Structural test verifies radar dome
Greg Reed, Contributing Technical Editor -- Test & Measurement World, 11/1/2005 2:00:00 AM
When a major aerospace manufacturer won a contract for producing a radar dome to sit atop the Boeing 737-700 aircraft, the company turned to KineticSystems for help in developing the necessary structural test. The radar dome project, known as "Project Wedgetail," includes an airborne early warning and control (AEW&C) device equipped with multi-role electronically scanned array (MESA) radar housed within a dome structure (figure). Tests for Project Wedgetail needed to include structural analysis as well as stress testing of the sensitive radar and antenna electronics inside.
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| This diagram shows components of the early warning and control system. The MESA radar component is located inside the dome structure. Courtesy of KineticSystems and Gage Applied Technologies. |
KineticSystems conducted initial ground testing with software that simulated air performance conditions on the Wedgetail module in isolation from the aircraft. Later, the company verified the Wedgetail's structural integrity by performing further simulated structural testing of the dome mounted on the aircraft. Eventually, in-flight tests fully confirmed the structural stability of the radar dome.
To simulate flight conditions, KineticSystems used a system of actuators linked to hydraulics to apply various loads to the Wedgetail module. A system of strain gages and transducers measured additional forces encountered during flight. The company used a data-acquisition system to process information gathered from all testing processes in real time and then analyzed the results using Excel files and data plots. The setup allowed operators to change parameters and zoom in on specific test processes, such as the aerodynamics profile.
The testing revealed failures that necessitated design modifications until both the module and the aircraft were deemed reliable under all flight conditions. To ensure all components remain reliable, the aerospace manufacturer will continue to conduct fatigue testing periodically throughout the life of the module and aircraft.
As a result of the structural lab testing, the manufacturer was able to develop a radar dome with a low aerodynamic drag profile while meeting the requirements of fore and aft coverage on Boeing's 737-700 aircraft. Along the way, the electronics test procedures also led to enhancements to the reception of radar data.
Bernie Spear, at KineticSystems-West observed, "The Wedgetail project presented significant test challenges, but the test team verified a structurally sound module within the dome which meets all flight requirements." Today, the airworthy radar dome system accounts for 360° coverage and a range of 200 nautical miles.
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