Table Of Content

Test Techniques for Flight Control Systems of Large Transport Aircraft Test Techniques for Flight Control Systems of Large Transport Aircraft Yakui Gao Xi’an Aircraft Design and Research Institute, Shaanxi, P.R. China Gang An Xi’an Aircraft Design and Research Institute, Shaanxi, P.R. China Chaoyou Zhi Xi’an Aircraft Design and Research Institute, Shaanxi, P.R. China AcademicPressisanimprintofElsevier 125LondonWall,LondonEC2Y5AS,UnitedKingdom 525BStreet,Suite1650,SanDiego,CA92101,UnitedStates 50HampshireStreet,5thFloor,Cambridge,MA02139,UnitedStates TheBoulevard,LangfordLane,Kidlington,OxfordOX51GB,UnitedKingdom Copyright©2021ShangaiJiaoTongUniversityPress.PublishedbyElsevierInc.Allrightsreserved. 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BritishLibraryCataloguing-in-PublicationData AcataloguerecordforthisbookisavailablefromtheBritishLibrary LibraryofCongressCataloging-in-PublicationData AcatalogrecordforthisbookisavailablefromtheLibraryofCongress ISBN:978-0-12-822990-3 ForInformationonallAcademicPresspublications visitourwebsiteathttps://www.elsevier.com/books-and-journals Publisher:MatthewDeans AcquisitionsEditor:GlynJones EditorialProjectManager:NaomiRobertson ProductionProjectManager:PoulouseJoseph CoverDesigner:MarkRogers TypesetbyMPSLimited,Chennai,India Contents Preface.................................................................................................................xv Introduction..........................................................................................................xix Chapter 1:Introduction.......................................................................................... 1 1.1 Overview...............................................................................................................1 1.2 Current situation and development trend of flight control system test verification technologies........................................................................................5 1.2.1 Development of the verification test...........................................................6 1.2.2 Current development of flight control system test verification technologies................................................................................................7 1.2.3 Development trends of the verification test...............................................10 1.3 Features and evaluation management of a flight control system verification test....................................................................................................13 1.3.1 Basic features of a verification test...........................................................13 1.3.2 Functions of a verification test..................................................................15 1.3.3 Principles for verification test design........................................................16 1.3.4 Technical management of a verification test.............................................17 1.4 Requirements definition of flight control system verification...............................18 1.4.1 Requirements definition............................................................................19 1.4.2 Requirements verification and assignment................................................22 1.4.3 Coverage and traceability..........................................................................24 1.4.4 Requirements management tools...............................................................24 1.4.5 System verification supports aircraft-level verification.............................24 1.5 Engineering practice of the flight control system test verification.......................25 1.6 Flight control system test verification..................................................................28 1.6.1 Introduction to the background aircraft flight control system....................28 1.6.2 Content of a verification test.....................................................................34 1.6.3 Procedures of a verification test................................................................37 v vi Contents Chapter 2:Unit test of the flight control system.................................................... 41 2.1 Overview...........................................................................................................42 2.1.1 Basic process of unit development..........................................................42 2.1.2 Categories of unit tests............................................................................43 2.1.3 Basic principles for the selection of test items........................................43 2.1.4 Classification of the flight control system unit........................................44 2.1.5 Basis and requirements for the preparation of the unit test outline..........44 2.2 Basic functional/performance test......................................................................46 2.2.1 General requirements of test...................................................................46 2.2.2 Control and display unit..........................................................................47 2.2.3 Computer unit.........................................................................................51 2.2.4 Manipulator unit.....................................................................................54 2.2.5 Mechanical drive unit.............................................................................58 2.2.6 Mechanical transmission unit..................................................................62 2.2.7 Mechanical actuating unit.......................................................................66 2.2.8 Sensor unit..............................................................................................79 2.3 Strength and stiffness test..................................................................................92 2.3.1 Test objectives and test requirements......................................................92 2.3.2 Test items and test methods....................................................................93 2.3.3 Judging criteria and results handling.......................................................93 2.4 Power characteristic test....................................................................................94 2.4.1 Test items and reduction principles.........................................................94 2.4.2 Test objectives and test requirements......................................................99 2.4.3 Test items and test methods..................................................................101 2.4.4 Judging criteria and results handling.....................................................101 2.4.5 Test example: Power characteristic test of flight control computer.......101 2.5 Dielectric strength test.....................................................................................112 2.5.1 Test objectives and test requirements....................................................113 2.5.2 Test items and test methods..................................................................113 2.5.3 Judging criteria and results handling.....................................................114 2.6 Mechanical environment test...........................................................................114 2.6.1 Acceleration test...................................................................................114 2.6.2 Vibration test........................................................................................115 2.6.3 Noise test..............................................................................................116 2.6.4 Shock test.............................................................................................117 2.7 Natural environment test..................................................................................119 2.7.1 Low pressure (altitude) test.................................................................119 2.7.2 High temperature test..........................................................................124 2.7.3 Low temperature test...........................................................................128 Contents vii 2.7.4 Temperature shock test.......................................................................130 2.7.5 Temperature(cid:1)altitude test...................................................................133 2.7.6 Temperature(cid:1)humidity(cid:1)altitude test..................................................137 2.7.7 Single event test..................................................................................140 2.7.8 Solar radiation test..............................................................................142 2.7.9 Rain test..............................................................................................145 2.7.10 Icing test.............................................................................................148 2.7.11 Damp heat test....................................................................................151 2.7.12 Mold test.............................................................................................153 2.7.13 Salt spray test......................................................................................156 2.7.14 Sand and dust test...............................................................................159 2.8 Electromagnetic environment protection test...................................................162 2.8.1 Electromagnetic emission and susceptibility test...................................162 2.8.2 Lightning direct effect test....................................................................167 2.8.3 Lightning-induced transient susceptibility test......................................167 2.8.4 High-intensity radiated field protection test..........................................171 2.8.5 Electrostatic discharge protection test...................................................176 2.9 Reliability test..................................................................................................177 2.9.1 Environmental stress screening test.......................................................177 2.9.2 Reliability preexposure test...................................................................178 2.9.3 Reliability growth test...........................................................................179 2.9.4 Reliability qualification test..................................................................179 2.9.5 Reliability acceptance test.....................................................................180 2.10 Endurance test.................................................................................................180 2.10.1 Test objectives and test requirements..................................................180 2.10.2 Test items and test methods................................................................181 2.10.3 Judging criteria and results handling...................................................181 2.11 Testability test.................................................................................................181 2.11.1 Test objectives and test requirements..................................................182 2.11.2 Test items and test methods................................................................182 2.11.3 Judging criteria and results handling...................................................183 2.12 Test piece selection and test sequence of the unit qualification test.................183 2.13 Organization and implementation of the unit qualification test........................184 References.................................................................................................................184 Chapter 3:Verification and validation of flight control system airborne software.........187 3.1 Overview...........................................................................................................187 3.1.1 Purpose and significance of verification and validation..........................187 3.1.2 Basic requirements of verification and validation...................................190 viii Contents 3.1.3 Basic process of verification and validation............................................194 3.2 Software testing.................................................................................................199 3.2.1 Unit testing.............................................................................................200 3.2.2 Component testing..................................................................................204 3.2.3 Configuration item testing.......................................................................208 3.2.4 System testing.........................................................................................210 3.3 Model-based flight control system airborne software development and testing methods..................................................................................................212 3.3.1 Overview of model-based development methods....................................212 3.3.2 SCADE model testing and verification features......................................214 3.3.3 SCADE software testing process.............................................................215 3.4 Software whole life cycle support environment.................................................222 3.4.1 Basic requirements of environment.........................................................222 3.4.2 Environment architecture........................................................................223 3.4.3 Environment composition and functions.................................................224 3.4.4 Construction process of software whole life cycle support environment............................................................................................229 3.5 Software safety and reliability test.....................................................................230 3.5.1 Safety and reliability...............................................................................230 3.5.2 Safety analysis and testing......................................................................232 3.5.3 Reliability analysis and testing................................................................232 Chapter 4:Flight control system control law and the flying quality evaluation test......239 4.1 Overview...........................................................................................................240 4.1.1 Design requirements for flying quality of large transport aircraft............242 4.1.2 Design requirements for flight control system control law of large transport aircraft......................................................................................243 4.2 Stage division and objectives of the evaluation test...........................................244 4.3 Design requirements for the engineering simulator............................................247 4.3.1 Composition............................................................................................247 4.3.2 Main functions........................................................................................247 4.3.3 Design requirements...............................................................................248 4.4 Test items and methods.....................................................................................253 4.4.1 Planning for test tasks.............................................................................254 4.4.2 Selection of test state points....................................................................254 4.4.3 Test items...............................................................................................255 4.4.4 Test control action..................................................................................257 4.4.5 Test task list............................................................................................259 Contents ix 4.4.6 Preparation of test report.........................................................................261 4.4.7 Test analysis report.................................................................................261 4.5 Data collection, processing, and evaluation methods.........................................262 4.5.1 Overview................................................................................................262 4.5.2 Requirements for data collection.............................................................262 4.5.3 Requirements for data processing...........................................................263 4.5.4 Objective evaluation methods.................................................................263 4.5.5 Subjective evaluation methods................................................................265 4.6 Management of control law and the flying quality evaluation test.....................266 4.6.1 Planning of test.......................................................................................267 4.6.2 Preparation for test..................................................................................268 4.6.3 Control of test process............................................................................269 4.6.4 Summary of test......................................................................................270 Chapter 5:Combined test of the flight control subsystem......................................271 5.1 Overview...........................................................................................................271 5.2 Combined test of the pilot control units.............................................................273 5.2.1 System introduction................................................................................273 5.2.2 Test objectives........................................................................................276 5.2.3 Test requirements....................................................................................276 5.2.4 Test items and methods...........................................................................278 5.2.5 Criteria for the assessment of test results................................................282 5.3 Combined test of the fly-by-wire flight control system......................................287 5.3.1 System introduction................................................................................287 5.3.2 Test objective..........................................................................................288 5.3.3 Test requirements....................................................................................290 5.3.4 Test items and test methods....................................................................297 5.3.5 Test results and judging criteria..............................................................315 5.4 Combined test of the high-lift system................................................................318 5.4.1 System introduction................................................................................318 5.4.2 Test objective..........................................................................................318 5.4.3 Test requirements....................................................................................320 5.4.4 Test items and methods...........................................................................322 5.4.5 Test results and judging criteria..............................................................332 5.5 Combined test of the automatic flight control system........................................334 5.5.1 System introduction................................................................................334 5.5.2 Test objectives........................................................................................334 5.5.3 Test requirements....................................................................................336 x Contents 5.5.4 Test items and methods...........................................................................338 5.5.5 Test results and judging criteria..............................................................342 5.6 Combined test of the machinery control system.................................................343 5.6.1 System introduction................................................................................343 5.6.2 Test objectives........................................................................................344 5.6.3 Test requirements....................................................................................344 5.6.4 Test items and methods...........................................................................346 5.6.5 Test results and judging criteria..............................................................352 Chapter 6:“Iron bird” integration test of the flight control system........................355 6.1 Overview.........................................................................................................355 6.2 Test environment and test support equipment..................................................358 6.2.1 “Iron bird” integrated test bed.............................................................359 6.2.2 Aircraft simulator cockpit...................................................................361 6.2.3 Vision system......................................................................................364 6.2.4 Sound system......................................................................................366 6.2.5 Sensor and test analysis system...........................................................367 6.2.6 Flight test interface.............................................................................371 6.2.7 Flight simulation system.....................................................................372 6.2.8 Flight control system tester.................................................................378 6.2.9 Avionics system exciter......................................................................383 6.2.10 Mechanical displacement signal generator..........................................385 6.2.11 Ground hydraulic energy and ground power supply............................391 6.2.12 Comprehensive test management system............................................394 6.2.13 Aircraft motion sensor driver..............................................................397 6.3 Debugging and preparation for the flight control system “iron bird” integration test.................................................................................................403 6.3.1 Static adjustment and inspection of the flight control system................405 6.3.2 Debugging and technical status of the cross-linking system..................408 6.3.3 Potential problems in the flight control system debugging process and cause analysis.......................................................................................412 6.4 “Iron bird” integration test of the cockpit control system.................................414 6.4.1 Overview..............................................................................................414 6.4.2 Test principle........................................................................................415 6.4.3 Static evaluation of man(cid:1)machine ergonomics of the cockpit control system...................................................................................................415 6.4.4 Static performance testing of the cockpit control system......................417 6.4.5 Dynamic performance testing of the cockpit control system.................422 Contents xi 6.5 “Iron bird” integration test of the machinery control system............................423 6.5.1 Overview..............................................................................................423 6.5.2 Test principle........................................................................................423 6.5.3 Evaluation of man(cid:1)machine ergonomics of the machinery control system...................................................................................................424 6.5.4 Static performance testing of the machinery control system.................425 6.5.5 Dynamic performance testing of the machinery control system............426 6.5.6 Fault mode verification of the machinery control system......................428 6.5.7 Study on effects of mechanism support stiffness on system dynamic (static) performance..............................................................................429 6.6 “Iron bird” integration test of the fly-by-wire flight control system.................429 6.6.1 Overview..............................................................................................429 6.6.2 Basic status inspection and testing........................................................430 6.6.3 Zero position and stroke inspection.......................................................432 6.6.4 Testing of servo actuator system...........................................................433 6.6.5 Logic function inspection......................................................................437 6.6.6 Built-in-test functional inspection and testing.......................................440 6.6.7 Redundancy management function inspection.......................................441 6.7 “Iron bird” integration test of the high-lift system...........................................442 6.7.1 Overview..............................................................................................442 6.7.2 Test principle........................................................................................443 6.7.3 Interface inspection...............................................................................444 6.7.4 Control function and logic inspection...................................................445 6.7.5 Modal conversion function inspection...................................................447 6.7.6 Safety protection function inspection....................................................449 6.7.7 Display and fault warning function test.................................................451 6.7.8 Built-in-test and redundancy management function inspection..............452 6.7.9 Failure effect test..................................................................................452 6.8 “Iron bird” integration test of the automatic flight control system...................454 6.8.1 Overview..............................................................................................454 6.8.2 Test principles.......................................................................................455 6.8.3 Interface inspection...............................................................................456 6.8.4 Polarity and transmission ratio inspection.............................................457 6.8.5 Control logic and display function inspection.......................................459 6.8.6 Control function and performance test..................................................461 6.8.7 Built-in-test...........................................................................................462 6.8.8 Failure effect test..................................................................................464 6.9 “Iron bird” integration test of the flight control system....................................466 6.9.1 Overview............................................................................................466 6.9.2 Test principles.....................................................................................467