 0005 232 FH / 191 cycles 0006 368 FH / 226 cycles 0007 More than 3000 hours flown
EMBRAER 170 - Structures Ground Tests 5000 cycles - May, 2003 320,000 cycles (4 lifes) Static Tests Fatigue Tests Barrel Tire Burst Bird Impact Loads Calibration
EMBRAER 170 - Systems Rig Tests Iron Bird, Fly By Wire over 7,000 hours Development and certification tests Avionics Rig - over 8,000 hours
EMBRAER 170 - Full Flight Simulators Two FFS s RFT (Ready for Training) before aircraft certification FFS #2 RFT by Oct, 2003 FFS #1 RFT by Oct, 2003 FFS#3 (US Airways) RFT by Aug, 2004 Also used for Certification Tests (FHA, Windshear)
EMBRAER 190 Flight Test Campaign Approximately 1800 FT Hours for Certification 4 prototypes, about 60 FT Hours/acft/month 3 fully-instrumented prototypes and 1 pre-series (interiors) Most of Flight Test Campaign in GPX (dimensions)
EMBRAER 190 Flight Test Campaign Prototypes Lay-out
1st Flight March 12th 2 hours and 45 min; Initial Envelope Clearance; Take-off, Cruise and Landing Configurations; From 1.3 V s up to 250 Knots. Flight as predicted, no abnormal condition; 190 flight dynamics very similar to 170; Direct mode only.
Prototype 190-001 001 Initial Envelope Opening GVT (Development) Ground Load Calibration (Development) Landing Gear Clearance & Development Flow visualization Full Flight Simulator Data Collection FBW (Development) Landing Gear Certification RVSM Flight Controls Stall Tests Flying Qualities Performance Engine Operation Crosswind Hydraulic Electrical AFCS (Certification & CATII)
Prototype 190-002 002 IFTD Farnborough Air Show Climb (development) Engine Cooling, Vent & Fire Detection Noise (development) AFCS (development) Dry Air AMS (development) Avionics (development) Performance (climb & cruise) RVSM V MCA, V MCG, V MCU AFCS Outer Loop TMS Engine Operation AMS Avionics Natural Icing, Cold Soak Performance (Take off & Landing)
Prototype 190-003 003 GVT (Certification); Ground Load Calibration (Certification); In-Flight Loads; External Noise (Development); Flutter; Buffeting; RVSM; External Noise (Certification); Flying Qualities; First flight July, 30 th
Prototype 190-004 004 Fuselage under structural completion at SJK; Wing assembly at GPX (KAB); Flight Scheduled for September 2004 A/C 004 Flight Test Campaign AMS & Interior (Development); Lighting, HIRF & EMI; Interior; Internal Noise; AMS; Avionics; Intra-systems; Function & Reliability;
190-99801 99801 - Structural Static Tests Device Structural completion activities on-going at EGM site; Test setup assembly started; Test start scheduled for October 04;
190-99802 99802 - Fatigue Testing Smaller Test Specimen for 190 Certification; Improved lead-time due to shorter pressurization and maintenance cycles; Final Assembly at EMBRAER is expected for Aug/04. 190 Wing-Fuselage full-scale fatigue test
EMBRAER 190 - Iron Bird Iron Bird Assembled; Integration tests: Eletronic Systems; Hydraulic Systems; Mechanical Systems. 190 Software version 2.0 already tested;
EMBRAER 190 - SITS Avionics and Utilities Software Integration tests; 190 Software version 2.0 already tested;
Full Flight Simulators at CAE CAE Full Fligth Simulator S/N 0005 190 Dedicated; Simulator 1st Flight expected for 4th Quarter 2004; Certification test on Full Flight Simulator scheduled for 1st half 2005.
Engine CF34-10E Certification Hailstorm Testing Engine Part 33 Certification: 3rd Quarter 2004. Engine 1 st Flight: GE Flight Test Bed.
Digital Mock-Up - DMU Virtual 3D Environment; Accurate representation of the real status of the project.
Digital Mock-Up - DMU Real Image DMU Image DMU Image Real Image
Virtual Reality Center
Computer Fluid Dynamics CFD Ground Test
Structural Analysis Integrated Structural Model FEM Real Test 3.01+01 2.82+01 2.62+01 2.42+01 2.22+01 2.02+01 1.82+01 1.63+01 1.43+01 1.23+01 1.03+01 8.34+00 6.36+00 4.38+00 2.39+00 4.11-01
Lessons Learned Use of simulation (offline and pilot in the loop): very important to improve flight test safety must be adequately scheduled and extensively used in order to reduce real flight test hours pilot in the loop simulation must be treated as a flight test campaign appropriate simulator must be provided very early to help in the design of the function Adequate knowledge of system operation and flight test techniques together with the use of simulation are essential for good test data and more efficient flights. Human factors issues have to be treated as part of the design from the scratch all the way to validation.
Lessons Learned Teamwork: flight mechanics, performance, aerodynamics, flight controls, system engineering and flight test groups working together in development and certification flight test process was a key factor for success. it enabled Embraer to come up with a simple, efficient and reliable FBW function, the AOA Limiter, which helped define outstanding flight characteristics and performance for the Embraer 170 and 190 airplanes. Similarity: the same development approach is being applied to the other models of the family Experience acquired and lessons learned: being presented aiming at increasing the flight test safety and bringing improvements to the flight test community.
Air Line Pilots Association, International 50t th Annual Air Safety Forum EMBRAER 170/190 FLIGHT TEST DEVELOPMENT PROGRAM THANK YOU!!