Flight envelope protection


Flight envelope protection is a human machine interface extension of an aircraft's control system that prevents the pilot of an aircraft from making control commands that would force the aircraft to exceed its structural and aerodynamic operating limits. It is used in some form in all modern commercial fly-by-wire aircraft. The professed advantage of flight envelope protection systems is that they restrict a pilot's excessive control inputs, whether in surprise reaction to emergencies or otherwise, from translating into excessive flight control surface movements. Notionally, this allows pilots to react quickly to an emergency while blunting the effect of an excessive control input resulting from "startle," by electronically limiting excessive control surface movements that could over-stress the airframe and endanger the safety of the aircraft.
In practice, these limitations have sometimes resulted in unintended human factors errors and accidents of their own.

Function

Aircraft have a flight envelope that describes its safe performance limits in regard to such things as minimum and maximum operating speeds, and its operating structural strength. Flight envelope protection calculates that flight envelope and uses this information to stop pilots from making control inputs that would put the aircraft outside that flight envelope. The interference of the flight envelope protection system with the pilot's commands can happen in two different ways :
For example, if the pilot uses the rearward side-stick to pitch the aircraft nose up, the control computers creating the flight envelope protection can prevent the pilot pitching the aircraft beyond the stalling angle of attack:
While most designers of modern fly-by-wire aircraft stick to either one of these to solutions, there are also approaches in science to combine both of them: As a study demonstrated, force-feedback applied to the side-stick of an aircraft controlled via role rate and g-load can be used to increase adherence to a save flight envelope and thus reduce the risk of pilots entering dangerous states of flights outside the operational borders while maintaining the pilots' final authority and increasing their situation awareness.

Airbus and Boeing

The Airbus A320 was the first commercial aircraft to incorporate full flight-envelope protection into its flight-control software. This was instigated by former Airbus senior vice president for engineering Bernard Ziegler. In the Airbus, the flight envelope protection cannot be overridden completely, although the crew can fly beyond flight envelope limits by selecting an alternate "control law". Boeing in the Boeing 777 has taken a different approach by allowing the crew to override flight envelope limits using excessive force on the flight controls.

Incidents

China Airlines Flight 006

One objection raised against flight envelope protection is the incident that happened to China Airlines Flight 006, a Boeing 747SP-09, northwest of San Francisco in 1985. In this flight incident, the crew was forced to overstress the horizontal tail surfaces in order to recover from a roll and near-vertical dive.. The pilot recovered control with about 10,000 ft of altitude remaining. But to do that the pilot had to pull the aircraft with an estimated 5.5 G, or more than twice its design limits. Had the aircraft
incorporated a flight envelope protection system, this excessive manoeuvre could not have been performed, greatly reducing chances of recovery.
Against this objection, Airbus has responded that an A320 in the situation of Flight 006 "never would have fallen out of the air
in the first place: the envelope protection would have automatically kept it in level flight in spite of the drag of a stalled engine".

FedEx Flight 705

FedEx Flight 705, in April 1995, a McDonnell Douglas DC-10-30, was a case of a FedEx Flight Engineer who, facing a dismissal, attempted to hijack the plane and crash it into FedEx Headquarters in order for his family to collect his life insurance policy. After being attacked and severely injured, the flight crew was able to fight back and land the plane safely. In order to keep the attacker off balance and out of the cockpit the crew had to perform extreme maneuvers, including a barrel roll and a dive so fast the airplane couldn't measure its airspeed.
Had the crew not been able to exceed the plane's flight envelope, the crew might not have been successful.

American Airlines Flight 587

American Airlines Flight 587, an Airbus A300, crashed in November 2001, when the vertical stabilizer broke off due to excessive rudder inputs made by the pilot.
A flight-envelope protection system could have prevented this crash, though it can still be argued that an override button should be provided for contingencies when the pilots are aware of the need to exceed normal limits.

US Airways Flight 1549

US Airways Flight 1549, an Airbus A320, experienced a dual engine failure after a bird strike and subsequently landed safely in the Hudson River in January 2009. The NTSB accident report mentions the effect of flight envelope protection: "The airplane’s airspeed in the last 150 feet of the descent was low enough to activate the alpha-protection mode of the airplane’s fly-by-wire envelope protection features... Because of these features, the airplane could not reach the maximum angle of attack attainable in pitch normal law for the airplane weight and configuration; however, the airplane did provide maximum performance for the weight and configuration at that time...
The flight envelope protections allowed the captain to pull full aft on the sidestick without the risk of stalling the airplane."

Qantas Flight 72

Qantas 72 had suffered an uncommanded pitch-down due to erroneous data from one of its ADIRU computers.

Air France Flight 447

Air France Flight 447, an Airbus A330, entered an aerodynamic stall from which it did not recover and crashed into the Atlantic Ocean in June 2009 killing all aboard.
Temporary inconsistency between measured speeds, likely a result of the obstruction of the pitot tubes by ice crystals, caused autopilot disconnection and reconfiguration to alternate law;
a second consequence of the reconfiguration into alternate law was that stall protection no longer operated.
The crew made inappropriate control inputs that caused the aircraft to stall and did not recognize that the aircraft had stalled.

MCAS on the Boeing 737 MAX

In October 2018 and again in March 2019, the MCAS flight protection system's erroneous activation pushed two Boeing 737 MAX airliners into an unrecoverable dive, killing 346 people and resulting in the worldwide grounding of the airliner.