New Engine Flight Test Bed, a De-Risking Vehicle for a New Generation of Turboprops

Alessandro Ramazzotti, Beechcraft Berlin Aviation GmbH (Germany)
Sigismond Monnet, Beechcraft Berlin Aviation GmbH (Germany)

Abstract

The aim of the present paper is to collect memories and lessons learned from the project of a Flight Test Bed, designed for the development and testing of a new generation of turboprop engines. The prototype of a new generation of turboprops, is installed on-board of a 40-yearold King Air 300 modified as a program dedicated Flying Test Bed. A European University in collaboration with a famous engine OEM asked Beechcraft Berlin Aviation GmbH, a company specialized in aircraft modifications, to modify an existing aircraft to accommodate the new turboprop. The aim was to have a reliable flying test bed to de-risk and starts the certification campaign for a new generation of turboprop. This paper is intended to describe, from the beginning, the role of the Flight Test Department as far as concerned in the design requirements of the modified aircraft, to alleviate as much as possible the workload and guarantee the safety of the flying crew. The main affected areas are the HMI part of the cockpit as well as the need for the safety device to be installed on-board. In addition, the individuation of the design driving factors for HMI and Safety, and the dedicated training of the test crew aimed at execute the flights with the highest situational awareness possible, due to the particular environment in which the aircraft will operate, are presented. The second part is strictly related to the engineering of the tests required for ensuring the minimum safety and controllability of the modified aircraft, while the feasibility of the tests requested from the customer (which is the engine OEM). The involvement of the Flight Test Department was strong since the beginning of the project, not only related to the flying test bed setup, but also for the operative decisions and the engineering of the tests. All the lessons learned and the flight testing “good habits” which were applied to this case will be collected and presented to have memories of what integration of a brand new part of the aircraft could have an impact on a relatively small aircraft, designed with simple rules in the past.