Full Scale Static & Fatigue Testing

Computer-controlled static and fatigue testing capabilities for full-scale aircraft and other vehicles have been developed over the past thirty-five years at Vought Aircraft Industries Test Operations Structures Test Laboratory. Central to this testing capability is the ability to integrate the electromechanical loading systems and electronic data acquisition systems under computer control. This integration is critical to cost effective, accurate simulation of the loading spectrum encountered by the vehicle under test while permitting "on-the-fly" data acquisition. Test Operations staff maintain a familiarity with USAF, USN, and FAA full scale static and fatigue test requirements.

As the need for more information about the test article’s status during testing is desired by analytical groups, the Lab’s ability for on-site, custom programming becomes extremely valuable. Starting with proven data acquisition and reduction programming modules, the Lab’s engineering staff is able to configure the data acquisition system to meet whatever the customer requirements are for a particular test. Typical static and fatigue test control systems feature fully redundant load monitoring, independent on-the-fly load spectrum verification, and independent on-the-fly data acquisition, test article monitoring, and overall test system monitoring. Data acquisition systems utilized are capable of real-time monitoring and display of all channels for the purpose of evaluating the response of the test article to the applied loading. The systems are capable displaying groups of channels at any given time with all channels available for display by paging through a channel grouping sequence. This sequence is selectable by the user and the number of channels displayed at any given time is sufficient to determine structural and test system interactions. The data acquisition system is capable of programmatic or manual activation at any time to record data on-the-fly for all channels. A network of computers control static loading and fatigue spectra loading as required for each test. As loads are applied, data is simultaneously acquired and made available for engineering review. Systems are continuously being upgraded for capability and the current VXI-based systems offer near real time display and review capability for all data collection requirements. Communication links make it possible to send data files almost anywhere in the world from the Dallas, Texas facility.

Techniques are well developed within the Structures Test Laboratory which enable complex loading systems comprised of multiple actuators to be setup and run effectively. These techniques provide the best testing value by optimizing the loading system to perform at efficient cycle rates for each test article. Test Engineers consider not only loads and loading geometry, but also hydraulic flow rates, line/actuator/servovalve sizing and servocontroller loop gain settings in the test design.

The 50,000 square feet of test floor features 12,000 square feet with integral loading rails with the remaining space available for self contained or free standing test fixtures. Standard columns, beams, and braces offer quick and inexpensive basic test fixtures and the central hydraulic system, together with a wide range of actuators in inventory, allows efficient test setup. Over 200 channels of servocontrollers and a wide range of hydraulic servovalves are available for use on structural tests together with 3500 channels of data acquisition for loads, strains, deflections, pressure or temperature.

View the history of our Full-Scale Testing services

For more information please contact:

John Vaught
e-mail: john_vaught@voughtaircraft.com