Air Line Pilots Association, International 50th Annual Air Safety Forum
EMBRAER 170/190 FLIGHT TEST DEVELOPMENT PROGRAM
Washington, DC August 19th, 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
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Ve n e zu e l a Colômbia
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THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED NOR USED IN ANY MANNER EXCEPT AS EXPRESSLY AUTHORIZED Customer Global Assistance
EmbraerEmbraer Aircraft Aircraft EmbraerEmbraer Aviation Aviation CorporationCorporation WeybridgeWeybridge InternationalInternational FortFort Lauderdale,Lauderdale, UnitedUnited KingdomKingdom LeLe Bourget,Bourget, FranceFrance Florida,Florida, EUAEUA
EmbraerEmbraer Beijing Maintenance Beijing Maintenance ChinaChina ServicesServices Inc.Inc. NashvilleNashville TennesseeTennessee
SingaporeSingapore
EmbraerEmbraer SãoSão José José dos dos Campos,Campos, SãoSão Paulo, Paulo, BrazilBrazil EmbraerEmbraer Aircraft Aircraft CorporationCorporation Melbourne,Melbourne, AustraliaAustralia
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Civil aircraft
EMB 110 EMBRAER 170 ERJ 140
EMB 121 EMBRAER 175
ERJ 145 EMB 120 EMBRAER 190
ERJ 135 LEGACY ERJ 135 EMBRAER 195
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Military aircraft
EMB 111
EMB 312 TUCANO
EMB 145 RS/ AGS
SUPER TUCANO/ ALX EMB 145 AEW&C
AMX-T P99
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. The 70 to 110 Seat Market
4 “The Seat Gap”
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. EMBRAER 170/190 Family
EMBRAEREMBRAER 170 170 70/7870/78 Seats Seats 95%
EMBRAEREMBRAER 175 175 78/8678/86 Seats Seats 85%
EMBRAEREMBRAER 190 190 98/10898/108 Seats Seats
95%
EMBRAEREMBRAER 195 195 108/118108/118 Seats Seats
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Two Views
98 ft 1 in
Fwd Plug Aft Plug 85 ft 4 in 33 in 33 in
103 ft 11 in
Fwd Plug Aft Plug 94.8 in 146.3 in
118 ft 11 in
94 ft 3 in Fwd Plug Aft Plug 126.8 in 209.3 in
126 ft 10 in
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. 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
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Engines
EMBRAER 170 EMBRAER 190 GE CF34-8E GE CF34-10E
Max TO Thrust ( SL, Static, ISA ) 14200lb Max TO Thrust ( SL, Static, ISA ) 18500lb Fan Diameter 46.2" Fan Diameter 53"
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Cockpit
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Overhead Panel 4 Dark and Quiet 12 o’clock philosophy
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Sales Order Book
*Commercial Proposal Signed
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Main Differences 170 X 190
Forward Fuselage Plug Center Fuselage II with overwing emergency exits
Aft Fuselage Plug
Engine
Horizontal Stabilizer Actuator
Flap actuators Horizontal Stabilizer Main Landing Gear Wing and Flight Control Surfaces
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Flight Control System
Note: This configuration is not used for the Flaps/Slats, & Aileron controls.
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Flight Control System
Note: This configuration is not used for the Flaps/Slats, & Aileron controls.
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. FBW High Level Functions
4 Elevator High Level Functions – AOA Limit function – Elevator Thrust Compensation (ETC) – Column gain shaper – adjust the pilot force 4 Rudder High Level Functions – Yaw Damper & Turn Cordination (via AFCS) 4 Spoilers – Speed brake/ Ground Spoiler function – Roll Spoilers – Spoiler Mixer – combines speed-brake and roll spoiler actuation 4 Horizontal Stabilizer System – Automatic configuration trim – compensates for spoilers deployment – Elevator offload to stabilizer – to reduce trim drag
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. 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.
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. AOA Limiting Function - Motivation
4 AOA limiting X Stick Pusher 4 Practical benefit - The AOA Limit allows 2 knots lower approach speed when compared to using a stick pusher 4 This allows a 1000kg increase in payload for airports like London City
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Simultaneous Development
2000 2001 2002 2003 2004 2005 2006
1Q/04 EMBRAER 170
3Q/04
EMBRAER 175
3Q/05 EMBRAER 190
EMBRAER 195 2Q/06
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. EMBRAER 170 Certification
4 Simultaneous Certification Process – CTA : 19 Feb 2004 – FAA : 20 Feb 2004 – EASA : 20 Feb 2004 4 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 4 1252 Reports 4 250 Laboratory Tests 4 Compliance Checklist Database with more than 5000 items 4 120 TSO’s 4 Hundreds of meetings (106 with JAA only).
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. EMBRAER 170 - Flight Tests
11stst FlightFlight FebruaryFebruary 1919thth,, 20022002
774 FH / 424 cycles 0001 545 FH / 573 cycles 0002 284 FH / 288 cycles 0003
523 FH / 732 cycles 0004 349 FH / 203 cycles 0005 232 FH / 191 cycles 0006 nn ss ffllowow 00 hhoourur nn 330000 rree tthhaa 99 MoMo 368 FH / 226 cycles 0007
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. EMBRAER 170 - Structures Ground Tests
9950005000 cycles cycles - - May, May, 20032003 99320,000320,000 cycles cycles (4 (4 lifes) lifes)
Static Tests Fatigue Tests Barrel Tire Burst Bird Impact Loads Calibration
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. EMBRAER 170 - Systems Rig Tests
Iron Bird , Fly By Wire – over 7,000 hours Development and certification tests
Avionics Rig - over 8,000 hours
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. 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)
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. EMBRAER 190 – Flight Test Campaign
4Approximately 1800 FT Hours for Certification
44 prototypes, about 60 FT Hours/acft/month
43 fully-instrumented prototypes and 1 pre-series (interiors)
4Most of Flight Test Campaign in GPX (dimensions)
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. EMBRAER 190 – Flight Test Campaign
PrototypesPrototypes LayLay--outout
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. 1st Flight – March 12th
¾ 2 hours and 45 min; ¾ Initial Envelope Clearance; ¾ Take-off, Cruise and Landing Configurations;
¾ From 1.3 Vs up to 250 Knots.
¾ Flight as predicted, no abnormal condition; ¾ 190 flight dynamics very similar to 170; ¾ Direct mode only.
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Prototype 190-001
9 Initial Envelope Opening 9 GVT (Development) 9 Ground Load Calibration (Development) 9 Landing Gear Clearance & Development 9 Flow visualization 9 Full Flight Simulator Data Collection 9 FBW (Development) ¾ Landing Gear Certification ¾ RVSM Flight Controls Stall Tests Flying Qualities Performance Engine Operation Crosswind Hydraulic Electrical AFCS (Certification & CATII)
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Prototype 190-002
9 IFTD 9 Farnborough Air Show 9 Climb (development) ¾ Engine Cooling, Vent & Fire Detection ¾ Noise (development) ¾ AFCS (development) Dry Air AMS (development) Avionics (development) Performance (climb & cruise) RVSM
VMCA, VMCG, VMCU AFCS – Outer Loop TMS Engine Operation AMS Avionics Natural Icing, Cold Soak Performance (Take off & Landing) THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Prototype 190-003
¾ GVT (Certification); ¾ Ground Load Calibration (Certification); In-Flight Loads; External Noise (Development); Flutter; Buffeting; RVSM; External Noise (Certification); Flying Qualities;
First flight July, 30th
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Prototype 190-004
¾ Fuselage under structural completion at SJK; ¾ Wing assembly at GPX (KAB); ¾ 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;
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. 190-99801 - Structural Static Tests Device
4 Structural completion activities on-going at EGM site; 4 Test setup assembly started; 4 Test start scheduled for October 04;
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. 190-99802 - Fatigue Testing
4 Smaller Test Specimen for 190 Certification; 4 Improved lead-time due to shorter pressurization and maintenance cycles; 4 Final Assembly at EMBRAER is expected for Aug/04.
190 – Wing-Fuselage full-scale fatigue test
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. EMBRAER 190 - Iron Bird
4 Iron Bird Assembled; 4 Integration tests: 4Eletronic Systems; 4Hydraulic Systems; 4Mechanical Systems. 4 190 Software version 2.0 already tested;
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. EMBRAER 190 - SITS
4 Avionics and Utilities Software Integration tests; 4 190 Software version 2.0 already tested;
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Full Flight Simulators at CAE
4 CAE Full Fligth Simulator S/N 0005 Æ 190 Dedicated; 4 Simulator “1st Flight” expected for 4th Quarter 2004; 4 Certification test on Full Flight Simulator scheduled for 1st half 2005.
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Engine CF34-10E Certification
Hailstorm Testing
Engine Part 33 Certification: 3rd Quarter 2004.
Engine 1st Flight: “GE Flight Test Bed”.
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Digital Mock-Up - DMU
•Virtual 3D Environment; •Accurate representation of the real status of the project.
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Digital Mock-Up - DMU
DMUDMU ImageImage RealReal ImageImage
DMUDMU ImageImage RealReal ImageImage
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Virtual Reality Center
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Computer Fluid Dynamics
CFD Ground Test
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Structural Analysis
Integrated Structural Model
Real Test FEM
2.82+013.01+01 2.42+012.62+01 2.22+01 1.82+012.02+01 1.43+011.63+01 1.03+011.23+01 8.34+00 4.38+006.36+00 4.11-012.39+00
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Lessons Learned
4 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
4 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.
4 Human factors issues have to be treated as part of the design from the scratch all the way to validation.
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Lessons Learned
4 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.
4 Similarity: – the same development approach is being applied to the other models of the family
4 Experience acquired and lessons learned: – being presented aiming at increasing the flight test safety and bringing improvements to the flight test community.
THE INFORMATION CONTAINED HEREIN IS THE PROPERTY OF EMBRAER AND SHALL NOT BE COPIED OR USED WITHOUT EMBRAER’S WRITTEN CONSENT. Air Line Pilots Association, International 50tth Annual Air Safety Forum
EMBRAER 170/190 FLIGHT TEST DEVELOPMENT PROGRAM
THANKTHANK YOUYOU !!!!