CAT-A Ground Test to Class-A Miship: Case Study of an Uncrewed Military Helicopter with Lessons Learned for the R&D, T&E, and Academic Community
Dr. Prof. Donald “Bucket” Costello III
Director, Test and Evaluation of Autonomous Systems, MATRIX Lab
University of Maryland, College Park
Abstract
On 16 November 2020, a MQ-8C Firescout was preparing for a form/fit/function ground test of a new battery. The ground test was considered low risk and therefore did not require extensive risk mitigation steps. The test points were simple: start the air vehicle, do a systems check, and shut down the air vehicle. On the morning of the test event, the MQ-8C was chained to the ground (as it was a maintenance ground turn), and a maintenance laptop was connected to interface with the air vehicle systems. A command-and-control communication link was not established with a ground station. The test team started the air system, and everything functioned as expected until test personnel initiated shutdown. Within 30 seconds, the air vehicle went to full power, the rotor disk shifted from parallel to the ground to full forward and full right, the shifted disk cut the only connection to the maintenance laptop, and the system ran for approximately 6 minutes until the transmission came apart causing over $2,500,000 of damage. This presentation summarizes the facts surrounding the mishap and offers conclusions and recommendations on how to avoid similar mishaps in the future.
Biography of the speaker
Donald H. Costello received the B.S. degree in Systems Engineering from the United States Naval Academy, Annapolis, MD, USA, in 2000, the MAS degree in Aeronautical Science from Embry-Riddle Aeronautical University, Daytona Beach, FL, USA, in 2005, the MS degree in Aeronautical Engineering from the Air Force Institute of Technology, Dayton, OH, USA, in 2009, the MS degree in Systems Engineering from the Naval Post Graduate School, Monterey, CA, USA, in 2011, and the PhD degree in Mechanical Engineering from the University of Maryland, College Park, MD, USA, in 2020.
He has served as a Naval Aviator, a Test Pilot, and a Permanent Military Professor with United States Navy, for the term of 2000-2025. His academic positions have included as an Adjunct Associate Professor with Embry-Riddle Aeronautical University and an Assistant Professor with the Weapons, Robotics, and Control Engineering Department, United States Naval Academy. Currently, he is an Associate Research Professor with the MATRIX Laboratory, A. James Clark School of Engineering, University of Maryland, and USMSM. His work focuses on the test and evaluation of unmanned and autonomous systems for practical use. His awards and honors include the Assistant Secretary of the Navy (Research, Development, and Acquisition) Dr. Delores M. Etter Top Scientists and Engineers of the Year Group Award for 2024, the 2021 International Test and Evaluation Association Publication Award, and Assistant Secretary of the Navy (Research, Development, and Acquisition) Dr. Delores M. Etter Top Scientists and Engineers of the Year Individual Engineer for 2021. He is a member of the AIAA, IEEE, Tailhook Association, the International Test and Evaluation Association, the Society of Flight Test Engineers, and the Society of Experimental Test Pilots.