The Iron Bird for the Fairchild-Dornier 728

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A full size representative system integration test rig (Iron Bird) for the Fairchild-Dornier 728 regional jet has been designed and built. The 728 is a full fly-by-wire aircraft without mechanical back-up and is the benchmark for system integration in its class. The primary focus of Iron Bird testing is on flight controls, landing gear and hydraulics; other aircraft systems are installed for support. To reproduce in-flight aerodynamic loads, a hydraulically powered computer-controlled loading system is employed. The rig is not only used to minimize the development risk by testing fully integrated systems well in advance of the first test aircraft, as in previous programs, but also to unload ground and flight testing to the greatest extent possible as well as to conduct certification testing. A description of the Iron Bird structure and the aircraft systems' integration into the rig is given. An overview is provided of the rig's mechanical and electrical design as well as of its control and data acquisition system. The Iron Bird's capability to run in a closed loop configuration with the Engineering Simulator is highlighted. The main test targets are pointed out and results to date are presented. An outlook with respect to possible future testing and the extension of the capabilities of the Iron Bird facility is provided.