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MASAAG Paper 109 Guidance for Aircraft Operational Loads MASAAG Paper 109 MASAAG Paper 109 Guidance for Aircraft Operational Loads Measurement Programmes S C Reed and D M Holford Airworthiness and Structural Integrity Group QinetiQ Farnborough 31 May 2007 ii MASAAG Paper 109 DISTRIBUTION Task Sponsor Sqn Ldr Kev Storer, ASI4, RAF Wyton MASAAG Members Dr John Moon, Technical Manager A&SI, QinetiQ Farnborough, MASAAG Co-Chairman Wg Cdr Andy March, Head of AVI, RAF Wyton, MASAAG Co-Chairman Mr Thomas Cook, Head of Stress A400M and Future Aircraft, Airbus UK Mr Peter Gates, Chief Structures Engineer, BAE SYSTEMS, Farnborough Dr Peter Hopgood, Air & Weapons Systems Division, Dstl Mr Chris Hoyle, Engineering Team Leader – Structural Integrity, BAE SYSTEMS, Chadderton Dr Peter Lloyd, Platform Sciences, Dstl Mr Rory Martin, Head Structures and Materials Department, CAA Safety Regulation Group Mr Tom McMichael, Head of Airworthiness & Structural Integrity, BAE SYSTEMS, Warton Mrs Alison Mew, Airworthiness & Structural Integrity, QinetiQ Farnborough, MASAAG Secretary Mr Mike Overd, Head of Structures and Materials, AgustaWestland Mr Dave Patterson, Chief Stress and Weights Engineer, Bombardier Aerospace Belfast Mr Graham Redgrave, Chief Structural Engineer, Marshall Aerospace Mr Matt Sheppard, DMSD-Pol1, DPA Abbey Wood Authorship Panel Mr Nigel Chard, Principal Loads Engineer, Marshall Aerospace Mr Peter Cross, A&SI, QinetiQ Farnborough Mr Mike Duffield, A&SI, QinetiQ Farnborough Dr Markus Engelhardt, A&SI, QinetiQ Farnborough Dr Mike Gelder, Structures Specialist Leader, BAE SYSTEMS, Brough Mr Paul Johnson, JSF SPHM, BAE SYSTEMS, Warton Mr David Harden, A&SI, QinetiQ Farnborough Mr John Hayden, OLM Specialist, BAE SYSTEMS, Woodford Mr Stephen Hunt, Eurofighter SHM, BAE SYSTEMS, Warton Mr Peter Kadwell, Harrier II OLM, BAE SYSTEMS, Farnborough Mr Ian Kaynes, A&SI, QinetiQ Farnborough Mr Michael Kolling, Project Leader Structural Lifetime Monitoring System A400M, Airbus Deutschland Mr Brian McCoubrey, Tucano OLM, Bombardier Aerospace Mr Andrew Mountfort, A&SI, QinetiQ Farnborough Mr Stephen Roberts, Structures Specialist Leader, BAE SYSTEMS, Brough Mr Gary Somers, Harrier II OLM, BAE SYSTEMS, Farnborough Mr Andrew Spence, Structures Specialist BAE SYSTEMS, Chadderton Sqn Ldr Kev Storer, ASI4, RAF Wyton MASAAG Paper 109 iii EXECUTIVE SUMMARY Aircraft Operational Loads Measurement (OLM) programmes are now firmly mandated in MoD policy and there is general acceptance within the military aviation community that these programmes need to be undertaken. However, OLM is technically complex, costly and often takes many years to complete. This means that, certainly from the MoD’s side, it is highly unlikely that an OLM programme will be completed on any one person’s tour of duty. From experience, it is not uncommon to deal with 6 or 7 MoD desk officers in the time scale of an OLM programme. This brings great inefficiency where a fundamental review and bringing-up- to-speed exercise is invoked every 2 years or so. Furthermore, with the MoD increasingly moving from a ‘provider’ to a ‘decider’ organisation, the technical knowledge within the MoD will only decrease further, making the challenge of conducting successful OLM programmes even greater. From an industry perspective, much hard won experience is frequently concentrated in a few key personnel. Furthermore, where programmes are cyclic rather than continuous, knowledge gained in industry is often lost in the intervening period between programmes. Additionally, in- depth technical and management problems have occurred in many OLM programmes; these have incurred additional cost, time delays and, in some cases, undesirable compromises have had to be made to make progress. Furthermore, with the dominance of commercial issues in today’s engineering environment it is easy to forget or fail to appreciate the technical complexity of these programmes. Therefore, there is a very real need for more detailed guidance to be made available for those involved in OLM programmes. The aim of this paper is to provide a basis for guiding those involved in an OLM programme through the planning, installation, data capture and analysis, and reporting phases of the programme. The reasons behind each of the steps in each phase are explained in generic terms and the key activities are captured in OLM Actions, which have been concatenated into a generic Statement of Requirement (Appendix B) for use as a starting point in OLM planning. Detailed technical data have also been included in Appendices where possible. A draft of this paper was circulated to MASAAG members and OLM practitioners for their consideration and comments. This draft provided the basis for an OLM Workshop held at QinetiQ Farnborough on 22 Mar 07, attended by OLM Practitioners. Invaluable comments and contributions were provided during the course of the workshop and these comments have been included within the version of this paper presented here. It is hoped to retain this paper as a ‘live’ document and readers are asked to forward their comments and experiences from ongoing and future OLM programmes to the MASAAG. iv MASAAG Paper 109 AUTHORSHIP Principal Authors: Dr Steve Reed, Principal Engineer, A&SI, QinetiQ Farnborough Mrs Dorothy Holford, Senior Fellow Loads Data, A&SI, QinetiQ Farnborough Authorship Panel: Mr Nigel Chard, Principal Loads Engineer, Marshall Aerospace Mr Peter Cross, A&SI, QinetiQ Farnborough Mr Mike Duffield, A&SI, QinetiQ Farnborough Dr Markus Engelhardt, A&SI, QinetiQ Farnborough Dr Mike Gelder, Structures Specialist Leader, BAE SYSTEMS, Brough Mr Paul Johnson, JSF SPHM, BAE SYSTEMS, Warton Mr David Harden, A&SI, QinetiQ Farnborough Mr John Hayden, OLM Specialist, BAE SYSTEMS, Woodford Mr Stephen Hunt, Eurofighter SHM, BAE SYSTEMS, Warton Mr Peter Kadwell, Harrier II OLM, BAE SYSTEMS, Farnborough Mr Ian Kaynes, A&SI, QinetiQ Farnborough Mr Michael Kolling, Project Leader Structural Lifetime Monitoring System A400M, Airbus Deutschland Mr Brian McCoubrey, Tucano OLM, Bombardier Aerospace Mr Andrew Mountfort, A&SI, QinetiQ Farnborough Mr Stephen Roberts, Structures Specialist Leader, BAE SYSTEMS, Brough Mr Gary Somers, Harrier II OLM, BAE SYSTEMS, Farnborough Mr Andrew Spence, Structures Specialist BAE SYSTEMS, Chadderton Sqn Ldr Kev Storer, ASI4, RAF Wyton MASAAG Paper 109 v TABLE OF CONTENTS DISTRIBUTION ..................................................................................................................................II EXECUTIVE SUMMARY ..................................................................................................................... III AUTHORSHIP ...................................................................................................................................IV TABLE OF CONTENTS........................................................................................................................V ABBREVIATIONS...............................................................................................................................XI 1 INTRODUCTION ................................................................................................................... 1 2 HISTORICAL PERSPECTIVE............................................................................................... 3 2.1 Relevance of Historical Perspective........................................................................ 3 2.2 Early Measurement of Service Loads in Aviation.................................................... 3 2.3 Post-War Years ....................................................................................................... 4 2.4 Early Fatigue Monitoring of Military Aircraft ............................................................ 6 2.5 The Introduction of the Fatigue Load Meter ............................................................ 7 2.6 The Advent of Operational Load Measurement Programmes ................................ 8 2.7 Development of Structural Monitoring Systems ...................................................... 9 2.8 The Role of OLM in Future Structural Monitoring Systems .................................. 10 3 OLM DEFINITION................................................................................................................ 11 4 REGULATORY AND GUIDANCE MATERIAL................................................................... 12 5 GENERIC OLM PROGRAMME .......................................................................................... 13 5.1 Background ........................................................................................................... 13 5.2 Establishment of OLM Management and Specialist Groups ................................ 15 vi MASAAG Paper 109 5.3 OLM Programme Aims ..........................................................................................17 5.4 Timing of an OLM Programme...............................................................................17 6 OLM PLANNING PHASE ....................................................................................................19 6.1 Aim: Substantiation of Design and Qualification Fatigue Usage Spectra and Review of Fatigue Clearances .................................................................................................19 6.1.1 MoD SI ‘ESVRE’ Policy..........................................................................................19 6.1.2 Design Assumptions ..............................................................................................19 6.1.3 Spectra Substantiation
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