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The experimental procedure employed to define the natural modes of vibration of the 747 Shuttle Carrier Aircraft and Space Shuttle Orbiter mated configuration is described. A discussion of test results and comparison to structural analysis results is also included. Random transient signals were used as inputs to electromagnetic shakers to provide excitation to the mated vehicle test configuration. Acceleration signals were processed via the Fast Fourier Transform algorithm. Magnitude and phase transfer functions were formed and processed to produce modal frequencies, damping, and modal displacements.

Commonality of flight deck geometry, airplane subsystems, controls and displays, airplane handling characteristics and crew procedures between 757/767 offers the potential for common pilot type rating on different airplanes with like crew complement: 2-crew 757/767's and 3-crew 757/767's.

The 757/767 Flight Management System provides the initial operational implementation of an integrated guidance, control and display equipments based upon digital technology for commercial transport airplanes. The applied equipments are based upon the new ARINC 700 series characteristics developed by the Industry over the past five years. These characteristics were developed on the basis of limited operational experience with selected elements of the system and upon R&D efforts within the Industry. The System features automatic/manual flight profiles for optimum economics, all weather landing including rollout guidance, electronic primary flight instruments based on color (shadow mask) CRTs, inertial attitude/velocity reference based upon laser gyros, improved caution/warning and other improved performance/functional features. The system also provides significant improvements in line and shop maintenance features.

The Automated Spar Assembly Tool (ASAT II) at the Everett, Washington, 777 Boeing manufacturing facility could be the largest automated fastening cell in the commercial aircraft industry. Based on the success of the ASAT I, Boeing's 767 spar assembly tool, the 285-foot long ASAT II cell was needed to accurately position and fasten the major spar components (chords and web), then locate and fasten over 100 components (ribposts and stiffeners) to assemble the 777 forward and rear wing spars. From its inception in 1990 to the first drilled hole in January 1993 and through two years of spar production, the more advanced ASAT II has proven to be a greater success than even its 767 ASAT I predecessor. This massive automated fastening system consistently provides accurate hole preparation, inspection, and installation of three fastener types ranging from 3/16 inches to 7/16 inches in diameter.

Wing panels for Boeing's new 777 airplane are assembled using fastening machines called Wing Fastener Systems (WFS). Compared to the wing riveting machines currently used to squeeze rivets for other airplane models, the 777 WFS provides significantly more features in that it also installs two part fasteners, collects process data for Statistical Process Control analysis, plus other functions. Historically, new operators for wing riveting machines have needed six months of on-the-job training to achieve basic qualification. Because of the increased functionality of the 777 WFS, an eight to nine month O.J.T. requirement was anticipated. Training requirements were further compounded by our need for up to thirty qualified operators in a relatively short time frame and a maintenance staff thoroughly trained in the new control architecture. Boeing's response to this challenge was to use simulation methods similar to those used to train pilots for our customer airlines.

This paper describes the wing and engine ice protection system, used on all 777 aircraft. The 777 ice protection system is unique in two ways: it has an advanced control system which minimizes aircraft power consumption. In addition, the system was procured by the prime contractor, Boeing, as a fully integrated subsystem from a single supplier.

Fabrication and assembly of the majority of control surfaces for Boeing’s 777X airplane is completed at the Boeing Defense, Space and Security (BDS) site in St. Louis, Missouri. The former 777 airplane has been revamped to compete with affordability goals and contentious markets requiring cost-effective production technologies with high maturity and reliability. With tens of thousands of fasteners per shipset, the tasks of drilling, countersinking, hole inspection, and temporary fastener installation are automated. Additionally and wherever possible, blueprint fasteners are automatically installed. Initial production is supported by four (4) Electroimpact robotic systems embedded into a pulse-line production system requiring strategic processing and safeguarding solutions to manage several key layout, build and product flow constraints.

Flight control technology for 8000 psi has emerged almost simultaneously with new fire-resistant hydraulic fluids, such as MIL-H-83282 and CTFE. A proliferation of industry recommendations has resulted in a wide variety of mechanisms for solving associated actuator design problems, including tighter clearances, special seals, finishes, materials, and many others. As there are few common agreements on the issues, an extensive three-phase test program was undertaken to attempt to corroborate some of these approaches or suggest others that may be better or more cost effective.

An 8000 psi test program was conducted to resolve conflicts and issues surrounding the use of CTFE and MIL-H-83282 fluid with vented and unvented actuator rod seals. Each of the four possible combinations had unique problems and each responded to appropriate corrections including new backup rings designed to operate with standard clearances. It was concluded that all combinations were viable within certain limits. Advantages and disadvantages of each configuration were identified and specific recommendations made for both dynamic and static seals within the context of existing military specifications.

In 1995, the Naval Research Laboratory (NRL) began a program to investigate whether a 90 Ah dependent pressure vessel (DPV) NiH2 battery pack could be a lower volume replacement for a 90 Ah NiH2 IPV spacecraft battery. Nickel Hydrogen (NiH2) dependent pressure vessel (DPV) battery cells are presumed to offer all the features of the NiH2 IPV battery cell with considerably less volume. To achieve this reduction in volume, the DPV cell utilizes a canteen shaped pressure vessel with reduced thickness wall, flat sides and curved ends. The cells can be packaged similar to prismatic nickel cadmium battery cells. Moreover, like NiCd cells, a fully charged DPV cell must rely upon an adjacent battery cell or structure for support and to maintain pressure vessel integrity. Seventeen 90 Ah NiH2 DPV cells were delivered to NR in 1998 for qualification tests. An eleven-cell half battery pack was manufactured and tested to validate the advantages of the DPV design.

The 912 engine is a well known 4-cylinder horizontally opposed 4-stroke liquid-/air-cooled aircraft engine. The 912 family has a strong track record: 40 000 engines sold / 25 000 still in operation / 5 million flight hours annually. 88% of all light aircraft OEMs use Rotax engines. The 912iS is an evolution of the Rotax 912ULS carbureted engine. The “i” stands for electronic fuel injection which has been developed according to flight standards, providing a better fuel efficiency over the current 912ULS of more than 20% and in a range of 38% to 70% compared to other competitive engines in the light sport, ultra-light aircraft and the general aviation industry. BRP engineers have incorporated several technology enhancements. The fully redundant digital Engine Control Unit (ECU) offers a computer based electronic diagnostic system which makes it easier to diagnose and service the engine.

The 94 GHz MMW airborne radar system that provides a runway image in adverse weather conditions is now undergoing tests at Wright-Patterson Air Force Base (WPAFB). This system, which consists of a solid state FMCW transceiver, antenna and digital signal processor, has an update rate of 10 times per second, 0.35° azimuth resolution and up to 3.5 meter range resolution. The radar B scope (range versus azimuth) image, once converted to C scope (elevation versus azimuth), is compatible with the standard TV presentation and can be displayed on the Head Up Display (HUD) or Head Down Display (HDD) to aid the pilot during landing and takeoff in limited visibility conditions.

In the course of CRYOSYSTEM phase B (development phase) financed by the European Space Agency, AIR LIQUIDE (France) and Astrium Space Infrastructure (Germany) have developed an optimized design of a −183°C freezer to be used on board the International Space Station for the freezing and storage of biological samples. The CRYOSYSTEM facility consists of the following main elements: - the CRYORACK, an outfitted standard payload rack (ISPR) accommodating up to three identical Vial Freezers - the Vial Freezer, a dewar vessel capable of fast and ultra-rapid freezing, and storing up to approximately 900 vials below −183°C; the dewar is cooled by a Stirling machine producing > 6 W at 90 K. The Vial Freezer is operational while accommodated in the CRYORACK or attached to the Life Science Glovebox (LSG). One CRYORACK will remain permanently on-orbit for several years while four Vial Freezers and two additional CRYORACKs support the cyclic upload/download of samples.

In the frame of the CRYOSYSTEM A-phase study financed by the European Space Agency, AIR LIQUIDE (France) and ORBITAL HYDRAULIC-BREMEN (Germany) have been studying a -183°C freezer to be used on-board the International Space Station for freezing and storing biological samples.

U S Army tactical vehicles are equipped with a wide range of electrical and electronic equipment to support a variety of missions. This equipment typically requires AC input power with varying voltage, power and phasing requirements. Presently, separate inverters with different voltage, power, and phase ratings are necessary to power the equipment, which imposes maintenance and support problems during field deployments. Avionic Instruments Inc. has developed a scalable inverter system that operates from 28V vehicular power and provides outputs that can easily be configured for a variety of load requirements.

A new concept of Head Up Display is presented, using the windshield as a transparent screen. This breakthrough technology does not need the use of complex combiner, bulky optics and overhead projection unit. The novel system uses several holographic optical elements to perform a 3D stereoscopic display, with the ability to present floating graphical objects in a large field of view. Augmented Reality display will be possible, increasing considerably the User Experience and situational awareness, without the need of wearing a bulky and complex Head Mounted Display.

A 3D Stereoscopic Head-Up Display (HUD) using direct projection on a transparent screen is presented. Symbol incrustation in conformity with the landscape is performed through the use of simulated collimation offering a large eye-box, in excess of conventional HUD. The use of spectral glasses for our transparent screen was decided as most commonly used polarizing or active glasses were not adapted. Furthermore it gave ususeful green laser attack protection.

Traditional User/Maintenance Manuals provide useful information when dealing with simple machines. However, when dealing with complex systems of systems and highly miniaturized technologies, like UAVs, or with machines with millions of parts, a commercial aircraft is a case in point, new technologies taking advantage of Augmented Reality can rapidly and effectively support the maintenance operations. This paper presents a User/Maintenance Manual based on Augmented Reality to help the operator in the detection of parts and in the sequence to be followed to assemble/disassemble systems and subsystems. The proposed system includes a handheld device and/or an head mounted display or special goggles, to be used by on-site operators, with software management providing data fusion and overlaying traditional 2D user/maintenance manual information with an augmented reality software and appropriate interface.

In low earth orbit satellite applications, spacecraft power is provided by photovoltaic cells and batteries. Unfortunately, use of batteries present difficulties due to their poor energy density, limited cycle lifetimes, reliability problems, and the difficulty in measuring the state of charge. Flywheel energy storage offers a viable alternative to overcome some of the limitations presented by batteries. FARE, Inc. has built a 50 Wh flywheel energy storage system. This system, called the Open Core Flywheel, is intended to be a prototype energy storage device for low earth orbit satellite applications. To date, the Open Core Flywheel has achieved a rotational speed of 26 krpm under digital control.