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Recommendations on Evidence and Process for Certification of Learning-enabled Components in Aerospace Systems

This report primarily identifies a collection of relevant and necessary evidence for assurance of machine learnt components (MLCs)—also known as learning-enabled components—integrated into aircraft systems, and gives preliminary suggestions on the elements of a certification process that invoke the identified evidence. The main focus is on feedforward neural networks that are static and trained offline through supervised learning. A brief background on the generic elements of the lifecycle of an MLC is given to contextualize the assurance considerations and, consequently, the evidence that is relevant and necessary to support certification. At the level of an MLC, those considerations relate to: (i) the consistency and correctness of MLC contributions to system functions in the context of a validated functional intent; and (ii) the absence of MLC contributions to aircraft-level failure conditions. At an ML model level, confidence in model and data properties contribute to assurance of the containing MLC, in particular: (a) generalizability and robustness of models, in the presence of inputs not previously seen during training, disturbances to inputs, and unexpected inputs; and (b) valid data, i.e., data that are at least representative, relevant, complete, and accurate. Evidence for the above span the elements of the ML lifecycle, and includes, at a minimum, lifecycle artifacts that pertain to: (1) properties of requirements capturing functional intent, safety constraints, and aspects of the intended use and operating environment; (2) model performance, model complexity and design, and algorithm choice; (3) achievement of required performance at the levels of a trained model during model development, a trained model after model development is complete, and a trained model that is transformed into an executable equivalent; (4) model implementation aspects necessary for transforming a trained model into the executable equivalent; (5) integration of the executable trained model into the containing MLC, and eventually the larger system; and, (6) lastly, the verification and validation (V&V) of each of the above. Such V&V lifecycle artifacts themselves include: aspects of coverage, e.g., of various levels of requirements by the input space of the model and the data; traceability (where applicable); application of formal methods for property specification, analysis, and checking. Examples of evidence generation methods and tools further ground the discussion on what constitutes evidence, and the contribution to assurance during certification. The identified assurance considerations and supporting evidence is not a comprehensive set. Additionally, neither what should be considered as sufficient evidence relative to the assigned criticality of an MLC, nor how criticality ought to be determined and adjusted, have been considered in this report. However, suggestions are made for potential activities of the ML lifecycle that are aimed at providing confidence that an MLC can be relied upon when integrated into its containing (aircraft) system. Those activities are proposed as candidate elements of a certification process for MLCs. The main purpose of this report to inform regulatory guidance and consensus standards that may be used to meet the safety intent of the applicable regulations.

Aviation safety↗

Advanced Durability and Damage Tolerance Design and Analysis Methods for Composite Structures: Lessons Learned from NASA Technology Development Programs

Aerospace vehicles are designed to be durable and damage tolerant. Durability is largely an economic life-cycle design consideration whereas damage tolerance directly addresses the structural airworthiness (safety) of the vehicle. However, both durability and damage tolerance design methodologies must address the deleterious effects of changes in material properties and the initiation and growth of microstructural damage that may occur during the service lifetime of the vehicle. Durability and damage tolerance design and certification requirements are addressed for commercial transport aircraft and NASA manned spacecraft systems. The state-of-the-art in advanced design and analysis methods is illustrated by discussing the results of several recently completed NASA technology development programs. These programs include the NASA Advanced Subsonic Technology Program demonstrating technologies for large transport aircraft and the X-33 hypersonic test vehicle demonstrating technologies for a single-stage-to-orbit space launch vehicle.

Harris, Charles E.↗

Aircraft System Noise Prediction Uncertainty Quantification for a Hybrid Wing Body Subsonic Transport Concept

Aircraft system level noise prediction for advanced, unconventional concepts has undergone significant improvement over the past two decades. The prediction modeling uncertainty must be quantified so that potential benefits of unconventional configurations, which are outside of the range of empirical models, can be reliably assessed. This paper builds on previous work in an effort to improve estimates of element prediction uncertainties where the prediction methodology has been improved, or new experimental validation data are available, to provide an estimate of the system level uncertainty in the prediction process. In general, the uncertainty of the prediction will be strongly dependent on the aircraft configuration as well as which technologies are integrated. While the quantitative uncertainty values contained here are specific to the hybrid wing body design presented, the underlying process is the same regardless of configuration. A refined process for determining the uncertainty for each element of the noise prediction is detailed in this paper. The system level uncertainty in the prediction of the aircraft noise is determined at the three certification points, using a Monte Carlo method. Comparisons with previous work show a reduction of 1 EPNdB in the 95%coverage interval of the cumulative noise level. The largest impediment for continued reduction in uncertainty for the hybrid wing body concept is the need for improved modeling and validation experiments for fan noise, propulsion airframe aeroacoustic effects, and the Krueger flap, which comprise the bulk of the uncertainty in the cumulative certification noise level.

June, Jason C.↗

Advanced automated glass cockpit certification: Being wary of human factors

This paper presents some facets of the French experience with human factors in the process of certification of advanced automated cockpits. Three types of difficulties are described: first, the difficulties concerning the hotly debated concept of human error and its non-linear relationship to risk of accident; a typology of errors to be taken into account in the certification process is put forward to respond to this issue. Next, the difficulties connected to the basically gradual and evolving nature of pilot expertise on a given type of aircraft, which contrasts with the immediate and definitive style of certifying systems. The last difficulties to be considered are those related to the goals of certification itself on these new aircraft and the status of findings from human factor analyses (in particular, what should be done with disappointing results, how much can the changes induced by human factors investigation economically affect aircraft design, how many errors do we need to accumulate before we revise the system, what should be remedied when human factor problems are discovered at the certification stage: the machine? pilot training? the rules? or everything?). The growth of advanced-automated glass cockpits has forced the international aeronautical community to pay more attention to human factors during the design phase, the certification phase and pilot training. The recent creation of a human factor desk at the DGAC-SFACT (Official French services) is a direct consequence of this. The paper is divided into three parts. Part one debates human error and its relationship with system design and accident risk. Part two describes difficulties connected to the basically gradual and evolving nature of pilot expertise on a given type of aircraft, which contrasts with the immediate and definitive style of certifying systems. Part three focuses on concrete outcomes of human factors for certification purposes.

Amalberti, Rene↗

Structural Similitude and Scaling Laws

Aircraft and spacecraft comprise the class of aerospace structures that require efficiency and wisdom in design, sophistication and accuracy in analysis and numerous and careful experimental evaluations of components and prototype, in order to achieve the necessary system reliability, performance and safety. Preliminary and/or concept design entails the assemblage of system mission requirements, system expected performance and identification of components and their connections as well as of manufacturing and system assembly techniques. This is accomplished through experience based on previous similar designs, and through the possible use of models to simulate the entire system characteristics. Detail design is heavily dependent on information and concepts derived from the previous steps. This information identifies critical design areas which need sophisticated analyses, and design and redesign procedures to achieve the expected component performance. This step may require several independent analysis models, which, in many instances, require component testing. The last step in the design process, before going to production, is the verification of the design. This step necessitates the production of large components and prototypes in order to test component and system analytical predictions and verify strength and performance requirements under the worst loading conditions that the system is expected to encounter in service. Clearly then, full-scale testing is in many cases necessary and always very expensive. In the aircraft industry, in addition to full-scale tests, certification and safety necessitate large component static and dynamic testing. Such tests are extremely difficult, time consuming and definitely absolutely necessary. Clearly, one should not expect that prototype testing will be totally eliminated in the aircraft industry. It is hoped, though, that we can reduce full-scale testing to a minimum. Full-scale large component testing is necessary in other industries as well, Ship building, automobile and railway car construction all rely heavily on testing. Regardless of the application, a scaled-down (by a large factor) model (scale model) which closely represents the structural behavior of the full-scale system (prototype) can prove to be an extremely beneficial tool. This possible development must be based on the existence of certain structural parameters that control the behavior of a structural system when acted upon by static and/or dynamic loads. If such structural parameters exist, a scaled-down replica can be built, which will duplicate the response of the full-scale system. The two systems are then said to be structurally similar. The term, then, that best describes this similarity is structural similitude. Similarity of systems requires that the relevant system parameters be identical and these systems be governed by a unique set of characteristic equations. Thus, if a relation or equation of variables is written for a system, it is valid for all systems which are similar to it. Each variable in a model is proportional to the corresponding variable of the prototype. This ratio, which plays an essential role in predicting the relationship between the model and its prototype, is called the scale factor.

Simitses, George J.↗

Certification Considerations for Adaptive Systems

Advanced capabilities planned for the next generation of aircraft, including those that will operate within the Next Generation Air Transportation System (NextGen), will necessarily include complex new algorithms and non-traditional software elements. These aircraft will likely incorporate adaptive control algorithms that will provide enhanced safety, autonomy, and robustness during adverse conditions. Unmanned aircraft will operate alongside manned aircraft in the National Airspace (NAS), with intelligent software performing the high-level decision-making functions normally performed by human pilots. Even human-piloted aircraft will necessarily include more autonomy. However, there are serious barriers to the deployment of new capabilities, especially for those based upon software including adaptive control (AC) and artificial intelligence (AI) algorithms. Current civil aviation certification processes are based on the idea that the correct behavior of a system must be completely specified and verified prior to operation. This report by Rockwell Collins and SIFT documents our comprehensive study of the state of the art in intelligent and adaptive algorithms for the civil aviation domain, categorizing the approaches used and identifying gaps and challenges associated with certification of each approach.

Bhattacharyya, Siddhartha↗

SOFIA: Flying the Telescope

The primary focus of this paper is how the flight test team for the Stratospheric Observatory For Infrared Astronomy (SOFIA) re-cast an extensive developmental test program to meet key milestones while simultaneously ensuring safe certification of the airframe and delivery of an operationally relevant platform, ultimately saving the overall program from financial demise. Following a brief introduction to the observatory and what it is designed to do, SOFIAs planned developmental test program is summarized, including analysis and design philosophy, envelope expansion, model validation and airframe certification. How NASA used lessons learned from other aircraft that employed open cavities in flight is explained as well as how and why the chosen design was selected. The approach to aerodynamic analysis, including bare airframe testing, wind tunnel testing, computational fluid dynamics and finite element modeling proved absolutely critical. Despite a solid analytical foundation, many unknowns remained. History provides several examples of disastrous effects on both systems and flight safety if cavity design is not approached properly. For these reasons, an extensive test plan was developed to ensure a safe and thorough build-up for envelope expansion, airframe certification and early science missions. Unfortunately, as is often the case, because of chronic delays in overall program execution, severe schedule and funding pressures were present. If critical milestones were not met, domestic as well as international funding was in serious jeopardy, and the demise of the entire program loomed large. Concentrating on rigorous model validation, the test team challenged certification requirements, increased test efficiency and streamlined engineering analysis. This resulted in the safe reduction of test point count by 72%, meeting all program milestones and a platform that soundly satisfied all operational science requirements. Results from early science missions are shown and a proof of concept mission for which SOFIA was opportunely positioned is showcased. Success on this time-critical mission to observe a rare astronomical event proved the usefulness of an airborne observatory and the value in waiting for the capability provided by SOFIA. Finally, lessons learned in the test program are presented with emphasis on how lessons from previous aircraft and successful test programs were applied to SOFIA. Effective application of these lessons was crucial to the success of the SOFIA flight test program. SOFIA is an international cooperative program between NASA and the German Space Agency, DLR. It is a 2.5 meter (100-inch) telescope mounted in a Boeing 747SP aircraft used for astronomical observations at altitudes above 35,000 feet. SOFIA will accommodate a host of scientific instruments from the international science community and has a planned operational lifespan of more than 20 years.

Asher, Troy A.↗

Aircraft Conceptual Design and Risk Analysis Using Physics-Based Noise Prediction

An approach was developed which allows for design studies of commercial aircraft using physics-based noise analysis methods while retaining the ability to perform the rapid trade-off and risk analysis studies needed at the conceptual design stage. A prototype integrated analysis process was created for computing the total aircraft EPNL at the Federal Aviation Regulations Part 36 certification measurement locations using physics-based methods for fan rotor-stator interaction tones and jet mixing noise. The methodology was then used in combination with design of experiments to create response surface equations (RSEs) for the engine and aircraft performance metrics, geometric constraints and take-off and landing noise levels. In addition, Monte Carlo analysis was used to assess the expected variability of the metrics under the influence of uncertainty, and to determine how the variability is affected by the choice of engine cycle. Finally, the RSEs were used to conduct a series of proof-of-concept conceptual-level design studies demonstrating the utility of the approach. The study found that a key advantage to using physics-based analysis during conceptual design lies in the ability to assess the benefits of new technologies as a function of the design to which they are applied. The greatest difficulty in implementing physics-based analysis proved to be the generation of design geometry at a sufficient level of detail for high-fidelity analysis.

Olson, Erik D.↗

Flutter Prediction for Aircraft Conceptual Design

Flutter prediction is usually a knowledge-based analysis process that aims to reduce the cost of aeroelastic stability margin certification. However, early detection of flutter problems is beneficial in the development of unconventional aircraft. The recently developed automation tool ConceptFEA for structural sizing of aircraft concepts paves the way for rapid physics-based flutter prediction of aircraft concepts. A match-point iteration procedure using the p-k method is implemented for ConceptFEA with minimum user input requirements to generate flutter boundary points. A subsonic business jet concept and its high aspect-ratio wing variant are used to demonstrate how the newly developed flutter prediction capability can be used during aircraft conceptual design. Sized structures, flutter boundary curves, and flutter sensitivity analysis results are generated for these two concepts using ConceptFEA. The relevant equivalent plate theory is provided to show the quantitative relationships between a stiffened panel and its equivalent NASTRAN PSHELL panel. The rapid flutter prediction capability of ConceptFEA makes multidisciplinary collaborations between systems analysts and aeroelasticity experts feasible in practice.

Li, Wu↗

Incorporation of EGPWS in the NASA Ames Research Center 747-400 Flight Simulator

The NASA Ames Research Center CAE Boeing 747300 flight simulator is used primarily for the study of human factors in aviation safety. The simulator is constantly upgraded to maintain a configuration match to a specific United Airlines aircraft and maintains the highest level of FAA certification to ensure credibility to the results of research programs. United's 747-400 fleet and hence the simulator are transitioning from the older Ground Proximity Warning System (GPWS) to the state-of-the-art Enhanced Ground Proximity Warning System (EGPWS). GPWS was an early attempt to reduce or eliminate Controlled Flight Into Terrain (CFIT). Basic GPWS alerting modes include: excessive descent rate, excessive terrain closure rate, altitude loss after takeoff, unsafe terrain clearance, excessive deviation below glideslope, advisory callouts and windshear alerting. However, since GPWS uses the radar altimeter which looks straight down, ample warning is not always provided. EGPWS retains all of the basic functions of GPWS but adds the ability to look ahead by comparing the aircraft position to an internal database and provide additional alerting and display capabilities. This paper evaluates three methods of incorporating EGPWS in the simulator and describes the implementation and architecture of the preferred option.

Sallant, Ghislain↗

Report on the test set-up for the structural testing of the Airmass Sunburst Ultralight Aircraft

This report reviews the test set-up and procedure for the structural testing of the Airmass Sunburst Ultralight Aircraft. In general aviation today, there is a growing need for more stringent design criteria for ultralight aircraft. Unlike most general aviation aircraft, the ultralight lacks sufficient design criteria and more importantly it lacks sufficient certification enforcement. The Airmass Sunburst ultralight that is currently being tested is responsible for over a dozen deaths. It is believed that had there been a more stringent criteria and certification process, this might have been prevented. Our attempt is to show that the failing loads of the aircraft in question are so far below that of the current design criteria, that the laws need to be changed.

Zimmerman, William↗

Proposal for Certifying Expandable Planetary Surface Habitation Structures

A factor-of-safety (FS) of 4.0 is currently used to design habitation structures made from structural soft goods. This approach is inconsistent with using a FS of 2.0 for metallic and polymeric composite pressure vessels as well as soft good structures such as space suits and parachutes. This inconsistency arises by using the FS to improperly account for the unknown effects of a variety of environmental and loading uncertainties. Using a 4.0 FS not only results in additional structural mass, it also makes it difficult to gain insight into the limitations of the material and/or product form and thus, it becomes difficult to make improvements. In order to bring consistency to the design and certification of expandable habitat structures, the approach used by the Federal Aviation Administration (FAA) to certify polymeric composite aircraft structures is used as a model and point of departure. A draft certification plan for Expandable Habitat Structures is developed in this paper and offered as an option for placing habitats made from soft goods on an equal footing with other structural implementations.

Dorsey, John T.↗

Flyover-Noise Reduction of Commercial Aircraft via Reduced Slat Deflections and Modified Flight Procedures

Current regulation and operation of commercial aircraft result in flyover noise that generates public protest from residents well outside the recognized noise footprint of modern airports. This noise issue was recently exacerbated by the implementation of NextGen air-traffic control which uses GPS-navigation for predictable flight paths and improved efficiency. A side-effect of the narrow flight corridors is a perceived increase in noise level and annoyance experienced by the residents directly under the flight paths. As a possible solution to the community noise issue, the feasibility of a lower slat deflections and modified flight procedures were explored. To document the maximum potential noise reduction, field measurements were conducted on the ground at locations before and after slat deployment. For safety considerations, the stall margin of a lower slat deflection was computed for a realistic geometry based on a modern commercial aircraft. The logistics of setting lower slat angles on current aircraft were also investigated through discussions with the FAA (Federal Aviation Administration) and aircraft manufacturers. The results suggest that community flyover noise could be reduced via lower slat deflections during early approach, but that modifying current aircraft would be difficult due to existing control systems and hurdles in certification. Alternatively, modifications to existing flight procedures could reduce the perceived noise of the NextGen flight patterns. For next generation commercial aircraft, reduced slat deflections could be considered if mandated by FAA noise requirements during early approach.

Storms, Bruce L.↗

Autonomy Verification & Validation Roadmap and Vision 2045

Advanced capabilities planned for the next generation of autonomous and increasingly autonomous air vehicles will include non-traditional components based on artificial intelligence, machine learning, and complex optimization and planning algorithms. These complex components will be used to provide enhanced safety and high-level decision-making functions. However, there are serious barriers to the deployment of autonomous aircraft in the National Airspace System (NAS). Current civil aviation certification processes are based on the concept that the correct behavior of a system or a component must be completely specified and verified prior to operation. This report from the Autonomy Verification and Validation (V&V) Roadmap and Vision 2045 project presents the most recent effort to build a comprehensive list of verification challenges and needs for autonomous aircraft, a roadmap to meet those autonomy V&V needs, the services they can enable, and point to the certification gaps they fill. To accomplish these goals, we assembled a team of world-class researchers from the aerospace industry (Boeing, Collins Aerospace, and GeneralElectric) and academia (University of Michigan, University of Texas, and Massachusetts Institute of Technology) with deep expertise in autonomy, aerospace systems, and assurance of Artificial Intelligence/machine learning systems.

Software Assurance↗

Development of Design Data for Propulsion PMR-15 Composites

The continuing development of PMR-15 composite materials and their associated design properties is pacing the implementation of this technology on commercial aircraft. The guidelines that the FAA has issued regarding the certification of advanced composite structures are very significant with respect to future PMR-15 research and development activities. The FAA has issued an advisory circular dated 1-5-83 concerning guidelines for composite aircraft structures. Of particular significance to PMR-15 technology development is the reliance on combined environmental exposure and component testing, coupled with the stipulation that reliance on previous experience be limited to where common structures and materials have been used for a similar function. Critical environmental exposures for commercial propulsion structures include 50,000 cycle service life, exposure to skydrol, moisture and other fluids, and nacelle fire conditions.

Postlewaite, J.↗

A Quiet Helicopter for Air Taxi Operations

NASA is exploring rotorcraft designs for VTOL air taxi operations, also known as urban air mobility (UAM) or on-demand mobility (ODM) applications. Several concept vehicles have been developed, intended to focus and guide NASA research activities in support of aircraft development for this emerging market. This paper examines a single main-rotor helicopter designed specifically for low-noise air taxi operations. Based on demonstrated technology, the aircraft uses a turboshaft engine with a sound-absorbing installation, and the NOTAR anti-torque system to eliminate tail-rotor noise, consequently the noise and annoyance of the aircraft are dominated by the main rotor. Several design parameters are explored to reduce the noise, including rotor tip speed, blade geometry, and higher-harmonic control. Commensurate with the level of design detail, the noise is calculated for compact loading and thickness sources on the rotating blades. The metric is the reduction of the noise for the helicopter certification conditions (takeoff, flyover, and approach), relative a baseline aircraft with typical (high) tip speed, conventional blade planform, and no higher-harmonic control.

Johnson, Wayne↗

Flight deck automation: Promises and realities

Issues of flight deck automation are multifaceted and complex. The rapid introduction of advanced computer-based technology onto the flight deck of transport category aircraft has had considerable impact both on aircraft operations and on the flight crew. As part of NASA's responsibility to facilitate an active exchange of ideas and information among members of the aviation community, a NASA/FAA/Industry workshop devoted to flight deck automation, organized by the Aerospace Human Factors Research Division of NASA Ames Research Center. Participants were invited from industry and from government organizations responsible for design, certification, operation, and accident investigation of transport category, automated aircraft. The goal of the workshop was to clarify the implications of automation, both positive and negative. Workshop panels and working groups identified issues regarding the design, training, and procedural aspects of flight deck automation, as well as the crew's ability to interact and perform effectively with the new technology. The proceedings include the invited papers and the panel and working group reports, as well as the summary and conclusions of the conference.

Norman, Susan D.↗