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Trailing cone

A trailing cone is a calibration apparatus employed in flight testing to accurately measure ambient static air pressure by deploying a lightweight, cone-shaped device trailed behind an on a flexible cable, which positions the pressure sensors in undisturbed airflow far from the aircraft's aerodynamic influences. This method corrects for static position errors in the aircraft's pitot-static system, ensuring precise determinations of , altitude, and across various flight conditions. Developed in the mid-20th century as an economical alternative to more complex calibration techniques, the trailing cone concept evolved from earlier static pressure measurement devices, with initial prototypes tested in the 1950s and refined through wind tunnel and in-flight evaluations by organizations including the U.S. Navy and NASA in the 1960s. The device typically consists of a fiberglass or similar lightweight cone, approximately 12.7 cm in base diameter, attached to a high-strength tubing system that includes pressure orifices located 5 to 6 cone diameters ahead of the cone's base to capture static pressure while the cone provides aerodynamic stability through drag. During operation, the cone is reeled out to a distance of at least one fuselage length—often 100 to 200 feet—behind the aircraft, where it aligns with the local airflow regardless of the aircraft's angle of attack, allowing direct comparison between the trailed pressure reading and the onboard static ports. Trailing cones have been validated in subsonic and transonic wind tunnel tests up to 0.95, demonstrating pressure measurement accuracies within 0.001 , with minimal sensitivity to variations or protective modifications like skids. In flight applications, they have supported position error s for and survey , reducing errors to as low as 0.3 mb (about 0.63 ) at altitudes up to 40,000 feet and speeds exceeding 1.0, proving effective in unaccelerated level flight across diverse types. Though primarily used during certification and developmental testing, the trailing cone remains a reliable tool for high-precision air data , particularly where advanced like trailing bombs or GPS-aided methods are impractical.

Overview and Principles

Definition and Purpose

A trailing cone is a lightweight, aerodynamic probe consisting of a cone-shaped towed behind an via a flexible, high-strength tube to measure undisturbed in the freestream airflow. This system serves as a specialized tool for obtaining precise data far removed from the aircraft's aerodynamic disturbances, such as boundary layers or shock waves that affect onboard sensors. The primary purpose of the trailing cone is to provide precision calibration for static pressure systems, which are essential for accurate determinations of , altitude, and , particularly in high-speed or flight regimes where fuselage-mounted static ports experience significant distortions from local airflow effects. By sensing true ambient , the device corrects position errors in the aircraft's instrumentation, ensuring reliable performance during and certification processes. Developed in the mid-20th century to address the limitations of traditional static ports on high-performance , the trailing cone emerged as a to the inaccuracies caused by shock waves and influences on airframe-mounted sensors. Early concepts originated from work by the Royal Aeronautical Society in the , with refinements by companies like Douglas and the (FAA) through the 1960s, driven by the need for better accuracy across to supersonic speeds. In basic operation, the cone trails 1-2 lengths behind the to escape its aerodynamic influence, with ports positioned forward of the cone to capture conditions without . This positioning allows the ports to align naturally with the undisturbed , stabilized by the cone's , thereby providing a direct measure of ambient for comparison against the 's onboard systems.

Underlying Principles

The trailing cone operates on the aerodynamic principle that positioning the measurement device sufficiently far aft of the —typically 30 to 60 meters behind—places it outside the viscous wake and distorted pressure field generated by the , wings, and other structures, enabling the static pressure ports on the cone to sample near-true conditions. This distance, often equivalent to one or two wingspans, ensures the cone resides in a region where the has recovered to ambient , free from local accelerations or decelerations induced by the . The underlying fluid dynamics rely on , which relates to and altitude through the equation p_s + \frac{1}{2} \rho V^2 = p_t, where p_s is , \rho is air density, V is , and p_t is total (stagnation) pressure; the trailing cone corrects for position errors in static ports by providing a reference p_s that minimizes deviations from this ideal relationship. The cone's streamlined shape, such as an or pointed nose with a flared base, reduces its own aerodynamic drag while allowing tension in the connecting tube to maintain a stable trailing angle, ensuring consistent alignment with the local flow. Stabilization of the trailing cone is achieved through its geometry, which generates a restoring aerodynamic moment that self-aligns the device with the direction, thereby preventing oscillations or misalignment due to or sideslip. This passive mechanism, combined with the drag from the cone's perforated or finned design, keeps the tube taut and the system steady during level flight, though it is limited to quasi-steady conditions to avoid dynamic instabilities. The primary benefit is the reduction of position error \Delta p_{pos} = p_{s,a} - p_s, where p_{s,a} is the static port and p_s is static ; this error can reach several percent of dynamic q = \frac{1}{2} \rho V^2 in flows due to shock-induced distortions, but the trailing cone typically limits it to 0.1–0.2% of q in well-calibrated setups. The correction for true static pressure using trailing cone data is derived from pressure coefficient differences. The measured pressure at the cone is p_c = p_s + C_{p,c} q, where C_{p,c} is the cone's pressure coefficient (often near zero due to its freestream placement). Similarly, the aircraft port pressure is p_{s,a} = p_s + C_{p,a} q, with C_{p,a} capturing the position error coefficient. Rearranging yields the true freestream static pressure approximation: p_s \approx p_c + \frac{1}{2} \rho V^2 (C_{p,c} - C_{p,a}) This equation accounts for any residual C_{p,c} (calibrated separately) and the known or estimated C_{p,a}, providing a direct link between and measurements; in practice, C_{p,c} is minimized by port placement on the cone's cylindrical section. For cases, such as at with 0.3, this yields altitude accuracies of ±8 feet (corresponding to ~0.3 pressure error), while at 60,000 feet, errors remain below ±37 feet. In regimes up to 0.9, normalized errors \Delta p / [q](/page/Q) are around -0.0026 at 0.8, though complexity increases due to effects, limiting overall accuracy to ~0.2% of [q](/page/Q) without additional wind-tunnel validation.

Design and Components

Cone Structure

The trailing cone is typically constructed as a , streamlined cone-shaped body designed to minimize aerodynamic disturbance while ensuring stable trailing in conditions. Representative designs feature a base of 5 to 10 inches (12.7 to 25.4 cm) and an apex angle of 32 to 42 degrees, enabling reliable alignment and stability at angles of attack up to 10 degrees during . The cone length varies by application but is generally 20 to 80 cm to accommodate internal pressure sensing components while maintaining a low-drag profile. Static pressure ports are integrated as multiple flush-mounted orifices along the cone's internal pressure tube or surface, typically numbering 4 to 48 in arrays (e.g., four rings of 12 orifices each, spaced 30 degrees apart azimuthally and positioned 4 to 10 cone diameters forward of the ). These ports connect to an internal manifold or averaging chamber to mitigate asymmetries and provide accurate static pressure measurement. The cone body is fabricated from high-strength, low-weight composites such as epoxy-resin or composite fibers to balance durability and minimal mass, while corrosion-resistant alloys like are used for ports, fittings, and structural reinforcements to endure environmental exposure during deployment. Total mass is maintained below 5 kg (e.g., 1.25 kg for compact models) to reduce tube tension needs and aircraft drag increment, which remains negligible at under 0.1% of total drag in operational use. Manufacturing adheres to standards, including surface finishes of ±0.1 mm or better to promote over the ports and ensure measurement precision, with components produced by certified facilities compliant with for FAA and EASA-approved RVSM applications.

Tubing and Deployment Mechanism

The tubing in a trailing cone system consists of a high-strength, flexible designed to transmit signals while supporting the mechanical load of trailing the cone behind the . Typically constructed from nylon-reinforced materials such as Nylaflow® with embedded for tensile strength, the tubing has a of 6-10 mm and lengths ranging from 50 to 100 meters to ensure the cone trails sufficiently far (often 1.5 to 2 lengths) from the 's disturbed . These specifications allow the tubing to withstand tensions up to 500 N and internal pressures suitable for pneumatic transmission, with maximum loads around 534 N and leak-tested at 10-12 to maintain . Deployment hardware is mounted in the aircraft's or section for optimal positioning and includes a motorized system to control the payout and retrieval of the tubing. The , often powered by a with control, enables smooth extension during flight without excessive drag or . A mechanism, typically incorporating skids or bushings, guides the tubing to prevent chafing against the aircraft structure during operation. The tubing provides an internal pathway for transmitting signals from ports on the to the aircraft's , minimizing errors from disturbances. Multiple orifices on the feed into an averaging chamber within the tubing, which connects via small-diameter lines (e.g., 0.04-0.135 inches) to transducers like Paroscientific models with 0.01% accuracy. To isolate vibrations and pressure lags, systems often incorporate flexible manifolds or bladders, with corrections applied for dynamic errors on the order of ±0.2 mb during stabilized flight. Safety features include breakaway links or shear pins integrated into the reel assembly to allow jettisoning the in emergencies, preventing entanglement or structural damage. Tension sensors monitor deployment stability, alerting to excessive loads (e.g., from cone deformation at dynamic pressures above 10 in ), while protective sleeves like Kevlar® cover the initial tubing segment to resist heat and abrasion up to 250°F. Integration with standard pitot-static systems is achieved through AN fittings and adapters, enabling direct connection to altimeters or data logging equipment such as systems for real-time recording. This compatibility supports applications like RVSM certification, with optional wireless links for remote up to 950 ft.

Operation and Calibration

Deployment Procedure

The deployment procedure for a trailing begins with thorough pre-flight preparations to ensure integrity and operational safety. Operators inspect the , tubing, and any associated or mechanism for , such as cracks, abrasions, or wear that could compromise structural integrity during flight. lines are calibrated on the ground using standards traceable to national bureaus, with leak tests conducted under simulated altitude conditions (e.g., 20,000 ft equivalent) to verify rates below 100 ft/min, typically achieving 40-60 ft/min. Clear behind the is confirmed, and like transducers is verified for accuracy within recent windows, often 60 days for critical s. In-flight deployment is initiated once the aircraft reaches a low speed, typically below 110 knots calibrated airspeed (KCAS), to minimize initial aerodynamic loads. For systems equipped with an onboard winch or reel, the tubing is gradually paid out from the cockpit or via ground control linkage, allowing the cone to extend 15-24 meters behind the fuselage in level flight at constant speed and altitude (e.g., Mach 0.4 at 3,000 meters). Tension in the tubing is monitored to ensure stability, with the cone achieving full extension and pressure stabilization as speed increases to 200-300 knots true airspeed, where it trails at least one fuselage length in undisturbed airflow. Ground-deployed systems, such as those mounted on the vertical stabilizer, may extend the cone at a 45-degree angle prior to takeoff, with the cone "flying" naturally during rollout and stabilizing in cruise. During operation, continuous monitoring is essential to maintain cone stability. Oscillations are checked using tension sensors, accelerometers, and visual from chase , limiting angular deviations to under 30 degrees to prevent dynamic errors in pressure readings. Flight speed is adjusted to sustain a stable trail, with data recorded only after stabilization (e.g., 1-3 minutes in level legs), avoiding periods of non-steady conditions that could introduce lags of several seconds in the system. In-flight or confirms the cone's position relative to the aircraft wake, ensuring it remains in free-stream air. Retraction follows a controlled sequence to avoid damage from whipping or entanglement. The slows to below 150 knots, and the tubing is reeled in at a steady rate using the mechanism, with issues noted during the final 7-10 meters of recovery. Upon , the pilot executes a sharp turn to clear the exhaust plume, allowing to coil the tubing and secure the cone (e.g., to a missile rail or stowage point) using ties or clips. A post-flight inspection examines the entire system for deformation, heat damage, or wear, replacing components if necessary. Safety protocols prioritize abort criteria and throughout the . Deployment or flight is aborted if excessive is detected (e.g., via increases exceeding operational norms) or structural warnings appear, such as tubing anomalies or instability beyond safe limits. Systems incorporate quick-release or jettison mechanisms for emergencies, tested over unpopulated areas, and all operations adhere to clean aircraft configurations with retracted gear and flaps at speeds above 70 m/s. Coordination with chase aircraft and ground teams ensures real-time feedback, with reinforced tubing (e.g., sleeving) protecting against heat and abrasion.

Pressure Measurement Process

The pressure from the static ports on the trailing cone, typically consisting of multiple orifices arranged in rings to average the static pressure, is transmitted pneumatically through a flexible tubing system—often or similar material with an inner diameter of about 0.635 cm—to onboard transducers located in the . These transducers, such as Rosemount models or Paroscientific DigiQuartz units with accuracies of 0.01% to 0.5% , convert the pressure signal into electrical outputs for systems. The system samples the pressure data at rates ranging from 10 Hz to 100 Hz, enabling real-time monitoring during maneuvers while capturing dynamic variations in atmospheric conditions. The core of the calibration process involves comparing the cone-derived (Pcone) to the aircraft's onboard (Pairframe) across a range of altitudes and numbers, typically during stabilized straight-and-level flight legs lasting 1-3 minutes. The position error, which represents the altitude offset due to inaccuracies in the airframe , is computed using the formula: \Delta h = \frac{RT}{g} \ln\left(\frac{P_\text{cone}}{P_\text{airframe}}\right) where R is the for dry air (287 J/kg·K), T is the ambient temperature in , and g is (9.81 m/s²). This equation derives from the hydrostatic relation in the atmosphere, where the pressure lapse rate is dP/P = -(g / RT) dh; integrating assuming isothermal conditions yields the logarithmic form, with the sign convention indicating that Pcone approximates pressure more accurately than Pairframe, which may be perturbed by local flow effects. For example, at a true altitude of 10,000 m where T ≈ 223 K, P ≈ 265 hPa, and Pcone exceeds Pairframe by 0.5 mb (50 ), the resulting Δh ≈ 12 m, providing a correction to indicated altitude and that scales with flight conditions. The acquired pressure data feeds directly into the aircraft's flight test instrumentation, such as systems (DAS) connected to onboard computers, where it is processed to generate calibration tables mapping and altitude errors as functions of and configuration. To account for tube lag—typically less than 1 second in short-tube setups but up to several seconds in longer configurations—digital filtering or time-lag corrections are applied during real-time processing and post-flight analysis. Accuracy is validated post-flight by cross-referencing the calibrated pressures against independent references like GPS-derived from D-value maneuvers, yielding errors as low as ±0.16 mb at 12 km altitude, which translates to errors below 0.5%. In wind-tunnel validations, trailing cone systems have demonstrated pressure measurement errors under 0.063% of , corresponding to discrepancies less than 0.0006. Modern enhancements include integrating digital pressure sensors directly on the cone, such as high-accuracy piezoelectric or quartz transducers, paired with wireless telemetry systems operating at frequencies like 915 MHz to transmit data up to 950 ft without pneumatic tubing, thereby eliminating lag and enabling higher-fidelity measurements in dynamic flight regimes.

Applications and Usage

Flight Testing

Trailing cones play a critical role in aircraft flight testing by providing a reference for calibrating static pressure sources in air data systems, particularly during high-speed runs that expand the performance envelope of new designs. This calibration ensures precise measurements of airspeed and altitude, which are essential for validating stall speeds and Mach number limits. By trailing behind the aircraft at a distance of at least one fuselage length, the cone minimizes position errors caused by the aircraft's aerodynamic interference, allowing for accurate determination of free-stream static pressure. Flight test scenarios involving trailing cones typically encompass to regimes, with numbers ranging from 0.3 to 0.95, conducted in straight-and-level unaccelerated flight at altitudes between 4,500 and 12,500 meters. Maneuvers are performed to map position errors, including variations in limited to small values (less than 2 degrees) to maintain cone , though broader ranges such as -5 to +15 degrees may be indirectly assessed through complementary . These tests occur in configurations at speeds above 70 m/s, often using pacer for verification via overtake maneuvers. Historical applications include later tests on the NCAR Sabreliner in the for pressure survey missions. The primary data output from trailing cone tests consists of correction curves plotting position error against , which are applied to pitot-static computers to refine air data computations. These curves achieve high accuracy, reducing errors to approximately ±0.39 millibars, corresponding to airspeed uncertainties of less than 1 in typical conditions. Integration into FAA and EASA certification campaigns involves pre-flight leak checks, deployment at specified trail lengths (15-18 meters), and multiple short flight legs (1-3 minutes each) totaling several hours per program, often 10-20 flight hours to cover the required matrix for validation.

RVSM Certification

Reduced Vertical Separation Minimum (RVSM) operations are mandated in from 290 (FL290) to FL410, where the vertical separation between is reduced to 1,000 feet to increase . To ensure safety, altimetry systems must achieve high precision, including an automatic altitude capable of maintaining altitude within ±65 feet at a 95% probability during stabilized flight. Trailing cones play a critical role in calibrating the 's ports to minimize altimetry system error (ASE), targeting a total ASE below 200 feet to meet these requirements. The RVSM certification process involves deploying the trailing cone during dedicated flight tests to measure and verify overall altimetry performance. These flights assess the total ASE across various numbers, weights, and configurations, ensuring it remains under 200 feet. The procedure incorporates temperature compensation to account for environmental variations and checks to evaluate differences during and deceleration, confirming the system's reliability under operational stresses. Regulatory standards for RVSM certification are outlined in FAA 91-85B, which provides guidance on airworthiness approval, including static system methods like trailing cones. In , equivalent requirements are detailed in Eurocontrol's Guidance Material for RVSM operations, emphasizing height-keeping performance. Data collected from trailing cone deployments informs adjustments to the 's barometric altitude settings and static system error correction (SSEC) tables, enabling regulatory approval for RVSM entry. Trailing cone usage is prevalent in certifying business jets, where dedicated flights validate static port accuracy and confirm compliance with ASE limits before obtaining RVSM operational approval. These tests ensure the aircraft meets the stringent height-keeping standards required for high-altitude en route operations, and as of 2025, trailing cone data continues to support RVSM monitoring requirements. Typically, RVSM via trailing cone involves 5-10 dedicated flights to gather sufficient data points, streamlining the process by delivering precise pressure measurements that reduce reliance on simulations. This approach can lower overall timelines and costs, often ranging from $70,000 to $100,000 for operators.

Advantages and Limitations

Key Benefits

Trailing cone systems provide superior accuracy in measuring freestream static pressure compared to fuselage-mounted ports, achieving errors as low as 0.016% to 0.063% of static pressure across Mach numbers from 0.30 to 0.95, which corresponds to Mach number errors less than 0.0006. In contrast, fuselage static ports are susceptible to position errors due to the aircraft's aerodynamic disturbance field, often resulting in higher inaccuracies that require extensive corrections. This precision enables reliable calibration of air data systems, with pressure differences typically ranging from 0.08% to 0.25% of impact pressure and minimal sensitivity to Reynolds number variations. The versatility of trailing cones allows their use across a broad range of speed regimes, from (Mach 0.30) to (up to Mach 0.95) and potentially supersonic conditions, without requiring major modifications to the system. Unlike fixed-length boom probes, which are constrained by structural limitations and issues at higher speeds, trailing cones maintain through adjustable tube lengths—often two wingspans or more—ensuring alignment with flow via proper placement 5-6 cone diameters ahead of the tip. This adaptability supports calibration in various flight envelopes while remaining effective in steady level flight. Trailing cones offer cost-effectiveness as a reusable tool, serving as a practical alternative to expensive methods like pacer or tracking for large-scale programs. Their design facilitates quick deployment and economical testing, reducing overall program expenses compared to dedicated infrastructure. Additionally, the systems impose minimal interference on performance, with total weights around 8.5 pounds (approximately 3.85 kg) and drag forces on the order of 7.7 pounds at moderate speeds, allowing normal flight profiles without significant alterations. Developed and tested since the 1950s, trailing cones have demonstrated proven reliability over more than 50 years of operational use in and , supported by extensive validation in wind-tunnel and in-flight studies with consistent stability and low error margins. Modern implementations, including self-contained variants, have operated reliably for over six hours during extended tests, transmitting data accurately over distances exceeding 950 feet.

Potential Drawbacks

Trailing cone systems, despite their utility in , are subject to several operational challenges and limitations that can impact , accuracy, and efficiency. Deployment of the trailing cone carries risks of tubing or oscillations, particularly in turbulent , which may lead to data inaccuracies or potential entanglement with the . These issues necessitate deployment only in calm atmospheric conditions and require experienced pilots to maintain steady, unaccelerated flight to minimize excursions. An emergency release mechanism is essential to prevent structural damage or control interference in case of malfunction. The system's effectiveness is constrained by speed and altitude ranges. At low speeds, the cone's weight can cause sagging of the tubing, potentially introducing total pressure errors into static measurements and limiting reliable use below approximately 100 knots, where alternatives like trailing static s are preferred for low-speed . At high speeds, tubing may occur, with the trailing bomb variant unstable above 200 knots, while cones have been tested successfully up to 1.12 but may require specialized designs or alternatives to avoid dynamic instability at higher supersonic speeds. Altitude operations are typically restricted below 10,000 feet for optimal performance, with higher altitudes demanding additional position error verification due to varying atmospheric effects. Maintenance requirements add to operational burdens, as the tubing and must undergo pre- and post-flight inspections for , leaks, and structural , alongside every 60 days using approved facilities. These demands can elevate costs relative to permanent static ports, though exact increments depend on usage . presents hurdles, as trailing cones are classified as temporary requiring approval under regulations such as 14 CFR § 23.1325, including demonstrations of dynamic and structural soundness across the operating envelope. All collected must maintain for regulatory audits, ensuring compliance with accuracy standards like ±30 feet per 100 knots for errors. Environmental sensitivities further complicate use, with the system vulnerable to turbulence-induced oscillations that degrade measurement precision, mitigated by restricting flights to smooth air masses. Potential icing on the or tubing in adverse can alter readings, often addressed through operational avoidance or protective measures like heated sleeves, while bird strikes pose risks of physical damage to the exposed trailing elements, necessitating vigilant .

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