Today’s commercial and military aircrafts are increasingly complex. Proving out systems, sub-system and components, before an aircraft’s initial flight, requires a sophisticated test system to ensure proper design, function, and durability. Wineman Technology’s iron bird test systems help aircraft suppliers and OEMs increase flight safety and long-term costs of operation.
Wineman Technology brings decades of exceptional focus on technical expertise, quality, service, and support in aerospace testing. Recent iron bird projects include turbine engine simulation, flight control labs, and hydraulic system integration test rigs.
When simulating a full iron bird, motors are used to simulate the output of the turbines. This provides a safe environment for testing, evaluating, and powering these components.
Example Project Solution: Our last program for a major aircraft manufacturer included two AC motors and the associated control system that were capable of continuous operation at an output of 350 HP at 18,000 RPM, and included an intermediate shaft that tied directly into the gearboxes for each of the two turbines. These gearboxes drove the primary pump that supplied the hydraulic pumps, which in turn provided power to the actuator pump and motors that powered all of the flight control surfaces and landing gear.
These systems integrate and test the avionics with the control of the flight surfaces. Not only do they provide an accurate simulated loading on the flight surface as would be seen during flight, but they also move each of the flight surfaces in reaction to these forces.
Example Project Solution: A major corporation in space exploration contracted Wineman Technology to create a hardware-in-the-loop (HIL) flight surface actuation simulator to verify the design and performance for the flight control system for a commercial transport spacecraft. Wineman Technology built a flight control integration laboratory (FCIL) control system for testing the lower body flap, which controls pitch and is one out of seven total control surfaces for the complete iron bird. The system included hydraulic actuators controlled by INERTIA software and PXI hardware.
These automated test rigs evaluate aircraft hydraulic sub-systems or components related to controlling the flight surfaces and landing gear systems. The HSITR provides actual aircraft fluid to these components, as well as the pump that delivers the hydraulics at the required pressure and flow rate.
Example Project Solution: One of the simulation systems we designed and built for a global leader of aerospace systems and components tested all components in the sub-systems provided by the client for the 787 flight actuators, pumps, and motors. These systems were interconnected and assembled on a frame with all hose lengths identically matching those in the aircraft. They could “fly” the airplane and ensure complete functionality. View video demo
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