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The Helios Prototype vehicle was one of several remotely piloted
aircraft funded and developed by NASA under the Environmental
Research Aircraft and Sensor Technology (ERAST) project, and
managed by NASA's Dryden Flight Research Center (DFRC). This
vehicle was a proof-of-concept, propeller-driven, flying wing built
and operated by AeroVironment, Inc. The vehicle consisted of two
configurations. One configuration, designated HP01, was designed to
operate at extremely high altitudes using batteries and
high-efficiency solar cells spread across the upper surface of its
247-foot wingspan. On 13 August 2001, this aircraft configuration
reached an altitude of 96,863 feet, a world record for sustained
horizontal flight by a winged aircraft. The other configuration,
designated HP03, was designed for long-duration flight. The plan
was to use the solar cells to power the vehicle's electric motors
and subsystems during the day and to use a modified commercial
hydrogen-air fuel cell system for use during the night. The vehicle
was also equipped with batteries as a backup source of power. The
aircraft design used wing dihedral, engine power, elevator control
surfaces, and a stability augmentation and control system to
provide aerodynamic stability and control. On 26 June 2003, HP03-2
took off at 10:06am local time from the Navy's Pacific Missile
Range Facility (PMRF) located on the island of Kauai, Hawaii. The
aircraft was under the guidance of AeroVironment, Inc. (AV)
ground-based mission controllers. At that time the environmental
wind conditions appeared to be within an acceptable envelope, and
consisted of a wind shadow over and offshore from PMRF, bounded to
the north, south, and above by zones of wind shear and turbulence
separating this region from the ambient easterly trade-wind flow.
However, compared to previous solar-powered flights from PMRF,
HP03-2 was subject to longer exposure to the low-level turbulence
in the lee of Kauai due to the shallower climb out trajectory. The
vehicle's longer exposure to Kauai's lee side turbulence and lower
shear line penetration were superposed on what the Board now
recognizes as greater airplane sensitivity to turbulence and may
have been compounded by the apparent narrow corridor between the
shear lines noted by the chase helicopter observer. At 10:22am and
10:24am, the aircraft encountered turbulence and the wing dihedral
became much larger than normal and mild pitch oscillations began,
but quickly damped out. At about 30 minutes into the flight, the
aircraft encountered turbulence and morphed into an unexpected,
persistent, high dihedral configuration. As a result of the
persistent high dihedral, the aircraft became unstable in a very
divergent pitch mode in which the airspeed excursions from the
nominal flight speed about doubled every cycle of the oscillation.
The aircraft's design airspeed was subsequently exceeded and the
resulting high dynamic pressures caused the wing leading edge
secondary structure on the outer wing panels to fail and the solar
cells and skin on the upper surface of the wing to rip off. The
aircraft impacted the ocean within the confines of the PMRF test
range and was destroyed. The crash caused no other property damage
or any injuries to personnel on the ground. Most of the vehicle
structure was recovered except the hydrogen-air fuel cell pod and
two of the ten engines, which sank into the ocean. The root causes
of the mishap include: Lack of adequate analysis methods led to an
inaccurate risk assessment of the effects of configuration changes
leading to an inappropriate decision to fly an aircraft
configuration highly sensitive to disturbances, and Configuration
changes to the aircraft, driven by programmatic and technological
constraints, altered the aircraft from a spanloader to a highly
point-loaded mass distribution on the same structure significantly
reducing design robustness and margins of safety.
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