Systems Integration Evaluation Remote Research Aircraft SIERRA Airworthiness and Flight Safety Review Board (Flight Readiness Review for Flight Testing ) November, 2006 Code SGE Randy Berthold

AFSRB Goal; To obtain authorization to commence flight test program for the SIERRA

SIERRA AFSRB2 Package Contents Overview –AFSRB presentation philosophy –Background –Features, Options, and Projected Performance Objectives Mission Objectives SIERRA Subsystems –Airframe –Power plant –Avionics Testing/Validation Plans –Ground Test Program –Flight Test Program Success Criteria Risk Assessment Operations Attachments, –Compliance Matrix, Ground Test Plan, Flight Test Plan, Drawing Package

SIERRA AFSRB3 Overview SIERRA AFSRB presentation philosophy; APR , Airworthiness and Flight Safety, 9 September 2005 is currently undergoing reviews and updates. The procedural requirements, as defined, are not yet fully developed for UAS, nor for new UAS AFSRBs. Hence this review will deviate from the outlined format and bridge those open items with a Compliance Matrix which will summarize requirement actions based on AFSRB Package, Ground Testing or Flight Testing elements. Because an AFSRB is a prerequisite for Flight Testing this review will serve as an Flight Readiness Review for Flight Testing The SIERRA AFSRB is focused on first flight authorization. Early development concepts were supported by Ames Aircraft Management Office

SIERRA AFSRB4 Overview SIERRA Compliance Matrix

SIERRA AFSRB5 Overview SIERRA Compliance Matrix

SIERRA AFSRB6 Overview Background SIERRA is a utility UAS, designed for testing, evaluating, and demonstrating developmental payloads and supporting associated missions. Its configuration and operation is highly versatile and adaptable to different payloads. SIERRA has proven design heritage Airframe designed by the Naval Research Labs Manufactured by recognized airframe manufacturer Components and control elements are designed for airframes by aircraft part manufactures Materials and fasteners, etc., where applicable use parts designed and manufactured to aircraft specifications Specifications and subsystem designs are base lined

SIERRA AFSRB7 Overview Features, Options, and Projected Performance Objectives Payloads up to 100 pounds Currently pusher (Can be re-configured as tractor) Engines 25.5 HP, gasoline fuel Flight control: RC pilot-in-loop Auto-stabilized manual (control stick steer) Autonomous GPS waypoint navigation Large payload volume  15”  15”  30” 2.5 hour endurance with 100 pound payload 55 kts. cruise speed 12 mile line-of-sight communications range

SIERRA AFSRB8 Overview Features, Options, and Projected Performance objectives SIERRA is an utility UAS for testing, evaluating, and demonstrating developmental payloads and supporting associated missions. Its configuration and operation is highly versatile and adaptable to different payloads. Payloads up to 100 pounds Currently pusher (Can be re-configured as tractor) Engines HP, gasoline fuel Flight control: RC pilot-in-loop Auto-stabilized manual (control stick steer) Autonomous GPS waypoint navigation Large payload volume  15”  15”  30” 2.5 hour endurance with 100 pound payload 55 kts. cruise speed 12 mile line-of-sight communications range SIERRA 3-View and Specifications, Pusher Configuration Wing Span Length Height Wing Area Empty Weight Gross Weight Max Speed Cruise Speed Stall Speed (clean) L/D Rate of Climb CG Position 20 ft ft. 4.6 ft sq. ft. 215 lbs. 345 lbs. 79 kts. 55 kts. 30 kts. 11:5 545 ft./min. 30% Chord

SIERRA AFSRB9 Overview Operating Limits Maximum gross weight: 330 lbs. Limit bank angle to 30° for autopilot operation Limit all flight conditions to 2.0 G maximum Maximum wind conditions, 20 kts. steady, 15 kts. gusting No operation in worse than light precipitation or icing conditions

SIERRA AFSRB10 Overview Mission Objectives First Order To validate and certify the SIERRA as a functional UAS Second Order To support a variety of research, first responder, Homeland Defense, applications with unique remote sensing payload capabilities in environments where UAS’s with SIERRA performance capabilities are advantageous Example mission, San Bernabe Vineyard Airborne Thermal Imaging Project Science objective is to demonstrate airborne thermal imaging systems as a means to mitigate frost damage to agricultural crops. Sensors, micro bolometer array camera, hyper spectral push-broom sensor to evaluate crop stress. Include are PC104+ data systems with supporting wireless modem, wireless network, GPS and INU subsystems to support remote operation, real time data downlink, and metadata infusion. Aircraft requirement (1)Altitude requirement in 3000 to ft range (2)Duration 4 to 8 hours (3)Payload 2 to 10 Kg (4)Cruise speed 20 to 40 m/sec

SIERRA AFSRB11 Overview Flight Envelope Elements Addressed in flight test program Hours of flight Altitude Duration Proven stability

SIERRA AFSRB12 SIERRA Subsystems Airframe –Design heritage and characteristics Dakota II (400+hours) and GHOST(25+hours) –Airfoil utilized on numerous NRL and vendor UAS –Materials Aircraft grade hardware and materials wehere applicable –All fasteners are A/C grade –Fabrication performed by recognized UAS manufacture –Predicted flight characteristics Base on Dakota and GHOST heritage

SIERRA AFSRB13 SIERRA Subsystems Power plant Engine, Herbrandson Dyad 290B Electrical system Designed and built by certified avionic technician, design concepts reviewed by Ames Flight Management Team Fuel system, NASA designed, Flight Management Team contributions Avionics Cloud Cap Piccolo II Autopilot Actuators HiTec digital, 1/4 scale R/Cats Honeywell Digital Compass

SIERRA AFSRB14 SIERRA Subsystems Systems health RCATS and Piccolo II RCATS covers: –RPM –4 currents – left aileron, left ruddervator, fuel qty., outboard flap –Power bus voltage and current –4 temperatures – left and right CHT, left and right EGT –Airspeed and altitude Piccolo II –Fuel flow –RPM –Airspeed and altitude Communications links Micro Hard, imbedded in Piccolo II AP –bidirectional –Up-command and control –On Data:AC systems information and positional location »Payload data

SIERRA AFSRB15 Testing/Validation Plan Ground Test Program (encompasses integrated systems testing) Testing Philosophy Static testing of all subsystems to verify system integrity, control, connectivity –Bench, static run ups, ground controls –Range check Subsystems tested Structural wing testing, loaded to 4.4 Gs –Successfully demonstrated the ability to support a positive 4.4 g flight load. –Performed by RnR Products Inc. »Approximately 1,232 lbs of sand was placed along the entire length of the wing to simulate a 4.4 g flight load. At full load, each tip deflected approximately 5.5 inches. The wing supported the total load for several minutes before sand removal commenced. »The wing recovered to its original position. –Reference Plan

SIERRA AFSRB16 Testing/Validation Plan Flight Test Program Testing Philosophy To systematically evaluate and validate handling qualities and tune flight control parameters –Test Plan will be implemented by certified team at Crow’s Landing –Test Plan will address ALL subsystem –Exercise all subsystems as designed to established operational boundaries Test Plan has compliance matrix of systems to be validated against AFSRB elements Example: AFSRB, Element; 4 Avionics, 4.1, Cloud Cap Piccolo II Autopilot, Section XXXXXXXFlight Test Plan –Piccolo II –Test Cards (from Cloud Cap) »Datalink validation »Turn rate control validation »Airspeed control validation »Pitch damper validation »Altitude control validation »Tracker control validation »Yaw damper control validation –Reference Plan

SIERRA AFSRB17 Testing/Validation Plan Flight Test Program Overview Pilot-in-loop operation Fail safe mode to terminate flight with loss of link 5 gallons maximum fuel load Inspection at conclusion of each test day. At 10 hours flight time, conduct full airframe inspection Test plan is progress, e.g., base on successful accomplishment of sequences

SIERRA AFSRB18 Risk Assessment Failure Modes and Effects Table Probability/Severity Table See pages 18A &18B

SIERRA AFSRB19 Risk Assessment Reliability Testing Engine, COTS with proven historical applications Actuators, COTS aircraft rated parts Servos used on NRL SPIDER autonomous helicopter As of July 6, 2006: 147 flights, 27.5 hrs and no problems with servos Cloud Cap systems, COTS with proven historical applications Communications –Micro Hard has significant flight time Flight termination system

SIERRA AFSRB20 Risk Assessment Engineered Risk Mitigation Extra braking capability Over engineered landing gear _____flaps for reduced take off and landing operations Implementation of dedicated NASA/FAA assigned command and control frequencies Fail safe mode to terminate flight with loss of link Inspection at conclusion of each test day Procedural Risk Mitigation Adherence to defined operational limits Utilize only trained, current, flight team personnel  Pilot-in-loop operation  5 gallons maximum fuel load  At 50 hours flight time, conduct full airframe inspection  Test plan is progressive, e.g., base on successful accomplishment of sequences

SIERRA AFSRB21 Risk Assessment FUNCTIONAL HAZARD ASSESSMENT MATRIX

SIERRA AFSRB22 ACCEPTED RISKS INDEXPROBABILITYCATEGORY 1.E1, 2FIRE / EXPLOSION 2.D1GROUND CREW MEMBER CONTACTING THE TURNING PROPELLER. 3.D1, 2LOSS OF CONTROL DURING TAXI, TAKEOFF OR LANDING 4.E1, 2LOSS OF CONTROL IN FLIGHT 5.D2LOSS OF ENGINE POWER IN FLIGHT 6.E1, 2MID-AIR COLLISION 7.D3LOSS OF RADIO UP-LINK, IN FLIGHT 8.D1, 2LOSS OF ALL VEHICLE ELECTRICAL POWER, IN FLIGHT 9.D3LOSS OF GROUND STATION POWER

SIERRA AFSRB23 RISK MITIGATION INDEX # 2 - GROUND CREWMEMBER CONTACTING THE TURNING PROPELLER - Only trained, qualified and required crewmembers allowed around a running vehicle INDEX # 3-LOSS OF CONTROL DURING TAXI, TAKEOFF OR LANDING - All controls and backups verified functional and in correct configuration prior to taxi, takeoff or landing. - Vehicle maximum wind speed and crosswind component will not be exceeded. - Operating area will be free of RF hazards. INDEX # 5-LOSS OF ENGINE POWER INFLIGHT - Proper maintenance, preflights and crew briefs. - Flight activity within glideback range. INDEX # 7-LOSS OF RADIO UPLINK IN FLIGHT - If in the system is in manual mode, after the designated pilot timeout time, the system will switch from manual to autopilot mode and will continue to the currently selected waypoint within the current flight plan. - If in the system is in autopilot (autonomous) mode, after the designated communication timeout time (usually longer than the pilot timeout), the system will switch to the lost communication waypoint (loss link routine) and continue with that flight plan from that point. - The pilot and communication timeouts are set within the autopilot control software. - During loss of communication, payload and system monitoring data will not be received or available on the ground. INDEX # 8LOSS OF ALL VEHICLE ELECTRICAL POWER INFLIGHT -Proper maintenance and preflight of the alternator, batteries and electrical systems. INDEX # 9LOSS OF GROUND STATION POWER -The portable ground station contains a backup battery in the event of loss of shore power. If both power systems fail, then this is equivalent to loss of radio unlink and that procedure will be followed.

SIERRA AFSRB24 Risk Assessment Actions taken during integration that have resulted in design modifications –Landing gear –wheels –Thermal plastic deformation……. –wiring power

SIERRA AFSRB25 Operations Area of Operation Within boundaries and defined operational parameters of Crow’s Landing for all test flight activities All operations conducted per base lined flight plan and procedures All activities performed by trained, certified, and current flight team

SIERRA AFSRB26 Operations Team roles and responsibilities Flight/Test Director (S. Dunagan) Responsible for development and implementation of fight plan Directs flight sequence, management of flight cards ATC interface Go-No-Go responsibility Pilot (L. Monforton) Full authority for platform operation during take off and landings Responsible for platform flight safety Responsible for performance/meta data interpretation and actions

SIERRA AFSRB27 Operations Team roles and responsibilities RSO (One of Certified SGE RSO Cadre) Air space and airstrip management. Early identification of potential airspace conflicts Direct communications to pilot Ground Station (B Lobitz) Responsibility for flight activities during autonomous control Direct interface to pilot Monitors meta data and responses to commands develop action recommendations Crew Chief (R Kolyer) Responsible for platform maintenance and airworthiness Provide preflight operations support to pilot

SIERRA AFSRB28 Operations Collision avoidance Utilize SVADS See and Avoid Communications Procedures Implement defined roles and responsibilities, and communications plan FAA COA Operate under Moffett Field COA for Crow’s Landing Emergency Procedures Implement procedure for personnel safety, i.e., location of medical facilities/capabilities, POCs Implement NASA Ames Emergency Contact/Incident Reporting Policy, as required Inspections Perform test site inspections and verify equipment readiness via established protocols Log book (airframe, engine, propeller, avionics ) Perform accurate and timely entries of activities Verify compliance with all required maintenance elements