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https://www.wsj.com/articles/the-four-second-catastrophe-how-boeing-doomed-the-737-max-11565966629
- https://www.wsj.com/articles/the-four-second-catastrophe-how-boeing-doomed-the-737-max-11565966629
- To use less fuel, the design called for larger engines that would be moved forward and higher than in the previous model. The changes affected how the plane handled, though. Its nose pitched up in certain high-altitude conditions, risking a stall, the term for a sudden loss of force called lift that keeps planes aloft.
- Boeing wrote: “same pilot type rating, same ground handling, same maintenance program, same flight simulators, same reliability.” Equally important was that it had to have the same flying characteristics. This was a regulatory necessity if the Max was to escape onerous reclassification as a new airplane. And there was a problem. Boeing test pilots discovered that the Max had unusual stall characteristics when the wing flaps were up and the engines were thrusting.
- One of Boeing’s bewildering failures in the MCAS design is that despite the existence of two independent angle-of-attack sensors, the system did not require agreement between them to conclude that a stall had occurred.
- Apparently the captain noted nothing about the failure of the newly installed angle-of-attack sensor, or the activation of the stick shaker, or the runaway trim, or the current position of the trim cutout switches. If true, it was hard to conclude anything other than that this was severe and grotesque negligence. Dave Carbaugh, the former Boeing test pilot, had the most charitable view of the matter. “I suspect that the pilot wrote what you see in the log, and he verbally told maintenance that, ‘Hey, the trim was running down, and we had to use the stabilizer cutout switches, and we flew the airplane back manually,’ ” he said. “And maintenance took no action on that, because the airplane had made it back to Jakarta. They just checked the fault messages and cleared them and called it a day. That’s my best guess. They were just hellbent to release that airplane.”
- According to the written record, the mechanics responded to the captain’s reports by flushing out a couple of air-data units, cleaning an electrical plug and declaring success after running some ground tests.
- => does this sound like "unittests passed, let's ship it" ?
- In the aftermath of the accident, it turned out that a warning light indicating disagreement between the two angle-of-attack sensors was absent from the airplane because it was being offered on the Max only as part of an optional angle-of-attack instrumentation package. On previous models, the light had come as standard equipment.
- trim controls the full horizontal tail, and elevator only a tab on it. At higher speeds, elevator cannot overrule the tail.
- The airplane was now so far out of trim that Getachew had to hold his control column halfway back (meaning half up-elevator) to keep the nose from dropping. It was urgent to retrim the airplane using the manual trim wheel. But there was a big problem: The pilots had still not throttled back from takeoff thrust, and the airplane now in level flight was going extremely fast, at least 25 knots faster than the maximum operating speed of 340 knots, and was rapidly accelerating into realms beyond the flight-testing range. The excessive speed was amply clear in the cockpit, where an overspeed clacker was sounding off, but neither pilot thought to reduce the thrust and slow. The flight-data recorder later showed that the throttles remained at a takeoff setting until the end.
- The speed, meanwhile, was producing such large aerodynamic forces on the tail that the manual trim wheel lacked the mechanical power to overcome them, and the trim was essentially locked into the position where the MCAS had left it — not fully nose-down, but dangerously out of whack. The only way to retrim the airplane at these speeds would be to use the much more powerful electrohydraulic mechanism associated with the thumb switches, which, however, would require the pilots first to flip the cutout switches back to “normal,” exposing the airplane to further attacks from the MCAS.
- This airplane had heavy pressures on the controls — remember, Getachew was muscling his control column halfway back. Now, in apparent desperation to persuade the autopilot to engage, Getachew did the unthinkable and released his pressure on the control column. The column snapped forward, and the airplane responded by violently pitching down, 20 degrees below the horizon. Just then, with the stick shaker still rattling, the MCAS kicked in and achieved full nose-down trim, doubling the angle of the dive. As the speed shot through 450 knots, the pilots hauled back on their control columns to no effect. Six minutes after takeoff, the airplane hit the ground doing approximately 600 miles an hour. It buried itself into a 30-foot-deep crater in farmland about 32 miles southeast of the airport. Within a week, the Boeing 737 Max was grounded worldwide.
- They would have had to remember to cut power before it was too late, but they were paniced. Once the nose was pointed down enough, even reducing power would have done nothing, there was not enough elevator control to counteract the trim. Turning autopilot back on would likely have saved the airplane, but a pilot is trained to never trust the AP when things are going wrong. They had no way to know it could have helped.
737 Max, The small print (you can read later)