Evolution of Aircraft Test Equipment

Oct. 5, 2011 - PRLog -- Recently I had the opportunity to visit the Air Museum in Tillamook Oregon.  Now, I have visited many air museums throughout the world in the past. But on this particular day looking at the various airplanes caused me to reflect on the Evolution of Aircraft Test Equipment.


The first plane that caught my attention was a PT-7 Stearman. In its day the PT-7 Stearman was a magnificent performer. It was considered a high performance aircraft and only the hot shot pilots flew it. But, I thought, just how mechanically complicated was it? Did it require allot of component testing before installation and if it did what kind of testing could be accomplished on Bell Cranks and Pulleys. At a minimum, the control cables had to be tensioned but to measure the tension all you used was your hand and then you made sure the elevator, rudder and ailerons all moved in the right direction. There was no electronics of any sort and as for fuel components they were all confined to the engine. Of course, the engine was tested and probably taken to full power before it was installed but what kind of testing was performed? Certainly its full power output wasn’t determined because dynamometers didn’t exist yet. I’m sure it was taken to full throttle and if everything stayed together all was well. The bottom line is the real test bed was flying the airplane.


Then out of the corner of my eye I spotted a F4U-7 Corsair and a P-51D Mustang, now we’re talking airplanes. These World War 2 aircrafts were the masters of their respective air space. The Corsair made its mark in the South Pacific flying off aircraft carriers and small islands (“Ba Ba Blacksheep”) in support of the war with Japan. It was a work horse that took allot of punishment and still kept flying. Of course along with the Corsair were the Hellcat and Bearcat. Together they were a great representation of American Aircraft Technology.


The P-51D Mustang was a whole different story. There was no question, even today, that the Mustang was the Air Superiority Aircraft of its day. It could fly at more than 500 MPH and climb to altitudes at a rate never before achieved. The P-51 was responsible for moving the War on Germany to the Allies advantage. However, considering all this, what kind of and how sophisticated was the technology used in these advanced, for their day, aircraft? Flight control was still accomplished with bell cranks and cables and electronics was still at a minimum. Although there were dynamometers for engine testing the real proof of performance and reliability was flying the airplane.
Then I spotted an F-14 Tomcat, you know “Top Gun”. What an airplane for its day or any other day.  Faster then the speed of sound, variable-swept wing design and it could maneuver like a fighter jet. All this performance certainly couldn’t be accomplished with bell cranks and cables; this was the real deal of aircraft hydraulic flight control, electronics and fuel components. The most advanced and complex systems flying were designed for the F-14. This was not an aircraft that could be assembled and tested in the air without prior component performances verification.


Along with the design of the F-14 came the design of advanced hydraulic test equipment. The HCT-12 Universal Hydraulic Test stand was designed and built for the US Navy to support all of the flight control hydraulic components on the F-14. Of course the F-14 servo controlled hydraulic flight controls were very advanced components that absolutely required testing and performance verification prior to being installed on the aircraft.


Additionally, the F-14 contained advanced flight control, communication and warfare electronics that were the most advanced and capable of its time. All these sophisticated electronic systems not only required testing but calibration prior to aircraft installation or operation.  Electronic test systems such as the Testek TS1650 and Testek 101990 Drive Stand were designed to support all these new and advanced electronic and electrical components. With the advent of all these new aircraft systems came a requirement for Aircraft Component Test Equipment to support a rapidly grow industry.  
Long before the F-14 flight and electronic controls hit the industry there were many less complicated hydraulic devices that required testing. During the early 1950s manually operated hydraulic test stands became necessary in all areas of aircraft manufacture and maintenance. Soon after came the early stages of electronics, fuel and electrical test equipment. This created a test equipment industry that over the years has become worldwide.


As the aircraft technology advanced so did the test equipment technology. Starting with totally manually operated controls where the operator was responsible for complete operation to computer controlled test systems that test the most advanced Fly-By-Wire servo controls, electronics and electrical systems. Few of the early test equipment designers and manufacturers were able to advance their own test systems technology to keep pace with the level of technology being presented for testing like Testek.
Testek being founded in 1969 has provided test system technology that has kept pace with aircraft technology for more than 40 years.


As the commercial aircraft industry matured into the complex system requirements so did the aircraft test equipment to support these new aircrafts. Then the government got involved and made rules to protect aircraft safety and the people flying. Requirements came forth that mandated ALL aircraft components to be flight certified prior to aircraft installation. This required testing would simulate aircraft flying environments and conditions to absolutely guarantee component and system performance. In other words, all components had to be Flight Certified before being installed on the aircraft. This of course created an aircraft test equipment industry to support the FAA rules.
Testek is a leader of the Aircraft Test Equipment Industry in all facets of aircraft test equipment. Testek provides industry leading Hydraulic test systems, CSD/IDG Drive test systems, ATE test systems, Fuel test systems, Pneumatic test systems and Electro-Mechanical test systems . All these products encompass the most advanced Manual/Semi-Automatic/Fully Automate controls using state-of-the-art designs.
Testek’s customer base is comprised of all the worldwide aircraft manufacturers, aircraft support activities and MROs.


Testek has supplied systems and complete aircraft component testing complexes to support and maintain any and all commercial and military aircraft throughout the world. Please visit Testek’s website at www.testek.com for a complete product description and capabilities listing.  


While standing in the Tillamook Air Museum viewing and reminiscing about all the history and accomplishments in aircraft test technology, I still reflect back on the PT-7 Stearman and wonder, “Did anyone imagine where and how far aircraft test technology would progress”?

Author:
Bryan Ellerman
Aerospace Sales, Testek Inc.
www.testek.com