Design of a Low-Cost General Aviation
Flight Data Recording and Analysis System
Team Members: Chad Bonadonna, Don Brody, & Alejandro Lopez
Faculty Advisor:
Dr. George Donohue
Sponsor:
Experimental Aircraft Association
Chapter 571
Department of Systems Engineering and Operations Research
©2014
Context and Gap
Experimental Aircraft
Kit-built experimental aircraft
Experimental Amateur Built
(E-AB) Aircraft
Constructed by an amateur builder, from
an amateur builder’s original design,
purchased plans, or pre-fabricated kit. The
amateur builder must assemble over onehalf of the aircraft. [2]
70% of experimental aircraft are
classified as E-AB (2012)
Kit-Built Experimental Light
Sport Aircraft (ELSA)
Constructed by an amateur builder, from a
kit manufactured by a licensed Light Sport
Aircraft manufacturer. The amateur builder
must assemble over one-half of the
aircraft. [3]
17% of experimental aircraft are
classified as ELSA (2012)
[1] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22-May-2012.
[2] “AIR-2030 - Light-Sport Aircraft Airworthiness Certification.” Federal Aviation Administration, 08-Jul-2013.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Cumulative Accidents by Airframe Hours
E-AB aircraft are 350% more likely to be involved in an accident than all other GA
aircraft during their first 40 hours of flight
2500
567 > Accidents
59% > Accident Rate
Cumulative Accidents
2000
1500
1000
224 > Accidents
350% > Accident Rate
500
Data Compiled: 2001-2010
0
<5
<10
<40
<100
<500
<1000
Airframe Hours
Non-E-AB
E-AB
[2] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22-May-2012.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Accident Rate Gap
E-AB aircraft are 123% more likely to be involved in an accident than all other General Aviation (GA) aircraft
30
Accidents per 100,000 Flight Hours
25
21.17
20
11.68 accidents
15
10
9.49
5
0
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
E-AB aircraft are 238% more likely to be involved in a fatal accident than all other GA aircraft
8
6
5.27
4
3.71 accidents
2
1.56
0
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
Time (years)
Non-Experimental Amateur-Built
Experimental Amateur-Built
[2] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22-May-2012.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Current Phase I Testing Process
Pre-Flight: Pilot determines flight-plan necessary to parameterize aircraft
Pilot must manually
record in-flight data
from cockpit gauges
Post-Flight: After landing, pilot manually parameterizes aircraft
Pilot must
compile manual
data for
submission to the
FAA
Department of Systems Engineering and Operations Research – Senior Design - 2014
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
E-AB FATAL Accidents by Category
Loss of control in flight:
“…insufficient takeoff speed, early rotation, or too steep a climb on
takeoff led to aerodynamic stalls and loss of control. Inadequate
airspeed…also led to aerodynamic stall and loss of control…[2]”
44%
Loss of Control in Flight
System/Component (Powerplant)
15%
14%
Collision With Objects or Terrain
9%
System/Component (Non-Powerplant)
6%
Fuel Related
3%
Weather Related
Midair Collision
2%
Loss of Control on Ground
2%
Unknown
1%
Low Altitude Operation
1%
0%
Data compiled from 2001 - 2010
10%
20%
30%
40%
50%
[2] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22-May-2012.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Project Scope
Out-of-Scope
In-Scope
FAA Governed non Amateur Built Experimental
Aircraft and non Experimental Light Sport Aircraft:
FAA Governed E-AB and ELSA Experimental
Aircraft:
-
-
11.2 ± 0.1% of all GA aircraft (2012)
23,474 total aircraft (2012)
E-AB Powerplant Accidents:
E-AB Loss of Control in Flight Accidents:
-
1.5 ± 0.1% of all GA aircraft (2012)
3,240 total aircraft (2012)
-
44% of all fatal E-AB accidents (2001-2010)
15% of all fatal E-AB accidents (2001-2010)
General Aviation Aircraft
89%
E-AB and ELSA
11%
Non E-AB and ELSA
[2] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22-May-2012.
[5] “2013 General Aviation Statistical Databook & 2014 Industry Outlook.” General Aviation Manufacturers Association, Jan-2014.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Problem and Need
Closing the Gap
Loss of Control
in Flight
Lack of Aircraft
Parameterization
Problem
E-AB Aircraft vs. GA Fleet
350% > Phase I Accidents
238% > Fatalities
“[D]ata obtained from…recording devices can significantly
enhance…the monitoring of parameters important to the
continuing airworthiness of the E-AB aircraft, provided that they are
demonstrated to be precise and reliable, record at sufficiently high
sampling rates, and are easily downloaded by the aircraft owner. [2]”
(2012)
NTSB recommended instrument
Dynon EFIS-D100: $2,600 + installation
NTSB: National Transportation Safety Board
High E-AB
Fatality Rate
+
High Recording and
Analysis Cost
Need
Need for a Low-Cost Flight Data
Recording and Analysis System
[1] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22-May-2012.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Proposed Phase I Testing Procedure
Pre-Flight: Pilot puts device in plane and executes pre-determined flight plan
Device
Flight
Plan
Pilot activates device prior to
entering maneuvers while in flight
Post-Flight: After landing, pilot connects device to computer for post-flight analysis
Device
Raw data is run through
analysis software and
outputs flight characteristics
Post-Simulation: Pilot uses simulation data to generate training record and handbook
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Prototype
Pre-Flight: Pilot puts device in plane and executes pre-determined flight plan
Device
Flight
Plan
Pilot activates device prior to
entering maneuvers while in flight
Post-Flight: After landing, pilot connects device to computer for post-flight analysis
Device
Raw data is run through
analysis software and
outputs flight characteristics
Post-Simulation: Pilot uses simulation data to generate training record and handbook
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Pilot’s Operating Handbook
Rate of Climb for Quicksilver GT500
Mitigating loss of
control in flight risk
“To steep a climb on takeoff [2]”
Obtaining the data
Climb 1,000 ft at 100% engine power with 0° and 10° flaps
Measurements required
3-axis velocity derived from 3-axis position
Rate of Climb
VERTICAL VELOCITY (FPM)
750
700
650
600
550
500
10° Flaps
0° Flaps
450
400
0
500
1000
1500
2000
2500
ALTITUDE (FT)
[2] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22-May-2012.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
3000
Sink Rate for GT500
Mitigating loss of
control in flight risk
“Inadequate airspeed [2]”
Obtaining the data
Descend 1,000 ft at set velocities
Measurements required
3-axis velocity derived from 3-axis position
VERTICAL VELOCITY (FPM)
Rate of Sink
1,500
1,400
1,300
1,200
1,100
1,000
900
800
700
600
50
55
60
65
70
75
INDICATED AIRSPEED (MPH)
[2] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22-May-2012.
[7] John Lowry, Performance of Light Aircraft. AIAA (American Institute of Aeronautics & Ast, 1999.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
80
Stall Speed for GT500
Mitigating loss of
control in flight risk
“Inadequate airspeed [2]”
Obtaining the data
Enter bank turn with flaps set, and reduce velocity until stall
Measurements required
3-axis velocity derived from 3-axis position
Bank angle of aircraft, and force applied to pilot
INDICATED AIRSPEED (MPH)
Stall Speed
54
0° Flaps
52
10° Flaps
20° Flaps
30° Flaps
50
48
46
44
42
40
0
10
20
30
40
50
BANK ANGLE (DEGREES)
[2] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22-May-2012.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
60
Device
Flight Monitoring Device Value Hierarchy
Monitoring
Suitability
.250
Sensitivity
.500
Usability
.500
Range
.500
Accelerometer
.087
Accelerometer
.250
Gyroscopic
.087
Gyroscopic
.250
Barometric
.435
Barometric
.500
Portability
.250
Data Analysis
.333
Battery Life
.400
Device Interaction
.250
Data Storage
.500
Device Placement
.417
Weight
.100
Global Positioning
.304
Variability
.087
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Low-Cost Monitoring Device Alternatives
Raspberry Pi
Microprocessor
Arduino
Microcontroller
Capable of reading and writing
real-time IMU sensor data for
post-flight analysis
iPhone 6
Smartphone App
Makes use of the iPhone 6’s
integrated IMU’s, GPS, and
barometer for both in-flight and
post-flight analysis
On-board processing enables in-flight
reading, writing, and calculation of
data for post-flight analysis
Configured with:
Arduino Mega
Adafruit 10 DOF IMU board
GPS Data logger
Hardware Cost - $105
Configured with:
Stock configuration
Hardware Cost - $650
Raspberry Pi
Adafruit 10 DOF IMU board
5” Touch-screen display
Adafruit GPS
Hardware Cost - $175
IMU: Inertial Measurement Unit
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Ranking of Monitoring Alternatives
Portability
Usability
Suitability
Arduino w/ GPS
Arduino
Raspberry Pi w/ GPS
iPhone 6
Raspberry Pi
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
Utility
1.00
0.98
Arduino w/ GPS
0.96
Utility
0.94
Arduino
0.92
0.90
0.88
Raspberry Pi w/ GPS
0.86
iPhone 6
0.84
Raspberry Pi
0.82
$-
$100.00
$200.00
$300.00
$400.00
$500.00
$600.00
Cost ($)
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
$700.00
Simulation and Requirements
Design of Experiment (Simulation)
Suitability
3-Axis Accelerometer
3-Axis Gyroscope
GPS (for latitude and longitude)
Barometer
Data Recorder
-----------
Maintainability
-----
Device Reliability
Device Availability
Portability
Battery Life
Data Storage
Static Random Access Memory (SRAM)
Weight
---------
Interface
File Format
---
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Design of Simulation
Inputs
Outputs
Navigation and Sensor Model
Device Error:
Device Parameters:





GPS (x,y) Accuracy
GPS(z) Accuracy
Accelerometer Sensitivity
Gyroscopic Sensitivity
Barometer Sensitivity
RNG Seed:




GPS
Accelerometer
Gyroscope
Barometer
Configuration:
 Iterations
 Sample Rate
 Flight Plan
Raw Data
Computation
XML
Flight
Plan
Analyze Raw
Data and
Reduce Noise
 Position
 Linear Acceleration
 Rotational Acceleration
Graphs:
 Uncorrected Position,
Acceleration, Gyro
 Corrected Position,
Acceleration, Gyro
 Actual Position,
Acceleration, Gyro
Statistical Data:
 Histograms of Error
 Confidence Intervals
Files:
 Original XML
 Condensed XML
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Analyze Raw Data and Reduce Noise
Line Smoothing Algorithm:
Raw Data
Computation
XML
Analyze Raw
Data and
Reduce Noise
Time (s):
Flight
Plan
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
Position (m):
3
5
8
9
10
12
14
15
18
21
Array Index:
0
1
2
3
4
5
6
7
8
9
(12+14+15+18+21) / 5 = 16
(3+5+8+9+10) / 5 = 7
1.0
2.0
7
16
0
1
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Sensitivity Analysis
1.6
Error (m/s^2)
1.4
Condensed
Smoothed
1.2
Raw
1.0
y = 6.7672x + 0.0144
0.8
0.6
0.4
y = 2.9x + 0.0268
0.2
0.0
0.01
0.03
0.05
0.07
0.09
0.11
0.13
0.15
0.17
0.19
Accelerometer Sensitivity (% of actual acceleration)
Error (degrees/second)
60.0
50.0
Smoothed
Condensed
40.0
Raw
y = 245.3x + 0.1642
30.0
20.0
y = 108.18x + 0.2857
10.0
0.0
0.01
0.03
0.05
0.07
0.09
0.11
0.13
0.15
0.17
0.19
Gyroscopic Sensitivity (% of actual rotational velocity)
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Device Subsystem Requirements
Suitability
3-Axis Accelerometer
3-Axis Gyroscope
GPS (for latitude and longitude)
Barometer
Data Recorder
Minimum range 20 m/s2 with max. 0.16% sensitivity
Minimum range 360° with max. 0.08% sensitivity
Maximum 6 meters sensitivity
Minimum .25 m operable range -30° to 50°C [2]
Minimum 5 readings per second [3]
Maintainability
Device Reliability
Device Availability
Minimum 96% with 5-year lifespan
Minimum 50,000 hours (MTBF)
Portability
Battery Life
Minimum 140 mAh (2 hours of battery life)
Data Storage
Minimum 76 MB (2 hours of raw data capacity)
Static Random Access Memory (SRAM)
Minimum 8 kB
Weight
Maximum 1 lb.
Interface
File Format
Extensible Markup Language (XML)
[3] “AC 90-101A: Approval and Guidance for RNP Procedures with AR.” Federal Aviation Administration, 23-Feb-2011.
[4] “TSO-C4C: Bank and Pitch Instruments.” Federal Aviation Agency, 01-Apr-1959.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Cost-Modeling and Results
Cost Model
TOTAL COST:
Prototyping and Production
Order Prototype Components
Assemble Prototype Components
Bench Test Prototype
Flight Testing
Production Kit Assembly
Marketing
Software Modules
Real-Time Device
Flight Plan Generator
Raw Data Analyzer
POH Generator
Training Records
*SLOC: source lines of code
$1.6 Million
Cost
$1,500
$1,000
$9,500
$5,000
$270,000
$100,000
$387,000
Platform
SLOC
Cost / Line
Total Cost
C++
Java
Java
Java
Java
250
3000
3000
5000
2000
$92
$92
$92
$92
$92
$23,000
$276,000
$276,000
$460,000
$184,000
$1,219,000
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Units Until Return on Investment (ROI)
$4,000,000.00
Break-Even:
800 Units Sold
$3,000,000.00
Break-Even:
1,067 Units Sold
Profit ($)
$2,000,000.00
$1,000,000.00
Break-Even:
1,600 Units Sold
$0.00
Break-Even:
3,200 Units Sold
-$1,000,000.00
$500
$1,000
$1,500
$2,000
-$2,000,000.00
0
500
1000
1500
2000
2500
Units Sold
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
3000
Stakeholder Interaction
Request for certification
Evaluates & provides certification
Requests for membership
Evaluates, inspects, approves aircraft &
builder
Other Aircraft
Associations
Experimental
Aircraft
Association (EAA)
Provides support & information
Provides avionics kit
Purchases avionics kit
Provides support
& Information
Provides
product
information
E-AB / ELSA
Builders
Requests membership
Avionics
Manufacturers
Federal Aviation
Administration
(FAA)
Provides advocacy
for the EAA community
Set regulations for
measurement requirements
Accepts or declines recommendations
Requests for inspection
& certification
Investigates accidents &
recommends solutions
Provides support & information
Requests membership
Provides support & information
Requests membership
Certified Pilots
National
Transportation
Safety Board
(NTSB)
Provides advocacy for the general aviation community
Provide product information
In-Scope
Out-of-Scope
Department of Systems Engineering and Operations Research – Senior Design - 2014
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Currently Available Monitoring Systems
MEMS: Microelectromechanical System
AHRS: Attitude Heading and Reference System
Dynon EFIS-D100
SBG Ellipse-N
Appareo Stratus 2
Garmin VIRB Elite
AHRS fits directly into
instrument panel for
in-flight analysis
MEMS driven device
connects to computer
for in-flight analysis
AHRS connects to iPad
or iPhone via Wi-Fi for
in-flight analysis
Records aircraft
instruments for manual
post-flight analysis
$2,600 + installation
$4,000
$900
Data recording not available
Data recording not available
$280
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Ranking of SYSTEM Alternatives
Portability
Usability
Suitability
Arduino Based System
Stratus 2
Garmin VIRB Elite 270
SBG Ellipse-N
Dynon EFIS-D100
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Utility
Utility
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
Arduino Based System
Stratus 2
SBG Ellipse-N
Garmin VIRB Elite 270
Dynon EFIS-D100
$-
$500.00
$1,000.00
$1,500.00
$2,000.00
$2,500.00
$3,000.00
$3,500.00
$4,000.00
Retail Price ($)
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
$4,500.00
1
Ranking of SYSTEM Alternatives
Portability
Usability
Suitability
Arduino Based System
Stratus 2
Garmin VIRB Elite 270
SBG Ellipse-N
Dynon EFIS-D100
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Utility
Utility
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
Arduino Based System
Stratus 2
SBG Ellipse-N
Garmin VIRB Elite 270
Dynon EFIS-D100
$-
$500.00
$1,000.00
$1,500.00
$2,000.00
$2,500.00
$3,000.00
$3,500.00
$4,000.00
Retail Price ($)
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
$4,500.00
1
easyPOH
Pre-Flight: Pilot mounts Garmin in plane and executes flight plan generated by easyPOH
Flight
Plan
Pilot activates device prior to
entering maneuvers while in flight
Post-Flight: Pilot manually enters data from Garmin recording into easyPOH
Raw data is run through
analysis software and
outputs flight characteristics
Post-Simulation: Pilot uses easyPOH to manually compile training record and handbook
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Conclusion and Recommendation
Portability
Arduino Based System
Usability
Suitability
Garmin w/ easyPOH
Stratus 2
Garmin VIRB Elite 270
SBG Ellipse-N
Dynon EFIS-D100
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
Utility
Utility
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
Arduino Based System
Garmin w/ easyPOH
SBG Ellipse-N
Stratus 2
Garmin VIRB Elite 270
Dynon EFIS-D100
$-
$500.00
$1,000.00
$1,500.00
$2,000.00
$2,500.00
$3,000.00
$3,500.00
$4,000.00
Cost ($)
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
$4,500.00
References
[1] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22May-2012.
[2] “AIR-2030 - Light-Sport Aircraft Airworthiness Certification.” Federal Aviation Administration, 08-Jul-2013.
[3] “AC 90-101A: Approval and Guidance for RNP Procedures with AR.” Federal Aviation Administration, 23-Feb-2011.
[4] “TSO-C4C: Bank and Pitch Instruments.” Federal Aviation Agency, 01-Apr-1959.
[5] “Air Pressure at Altitude Calculator,” MIDE. [Online]. Available: http://www.mide.com/products/slamstick/airpressure-altitude-calculator.php.
[6] Accident Database. Aircraft Owners and Pilots Association, 2015.
[7] John Lowry, Performance of Light Aircraft. AIAA (American Institute of Aeronautics & Ast, 1999.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Agenda
Backup Slides
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Experimental Aircraft Association
Founded in 1953
180,000 members worldwide
Established EAA Flight Advisor Program:
- “Designed to increase sport aviation safety… [for] EAA members who may be
preparing to fly unfamiliar aircraft [1]”
The EAA serves the community by:
-
“Encouraging affordable flying in a local environment.”
[1] “EAA Mission & Vision,” Experimental Aircraft Association. [Online]
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
E-AB and ELSA Certification Process
Build Aircraft
Register the aircraft with the FAA
First 40 hours of flight
Develop pilot’s operating handbook
Identify and mark the aircraft
Apply for Airworthiness Certificate
Continued airworthiness
Annual condition inspection
Phase I Testing:
Flight test the aircraft
Phase II Testing:
Operate and maintain the aircraft
[4] “AC 20-27G: Certification and Operation of Amateur-Built Aircraft.” Federal Aviation Administration, 30-Sep-2009.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
E-AB Accidents by Phase of Flight (2011)
Loss of control in flight:
“…insufficient takeoff speed, early rotation, or too steep a climb on
takeoff led to aerodynamic stalls and loss of control. Inadequate
airspeed…also led to aerodynamic stall and loss of control…[2]”
9% of fatalities
Takeoff
24% of fatalities
Initial Climb
22% of fatalities
En Route
Maneuvering
22% of fatalities
15% of fatalities
Approach
8% of fatalities
Other Fatal
0
10
Fatal
20
30
40
Total
50
Number of Accidents
[2] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22-May-2012.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
60
E-AB Accidents by Category
Loss of control in flight:
“…insufficient takeoff speed, early rotation, or too steep a climb on
takeoff led to aerodynamic stalls and loss of control. Inadequate
airspeed…also led to aerodynamic stall and loss of control…[2]”
23%
Loss of Control in Flight
System/Component (Powerplant)
23%
12%
Collision With Objects or Terrain
11%
Loss of Control on Ground
10%
Fuel Related
9%
System/Component (Non-Powerplant)
6%
Runway Contact
2%
Weather Related
Runway Excursion
1%
Midair Collision
1%
0%
Data compiled from 2001 - 2010
5%
10%
15%
20%
25%
[2] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22-May-2012.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Annual Increase of E-AB Aircraft
Certified E-AB Aircraft
30000
E-AB aircraft are increasing at a rate of 671 aircraft per year
25000
20000
15000
10000
5000
0
Percent of General
Aviation (GA) Fleet
1994
12.0%
1996
1998
2000
2002
2004
2006
2008
2010
2012
E-AB aircraft are increasing at a rate of .25% annually vs. the General Aviation (GA) Fleet
10.0%
8.0%
6.0%
4.0%
2.0%
0.0%
1994
1996
1998
2000
2002
2004
2006
2008
2010
Time (years)
[4] “2013 General Aviation Statistical Databook & 2014 Industry Outlook.” General Aviation Manufacturers Association, Jan-2014.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
2012
Cruise Performance for GT500
Mitigating loss of
control in flight risk
“Inadequate airspeed [2]”
Obtaining the data
Maintain level flight at a fixed rpm and altitude
Measurements required
3-axis velocity derived from 3-axis position
5700
Engine RPM
5500
1000 ft.
5300
2000 ft.
3000 ft.
4000 ft.
5100
4900
4700
4500
70
75
80
85
90
Airspeed (mph)
[2] “NTSB/SS-12/01: The Safety of Experimental Amateur-Built Aircraft.” National Transportation Safety Board, 22-May-2012.
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
95
Lift Coefficient
1.60
Coefficient of Lift
1.40
1.20
1.00
0.80
0.60
0.40
0.20
0.00
40
45
50
55
60
65
70
75
80
85
90
95
Velocity (mph)
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
100
V = 70 mph
V = 90 mph
Wind speed: 20
mph
V = 110
mph
5/12/2015
V = 90 mph
Raw Data Computation
Arc Length Formula:
Raw Data
Computation
Flight
Plan
XML
Analyze Raw
Data and
Reduce Noise
Model
Controller
event
request
GPS
Microcontroller
event
Accelerometer
event
XML Writer
Utility
raw data
Gyroscope
Barometer
Each sensor executes
independently and concurrently
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Analyze Raw Data and Reduce Noise
Line Smoothing Algorithm:
Raw Data
Computation
Time (s):
Flight
Plan
XML
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
Position (m):
3
5
8
9
10
12
14
15
18
21
Array Index:
0
1
2
3
4
5
6
7
8
9
Analyze Raw
Data and
Reduce Noise
raw
data
XML Reader
Utility
(12+14+15+18+21) / 5 = 16
(3+5+8+9+10) / 5 = 7
data
request
raw data
Controller
Simulation
Controller
compressed
data
raw data
1.0
2.0
7
16
0
1
Model
Noise Reduction
Algorithm
XML Reader
Utility
compressed
data
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Output Analysis
Position Error (m):
Uncorrected Data
Velocity Error (m/s):
Position Error (m):
Compressed Data
Velocity Error (m/s):
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Output Analysis
Position Error (m):
Uncorrected Data
Velocity Error (m/s):
Position Error (m):
(105%)
(322%)
Compressed Data
Velocity Error (m/s):
(980%)
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Portability Goal Values
Battery Life
Data Storage Capacity
Weight
Mid Value:
120 min
Mid Value:
2 GB
Mid Value:
655 grams
Range of Variation:
0 to 1400 min
Range of Variation:
0 to 64 GB
Range of Variation:
47 to 1360 grams
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Suitability Goal Values: Measurement Range
Accelerometer Range
Barometer Range
Gyroscopic Range
Mid Value:
±2g
Mid Value:
3000 m
Mid Value:
360 degrees/sec
Range of Variation:
± 0 to ± 16 g
Range of Variation:
0 to 9144 m
Range of Variation:
0 to 2000 degrees/sec
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Suitability Goal Values: Measurement Sensitivity
Accelerometer Sensitivity
Mid Value:
0.1 % error
Range of Variation:
0 to 0.35 % error
GPS Accuracy
Mid Value:
6 m error
Range of Variation:
0 to 8 m error
Barometer Sensitivity
Mid Value:
15 m error
Range of Variation:
0 to 30 m error
Variable Sensitivity
Mid Value:
2 additional settings
Range of Variation:
0 to 3 additional settings
Gyroscopic Sensitivity
Appareo Stratus 2:
Arduino:
Arduino w/ GPS:
Dynon EFIS-D100:
Garmin Virb:
Raspberry Pi:
Raspberry Pi w/ GPS:
SBG Ellipse-N:
iPhone 6:
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
.500
.766
.766
.500
.500
.766
.766
.715
.766
Discrete Value Function Descriptions
Data Analysis
0
None
1
Manual: calculations must be done manually from device recording
2
External Software: calculations completed by external software
3
On-Board Processor: calculations performed on device processor
Device Interaction
0
None
1
Screen: touch-screen display
2
Button: device mounted push-button
3
Extended Button: push-button attached to extended cord
Device Placement
0
Panel-Mounted: device must be mounted in dash
1
Position Mounted: device must be mounted in a specified position
2
Level Mounted: device must be mounted level with the aircraft
3
Free Mounted: device may be mounted in any position within aircraft
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Usability Goal Values
Data Analysis
Device Placement
On-Board Processing:
External Software:
Manual:
None:
Free Mounted:
Level Mounted:
Position Mounted:
Panel Mounted:
1.000
0.857
0.286
0.000
1.000
0.714
0.143
0.000
Device Interaction
Extendable Push Button:
Non-Extendable Push Button:
Touch Screen Display:
None:
1.000
0.714
0.143
0.000
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Project Cost Analysis
100000.0
90000.0
80000.0
Cost (USD)
70000.0
60000.0
50000.0
40000.0
30000.0
20000.0
10000.0
Planned Value (PV)
Actual Cost (AC)
Earned Value (EV)
0.0
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
Time (weeks)
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
37
Performance Index
1.20
1.10
Performance Index
1.00
0.90
0.80
0.70
0.60
Cost Performance Index (CPI)
0.50
1
2
3
4
5
6
7
8
Schedule Performance Index (SPI)
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Time (weeks)
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Work Breakdown Structure
Flight Recording
System
1.0
Project
Management
1.1
Project Plan
1.1.1
Project Schedule
1.1.2
Budget
1.1.3
CONOPS
Requirements
Data Analysis
Simulation
1.2
1.3
1.4
1.5
Fundamental
Requirements
Gap Analysis
Aircraft Model
1.4.1
1.5.1
Context Analysis
1.2.1
Problem
Statement
1.2.2
Stake Holder
Analysis
1.2.3
1.3.1
Means
Requirements
1.3.2
Risk Analysis
1.4.2
Design
Alternatives
Research/Develop
ment
Deliverables
1.6
1.7
1.8
Sensitivity
Analysis
1.6.1
Software
Briefings
1.7.1
1.8.1
Develop
Trade-off Analysis
Hardware
Faculty
1.5.1.1
1.6.2
1.7.2
1.8.2
Test
Cost/Utility
Background
Conferences
1.5.1.2
1.6.3
1.7.3
1.8.3
EVM
Need Statement
Gather Results
Final
1.1.4
1.2.4
1.5.1.3
1.8.4
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System
Budget
Rates and Estimates
Estimated Hours
2,000
Equipment Cost
$500.00
Direct Labor
$20.00/hr
Overhead
$20.00/hr
G&A
$4.00/hr + $100.00
Fringe
$2.00/hr
Fee
$2.00/hr
Fully Burdened
Planned Cost
$48.00/hr + $600.00
$96,600.00
Department of Systems Engineering and Operations Research – Senior Design - 2015
Design of a Low-Cost General Aviation Flight Data Recording and Analysis System