A model-based design methodology for flight control systems: Global 7500 pitch control case study

Abstract

This article introduces an original model-based design methodology addressing a high-performance aircraft design challenge: conflicting performance requirements. The case study of the Global 7500 elevator actuation system also provides in-depth insight into the complex design process of today’s fly-by-wire flight control systems. The methodology presented here redefines the aircraft manufacturer’s involvement in the design process of the systems, implementing analysis and iteration capabilities early in system development. To this end, it introduces a novel modeling approach for analyzing loaded rate requirements by simulating closed-loop performance with a generic nonlinear second-order state filter, including the main performance limitations without requiring a preliminary design definition. In this way, it provides means to mature the system requirements and addresses requirement conflicts upfront. Then, a simulation-based preliminary sizing and performance assessment validates the candidate design concept. It also secures the preliminary design phase by implementing advanced design uncertainties and involving interfacing systems and disciplines early in the process. The redefined methodology identified directly that the problem’s root cause was a conflict between stability and control and flutter protection requirements. It also indicated that the first sizing driver is the response time required under a specific failure case. These findings lead to an optimal elevator actuator design compliant with matured performance requirements. Thus, the methodology resolved a design challenge blocking the Global 7500 aircraft development and prevented redesign occurrences later during the detailed design phase. In this way, it directly contributed to the successful development of the Global 7500 and its optimal operational performance. This methodology applies to future aircraft design challenges, and the technical insight provides valuable lessons learned for high-performance T-tail business jets.