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Statistical Loads Data for the Boeing 777-200 Aircraft in Commercial DOT/FAA/AR-06/11 Statistical Loads Data for the Office of Aviation Research and Development Boeing 777-200ER Aircraft in Washington, DC 20591 Commercial Operations November 2006 Final Report This document is available to the U.S. public through the National Technical Information Service (NTIS), Springfield, Virginia 22161. U.S. Department of Transportation Federal Aviation Administration NOTICE This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange. The United States Government assumes no liability for the contents or use thereof. The United States Government does not endorse products or manufacturers. Trade or manufacturer's names appear herein solely because they are considered essential to the objective of this report. This document does not constitute FAA certification policy. Consult your local FAA aircraft certification office as to its use. This report is available at the Federal Aviation Administration William J. Hughes Technical Center's Full-Text Technical Reports page: actlibrary.tc.faa.gov in Adobe Acrobat portable document format (PDF). Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. DOT/FAA/AR-06/11 4. Title and Subtitle 5. Report Date STATISTICAL LOADS DATA FOR THE BOEING 777-200ER AIRCRAFT IN November 2006 COMMERCIAL OPERATIONS 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Daniel O. Tipps, Donald A. Skinn, John W. Rustenburg, Todd Jones, and UDR-TR-2005-00106 David A. Harris 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) University of Dayton Research Institute 065110 RPD-510 RD0300 Structural Integrity Division 11. Contract or Grant No. 300 College Park Grant No. 2001-G-005 Dayton, OH 45469-0120 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered U.S. Department of Transportation Final Report Federal Aviation Administration 14. Sponsoring Agency Code Office of Aviation Research and Development ANM-110 Washington, DC 20591 15. Supplementary Notes The Federal Aviation Administration Airport and Aircraft Safety R&D Division Technical Monitor was Thomas DeFiore. 16. Abstract The University of Dayton Research Institute supports the Federal Aviation Administration (FAA) by conducting research on the structural integrity requirements for the U.S. commercial transport airplane fleet. The primary objective of this task was to support the FAA’s Airborne Data Monitoring Systems Research by developing new and improved methods and criteria for processing and presenting large commercial transport airplane flight and ground loads usage data. The scope of activities included: (1) defining the service-related factors that affect the operational life of commercial aircraft; (2) designing an efficient software system to reduce, store, and process large quantities of optical quick access recorder data; and (3) reducing, analyzing, and providing processed data in statistical formats for the FAA to reassess existing certification criteria. Equally important, these new data also will enable the FAA, the aircraft manufacturers, and the airlines to better understand and control those factors that influence the structural integrity of commercial transport aircraft. Presented herein are Boeing 777-200ER aircraft operational usage data collected from 10,047 flights, representing 67,000 flight hours, recorded by a single international operator. Data are presented that will provide the user with statistical information on aircraft usage, ground and flight loads occurrences, and system operational usage based on actual B-777-200ER operational usage. The aircraft usage data include statistics on aircraft weights, flight distances, altitudes, speeds, and flight attitudes. Flight loads data include statistical information on gust and maneuver load factors, derived gust velocities, and ground-air-ground cycles. Ground loads data include statistics on lateral, longitudinal, and vertical load factors during different ground operational phases. Systems operational data include statistics on flap usage, thrust reverser usage, and engine fan speed. The B-777 airplane sensors, which measure vertical, lateral, and longitudinal acceleration, are located in the cockpit area. The estimates of the center of gravity (c.g.) accelerations are computed in the Air Data Inertial Reference Unit, which converts the measured crew station accelerations to accelerations at the c.g. For some dynamic and ground load conditions, inaccuracies could exist in these filtered c.g. time history measurements. Operators and inspectors who use the recorded B-777 acceleration values as maintenance action triggers or Flight Operational Quality Assurance events should recognize the possibility of recorded Digital Flight Data Recorder acceleration inaccuracies. 17. Key Words 18. Distribution Statement Optical quick access recorder, Flight profiles, Flight loads, This document is available to the public through the National Ground loads, Systems operational data, Statistical loads data Technical Information Service (NTIS) Springfield, Virginia 22161. 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified Unclassified 106 Form DOT F1700.7 (8-72) Reproduction of completed page authorize PREFACE The Flight Systems Integrity Group of the Structural Integrity Division at the University of Dayton Research Institute (UDRI) performed this work under Federal Aviation Administration (FAA) Grant No. 2001-G-005 entitled “Assessment of Actual Operational Usage on Large Wide Body Transport Aircraft.” The Research Manager for the FAA was Mr. Thomas DeFiore of the Airport and Aircraft Safety Research and Development Division at the FAA William J. Hughes Technical Center, Atlantic City International Airport, New Jersey. The Program Technical Advisor was Mr. John Howford, FAA Chief Scientific and Technical Advisor (CSTA) for Loads/Aeroelasticity. Mr. Daniel Tipps was the principal investigator for the University of Dayton and provided overall technical direction for this effort. Mr. Donald Skinn developed the data reduction algorithms, programmed the data reduction criteria, and performed the data reduction. Mr. David Harris prepared the graphical presentations. Mr. Todd Jones and Mr. John Rustenburg performed the data analysis and compiled the final report. iii/iv TABLE OF CONTENTS Page EXECUTIVE SUMMARY xi 1. INTRODUCTION 1 2. AIRCRAFT DESCRIPTION 1 3. AIRLINE DATA COLLECTION AND EDITING SYSTEMS 3 3.1 Airline Data Collection System 3 3.2 Airline Data Editing System 4 4. UNIVERSITY OF DAYTON RESEARCH INSTITUTE DATA PROCESSING 4 4.1 Recorded Data Parameters 4 4.2 Computed Parameters 5 4.2.1 Atmospheric Density 6 4.2.2 Equivalent Airspeed 6 4.2.3 Dynamic Pressure 6 4.2.4 Derived Gust Velocity 7 4.2.5 Continuous Gust Intensity 7 4.2.6 Lift-Curve Slope 9 4.2.7 Flight Distance 9 4.2.8 Rate of Climb 10 4.3 Data Reduction Operations 10 4.3.1 Initial Quality Screening 10 4.3.2 Time History Files 11 4.3.3 Relational Database 12 4.3.4 Permanent Data Files 12 4.3.5 Loads Data Reduction 12 4.4 Data Reduction Criteria 12 4.4.1 Phases of Flight Profile 12 4.4.2 Specific Events 14 4.4.3 Sign Conventions 17 4.4.4 Peak Selection Technique 17 4.4.5 Separation of Maneuver and Gust Load Factors 18 4.4.6 Flap Detents 19 v 5. DATA PRESENTATION 19 5.1 Aircraft Usage Data 23 5.1.1 Weight and Flight Distance Data 23 5.1.2 Altitude and Speed Data 24 5.1.3 Attitude Data 25 5.2 Ground Loads Data 25 5.2.1 Lateral Load Factor Data 26 5.2.2 Longitudinal Load Factor Data 27 5.2.3 Vertical Load Factor Data 28 5.3 Flight Loads Data 29 5.3.1 Gust Vertical Load Factor Data 29 5.3.2 Derived Gust Velocity Data 30 5.3.3 Continuous Gust Intensity Data 30 5.3.4 Maneuver Vertical Load Factor Data 30 5.3.5 Combined Maneuver and Gust Vertical Load Factor Data 31 5.3.6 Combined Maneuver and Gust Lateral Load Factor Data 31 5.3.7 Ground-Air-Ground Cycle Data 32 5.4 Systems Operational Data 32 5.4.1 Flap Usage Data 32 5.4.2 Thrust Reverser Data 32 5.4.3 Propulsion Data 33 6. CONCLUSIONS 33 7. REFERENCES 34 APPENDICES A—Boeing 777 Center of Gravity Transfer Equations B—Great Circle Distance Calculation C—Data Presentation vi LIST OF FIGURES Figure Page 1 B-777-200ER Three-View Drawing 2 2 Airline Recording and Editing System 3 3 Data Processing Flow Chart 10 4 Description of Flight Profile Phases 13 5 Sketch of Ground Phases and Specific Events 15 6 Sign Convention for Airplane Accelerations 17 7 The Peak-Between-Means Classification Criteria 18 vii LIST OF TABLES Table Page 1 B-777-200ER Aircraft Characteristics 2 2 Recorded Parameters Provided to UDRI 4 3 Parameter Editing Values 11 4 Flight Phase Criteria 13 5 Summary of Specific Events Criteria 15 6 Flap Detents (B-777-200ER) 19 7 Statistical Data Formats 20 viii LIST OF ACRONYMS AND ABBREVIATIONS ADIRU Air Data Inertial Reference Unit CD Compact disk DOS Disk Operating System c.g. Center of gravity DFDAU Digital Flight Data Acquisition Unit FAA Federal Aviation Administration GAG Ground-air-ground MAC Mean aerodynamic chord MO Magneto-optical nmi Nautical mile PSD Power spectral density RC Rate of climb (ft/sec) rms Root mean square URDI University of Dayton Research Institute ix/x EXECUTIVE SUMMARY The University of Dayton Research Institute supports the Federal Aviation Administration (FAA) by conducting research on the structural integrity requirements for the U.S. commercial transport airplane fleet. The primary objective of this task was to support the FAA’s Airborne Data Monitoring Systems Research Project by developing new and improved methods and criteria for processing and presenting large commercial transport airplane flight and ground loads usage data. The scope of activities included (1) defining the service related factors that affect the operational life of commercial aircraft; (2) designing an efficient software system to reduce, store, and process large quantities of optical quick access recorder data; and (3) reducing, analyzing, and providing processed data in statistical formats for the FAA to reassess existing certification criteria.
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