Testing aircraft flying control surfaces and systems
Overview
This standard identifies the competences you need to test aircraft flying control surfaces and systems, in accordance with approved procedures. You will be required to select the appropriate tools and equipment to use, based on the operations to be performed and systems to be tested. The flying control systems to be tested will be on either fixed or rotary wing aircraft and will include items such as flaps, air brakes, autopilot systems, sticks and pedals, ailerons, rudders, main and tail rotors, trim tabs and stabilisers.
Testing activities will include making all necessary checks and adjustments to ensure that components are correctly positioned and aligned, and making rigging and function tests, 'full and frees', ground running activities, and `before and after' flight inspections and tests.
Your responsibilities will require you to comply with organisational policy and procedures for the flying control surface testing activities undertaken and to report any problems with these activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to the testing techniques and procedures used. You will understand the flying control system being tested and its function, and will know about the equipment, relevant components, alignment, adjustment and rigging methods, in adequate depth to provide a sound basis for carrying out the testing activities to the required specification.
You will understand the safety precautions required when carrying out the testing activities and with the tools and equipment used. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the appropriate procedures for use of tools and equipment to carry out the required tests
- set up and carry out the tests using the correct procedures and within agreed timescales
- record the results of the tests in the appropriate format
- review the results and carry out further tests if necessary
- leave the aircraft and work area in a safe and appropriate condition, free from foreign object debris on completion of the activities
Knowledge and Understanding
You need to know and understand:
- the specific safety practices and procedures that you need to observe when testing aircraft control surfaces and systems (including any specific legislation, regulations/codes of practice for the activities, equipment or materials)
- the health and safety requirements of the work area where you are carrying out the activities and the responsibility these requirements place on you
- the safety procedures that must be carried out before work is started on the aircraft
- the protective clothing and equipment (PPE) to be worn during the testing activities and where it can be obtained
- hazards associated with testing flying control surfaces and systems and with the tools and equipment used and how to minimise them and reduce any risks
- the correct operating procedures of the system being tested
- electrical bonding specifications and their importance
- how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken
- how to obtain the required test schedules and specifications for the aircraft type being tested and how to check their currency and validity
- how to read and interpret the test schedules and specifications and whom you can seek assistance from if you have problems or issues regarding the test schedules or specifications
- the methods and procedures to be used to carry out the various tests on the flying control surfaces and system components
- test equipment to be used and its selection for particular tests
- why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
- the principle of operation of the system under test and the function of the individual components within the system
- the need to apply the tests in incremental stages and to check all readings, movements and pressures at each stage
- the importance of ensuring that pressure is maintained and the methods used to detect leaks and faults with the system
- how to record the results of each individual test and the documentation that must be used
- from whom to seek authorisation if you need to alter or change the test procedures
how to analyse the test results and how to make valid decisions about the acceptability of the aircraft
problems that can occur with the testing activities and how they can be overcome
the items that may cause errors or discrepancies in/with the test results and how to avoid these
- any required environmental controls relating to the testing
- the documentation to be completed at the end of the testing activities
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
- Carry out all of the following during the testing of the aircraft flying control surfaces and systems:
- obtain and use the appropriate documentation (such as job instructions, aircraft flying control surface test procedures, quality control documentation, history sheets, flight logbook, aircraft standards and specifications)
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide and maintain a safe working environment for the testing activities
- obtain the correct tools and equipment for the activity, and check that they are in a safe, tested and usable condition and within current calibration date
- obtain clearance to work on the aircraft and observe all relevant safety procedures
- ensure that isolation procedures are followed and that safe working distance procedures are set up
- carry out the tests, using the specified techniques and procedures
- return all tools and equipment to the correct location on completion of the testing activities
- Either: test a range of flying control components for fixed wing aircraft, to include four of the following:
- rudder pedals
- control columns
- trim wheels
- auxiliary controls
- flap selectors
- air brake selectors
- auto pilot systems
- throttle boxes
- other specific flying control component
Or: test a range of flying control components for rotary wing aircraft, to include four of the following: - gradient boxes
- connecting rods
- locks and stops
- torque tubes
- control sticks
- bell cranks
- turnbuckles
- levers
- AFCs series and parallel actuators
- cables and pulleys
- mixer units
- pedals
- other specific flying control component
- Either: test a range of flying control surfaces for fixed wing aircraft, to include three from the following:
- air brakes
- flaps
- ailerons
- elevators
- trim tabs
- rudders
- spoilers
- tail plane
- canards
- slats
- wing tips
- foreplanes
- flaperons
- tailerons
- other specific flying control surface
Or: test a range of flying control surfaces for rotary wing aircraft, to include two items from the following: - main rotor blades
- stabilisers
- tail rotor blades
- trim tabs
- other specific flying control surface
- Carry out flying control system and surface tests, to include three from the following:
- functional check
- before flight checks
- ground run tests
- tension adjuster checks
- full and free tests
- use of safety locks
- rigging check
- after flight checks
- static friction check
- Deal with two of the following complexities during the testing activities:
- system with no faults
- system with faults
- system with intermittent faults
- Use three of the following fault finding techniques during tests:
- six point
- input to output
- equipment self diagnostics
- injection and sampling
- half split
- function testing
- emergent problem sequence
- unit substitution
- Carry out tests of the flying control system in compliance with one of the following standards:
- Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
- Ministry of Defence (MOD)
- Military Aviation Authority (MAA)
- Aerospace Quality Management Standards (AS)
- customer standards and requirements
- Federal Aviation Authority (FAA)
- company standards and procedures
- BS, ISO or BSEN standards and procedures
- specific equipment requirements
- manufacturer standards and procedures
- Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:
- build records
- log cards
- job cards
- aircraft flight log
- other specific recording method
Scope Knowledge
Values
Behaviours
You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:
- strong work ethic
- positive attitude
- team player
- dependability
- responsibility
- honesty
- integrity
- motivation
- commitment