Engineering, simulation, test tools help Bombardier business jet achieve milestones, exceed expectations

Bombardier Global 7500 business jet full-scale mock-up continues worldwide tour, surpasses 2,300 flight hours in flight test program, and progresses toward entry-into-service by year’s end.
The Global 7500 business jet from Bombardier Inc. in Montreal appears to be on the fast track to entering service, thanks in large part to high-tech engineering design, simulation, and test tools. Bombardier engineers and officials are crediting the program’s extensive use of proven engineering tools, digital simulation, innovative ground testing systems for helping to ensure: a mature aircraft at the start of flight testing, an efficient flight validation program, test aircraft that exceed original performance goals, and completion of one lifetime of simulated flights, which exceeds the requirements at time of certification.
“This is a significant year for the Global 7500 aircraft, with its planned certification and entry into service,” says Peter Likoray, senior vice president, worldwide sales and marketing, Bombardier Business Aircraft. 

A full-scale mock-up of the Bombardier Global 7500 business jet is currently on a worldwide tour and will be on display at the airport in Olbia, Italy, in mid-July and throughout the summer. The aircraft previously made stops in Dubai, Singapore, and Shanghai. 

The mock-up features a cutting-edge cockpit, officials say, as well as a luggage bay designed to be accessible during flight and a customizable interior, with fully equipped kitchen includes high-end appliances, dining area, entertainment lounge, a master suite, and en suite. 

Bombardier officials announced the Global 7500 business jet and its exclusive nice Touch cabin management system, a Bombardier-designed platform developed in collaboration with Lufthansa Technik, at the European Business Aviation Convention & Exhibition (EBACE) in Geneva in May 2018. 

Bombardier Global 7500 aircraft started arriving in May at the company’s Montreal facilities, where high-precision completion work is being performed. Workers at Bombardier’s Centre of Excellence in Dorval, Quebec, have been building and assembling complete interior sets including kitchens, state room beds, dining furniture, and new Nuage seats for multiple customer aircraft since the center’s inauguration in 2017. In November 2017, Bombardier announced that approximately 1,000 new positions were created to support the interior completion of the Global 7500 aircraft. With more than 80 percent of these positions already filled, Bombardier continues to recruit candidates to join its workforce.

“The Global 7500 interior completion work requires fine craftsmanship and cutting-edge technology. Bombardier Business Aircraft is taking its world-class expertise a step further through a new modular completion process leveraging advanced test rigs that ensure all customer aircraft surpass expectations at every level,” says David Coleal, president, Bombardier Business Aircraft.

As part of the development program, interiors are validated on the ground in a Bombardier-designed test rig that replicates the conditions of flight related to airframe motions and flight loads using a production fuselage mounted on a pneumatic bed. This process allows for the validation of the interior’s fit and finish in advance of its actual installation on the Architect, the fourth flight test vehicle. Bombardier is now using this unique tool for the interiors installation process of its production aircraft to ensure enhanced operational efficiency.  

“The Global 7500 aircraft’s production process, specifically the interior completion work, results from years of thoughtful planning to maximize efficiency while ensuring the utmost quality for customers,” explains Paul Sislian, chief operating officer, Bombardier Business Aircraft. “Our cutting-edge interior test rig allows our teams to conduct all major fit and finish adjustments at our Centre of Excellence, in advance of installation in the aircraft. This process significantly reduces our completions cycle time and will ensure a smooth entry-into-service and an exceptional product right from the start.”

Bombardier engineers credit the aircraft’s sophisticated wing design, rigorously tested during the flight validation program, for the Global 7500 aircraft having exceeded takeoff and landing performance commitments, leading to a new published takeoff distance of 5,800 feet at full fuel in standard operating conditions. This improved takeoff performance distance is almost 500 feet shorter than the closest competitor aircraft and enables the Global 7500 aircraft to access airports with shorter runways, officials say. 

The landing performance of the Global 7500 aircraft has also been improved -- now rivalling the stopping distance of aircraft in the Light jet category -- and with the low-speed aerodynamics of its wing, the aircraft can land effortlessly in steep approach air fields, such as London City, officials say. 

In May, Bombardier completed full-scale structural testing of the aircraft on the Complete Airframe Static Test (CAST). Full-scale fatigue testing is also executing per plan, and Bombardier has completed one lifetime of simulated flights, which exceeds the requirements at time of certification.

The Global 7500 aircraft is on track to enter service during the second half of 2018. All five of its test vehicles are in the flight test program, with more than 2,000 hours of flight testing accomplished.

“The rigor and innovation behind our Global 7500 aircraft design and test program have allowed us to deliver enhanced performance without compromise,” says Stephen McCullough, Bombardier’s vice president of integrated product development for the Global 7500 and Global 8000 Program. “Thanks to our innovative designs, coupled with extensive and unprecedented use of integrated ground test rigs and simulators, our flight test vehicles have shown maturity and performance that surpass our initial commitments.”

Bombardier has signed a letter of intent (LOI) for up to 18 Global 6500 and Global 7500 business jets with HK Bellawings Jet Limited, an aircraft management company based in Hong Kong. If all firm orders and options are exercised, the transaction would be valued at approximately $1.14 billion (U.S.) based on 2018 list prices.

Bombardier’s Global 7500 aircraft is the recipient of a 2018 Red Dot Award for Product Design, selected by a 39-person jury from among more than 6,300 submissions from nearly 60 countries competing in several categories. 

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