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Aircraft's black-box flight recorders

Accident investigators are searching for the aircraft's black-box flight recorders

Wreckage search - read about black boxesSuch words are sometimes heard on TV news reports about aircraft accidents...

Australia was one of the first countries to introduce this requirement and today, all aircraft on the Australian register with a maximum takeoff weight greater than 5,700 kg are required to carry both a cockpit voice recorder (CVR) and a flight data recorder (FDR).

These 'black boxes' are in fact painted orange to help in their recovery following an accident. They are also fitted with battery-powered sonar transducers to aid underwater recovery.

ATSB's central office in Canberra includes an audio laboratory and an FDR laboratory. The principal purpose of the ATSB laboratories is to perform CVR and FDR readouts for the investigation of occurrences, both within Australia and overseas. Australia is one of the only countries in the Asia-Pacific region to have these laboratories and ATSB has offered its services to overseas authorities to assist in the investigation of major accidents. ATSB assists regional neighbours such as New Zealand, Indonesia, Singapore, Taiwan and Bangladesh with investigation readouts. The ATSB has read out and analysed the flight recorders from:

Example of a computer graphics animation

  • the A300B4-220 accident in Medan, Indonesia on 26 September 1997; and
  • the A300B4-600R accident in Taipei on 16 February 1998.

Readouts are also carried out for certification of new recorder-type/aircraft-type combinations.

In addition to its recorder readout capability, ATSB has advanced computer graphics software which allows data obtained from all available sources to be combined to create a graphical reconstruction of the sequence of events in an accident or incident. These sources include FDR, CVR, ground-based radar recorders, eye-witness reports, ATS communications tapes and wreckage analysis. Videos can also be produced from the computer graphics workstation. Computer graphics is a powerful tool for investigators, being an excellent means of explaining accident scenarios to people unfamiliar with aviation, and also providing a valuable educational tool for pilots and other aviation professionals.

Example of a computer graphics animation. 'Chase plane' view of a BAe146 landing...

If an accident occurred at night in a remote area or at sea, the flight recorders may be the principal, if not the only, means of establishing the sequence of events immediately preceding the accident. At the very least, CVR and FDR data can save an investigation team many days or weeks of delay as the team examines the wreckage.

flight recorder

Many accidents have involved aircraft without flight recorders, and despite thorough investigation, the factors underlying these occurrences remain inconclusive or unknown. On the other hand, accidents leaving very little recoverable aircraft wreckage have been resolved once the flight recorders were found.

Flight recorders are also particularly useful for cases in which evidence is transitory, e.g. occurrences involving windshear. In such instances, flight recorders will reveal the sudden effects of windshear upon an aircraft's flight path. The evidence available from flight recording indicates that, prior to flight-parameter recording, the effect of the wind in many aircraft accidents was underestimated.

VH-IWJ Westwind 1124 accident

This aircraft crashed into the sea off Sydney shortly after takeoff on 10 October 1985. It was completely destroyed on impact and very little wreckage was found immediately after the accident. Approximately three months later, the CVR and FDR were located on the seabed and recovered. Analysis of both recorders at the Bureau's laboratories in Canberra was crucial in determining the factors underlying this accident. In particular, the CVR revealed that the pilot in command was simulating emergency instrument flight conditions during a check of the co-pilot and the FDR revealed that a loss of control occurred at an altitude of 5,000 ft.

CVR partially dismantled showing protective tape enclosure...

The requirement for the fitment of flight recorders to Australian-registered aircraft is contained in Civil Aviation Order CAO 20.18. The equipment standards are detailed in CAO 103.19 and CAO 103.20.

Under the Transport Safety Investigation Act 2003 a CVR is classified as an On-board recording (OBR). The term OBR is used to describe a recording that consists of sounds and/or images of persons in the control area of a transport vehicle. The other requirements include:

  • The recording was made in order to comply with a law in force in any country (Presently the OBRs that are made to comply with a law in Australia are Cockpit Voice Recordings (CVRs) in aviation and in marine Voyage Data Recorders are required on some Ships).
  • Any part of the recording was made at the time of the occurrence of an immediately reportable matter that involved the transport vehicle.

ATSB has the statutory power under the Transport Safety Investigation Act 2003, to take into custody and examine any OBR from an aircraft that has been involved in a Transport Safety Matter.

As a flight recorder has a limited length recording cycle, prompt action is required to quarantine any recorders after an incident or accident to ensure that the data are not overwritten.

Access to the information from a CVR is limited.

An investigation, due to its size and the expertise required, may necessitate the allocation of more resources than are available within the Bureau. In such cases, individuals from outside organisations will form part of the investigation team. Outside organisations may be represented on investigations in one of three ways: accredited representative; participant; and observer. ATSB grants accredited representatives the rights and privileges expressed in the standards and recommended practices of the ICAO Convention on International Civil Aviation - Annex 13, by allowing accredited representatives to act as participants. Participants are permitted to observe and participate in an investigation, with the exception of the output of the CVR.

In the case of occurrences involving Australian registered aircraft outside Australian territory, Australia will appoint an accredited representative, normally an ATSB investigator. The accredited representative may appoint advisers who will be permitted access to data and information in accordance with the provisions of ICAO Annex 13 Paragraphs 5.24 and 5.25 in so far as is necessary to enable the accredited representative to make his or her participation effective.

ATSB will advise flight crew members and their union representative(s) when a CVR is to be used in an investigation. The crew and their nominated representative(s) will be invited to be present during the CVR replay and may be invited to participate in the preparation of the CVR transcript. A complete or partial transcript of a CVR recording will only be made by the investigator in charge if he or she considers that such a document is essential to an understanding of the occurrence. The investigator in charge will endeavour to obtain the agreement of the surviving crewmembers and their union representative(s) that the CVR transcript is accurate.

The Executive Director of ATSB may if it is necessary or desirable for the purposes of transport safety disclose the information to any other person. However, in accordance with ICAO Annex 13 Paragraph 5.12, the CVR transcript will only be used in the final report when it is pertinent to the analysis of the occurrence. Parts of the transcript not relevant to the analysis will not be disclosed.

Confidentiality provisions are in the Transport Safety Investigation Act 2003 to ensure the future free-flow of safety information. OBRs are primarily installed on transport vehicles for safety purposes and it is acknowledged that they constitute an invasion of privacy for the operating crew that most other employees in workplaces are not subject to. The confidentiality provisions recognise the context in which OBRs are installed, which is to provide valuable safety information to assist in determining the factors that relate to a serious occurrence.

The Transport Safety Investigation Act 2003 strictly controls the use of OBR information to ensure it is not used for inappropriate purposes. Unless it is otherwise permitted by the Act, section 53 makes it an offence for any person to copy or disclose OBR information. The Act also prevents the use of OBR information against crew members in criminal proceedings and it cannot be used against employees for disciplinary action. The use of OBR information is also heavily restricted in civil proceedings. Before OBR information can be disclosed or admitted in civil proceedings the Executive Director must issue a certificate stating the disclosure is not likely to interfere with any investigation. This broad test means that it will be unlikely that OBR information will be disclosed in civil proceedings. In the unlikely event of a certificate being issued, the court must conduct a public interest test under section 56 of the Transport Safety Investigation Act 2003.

The only exception to the foregoing is a coronial inquest where an OBR must be divulged to a coroner where the coroner requests it and the Executive Director believes the OBR will not have an adverse impact on the investigation to which the OBR relates.

Note that a recording only becomes an OBR on the occurrence of an immediately reportable matter. The Executive Director must issue a declaration that the OBR is not to be treated as an OBR if the ATSB does not investigate the immediately reportable matter. If the Executive Director does decide to investigate the immediately reportable matter to which the OBR relates and the Executive Director is satisfied that any part of the OBR is not relevant to an investigation then the Executive Director must declare that part not to be an OBR.

If an OBR that is a CVR ceases to be an OBR then it will receive the confidentiality protections of Part IIIB of the Civil Aviation Act 1988 (CA Act). Part IIIB of the CA Act covers all CVRs that are not OBRs under the Transport Safety Investigation Act 2003.

Copies of Annex 13 may be purchased from ICAO. Please visit the ICAO website or e-mail the ICAO Document Sales Unit.

Most CVRs today are analogue recorders using magnetic tape as the recording medium. Recently, solid-state CVRs in which the audio information is sampled, digitised, recorded and transferred into memory chips for storage, have become available.

Solid-state digital flight data recorder pictured

Modern FDRs are mostly digital recorders using magnetic tape as the recording medium. As with CVRs, solid-state FDRs are now available in which the recorded and digitised data is stored in memory chips

Solid-state digital flight data recorder pictured...

Flight recorders are crash-protected to survive both high-speed impact and post-impact fire. They are, however, sometimes destroyed.

The data, rather than the recorder, must survive an accident. The data storage medium (tape or microchips) is mounted inside an impact and fire resistant container. The other components need not survive and are mounted outside the container.

Cockpit voice recorder as received by ATSB showing accident damage

The crashworthiness standards of flight recorders have been recently reviewed by the European Organisation for Civil Aviation Equipment (EUROCAE) committee, an international body on which ATSB was represented. The recorder's memory module is now required to withstand an impact producing a 3,400-g deceleration for 6.5 milliseconds (equivalent to an impact velocity of 270 kts and a deceleration or crushing distance of 45 cm) and then to withstand a fire of 1,100 degrees C for 60 min.

Flight recorders are normally located near the aircraft's tail, as experience has shown that this area generally suffers the least damage during an accident.

Cockpit voice recorder as received by ATSB showing accident damage...

The Cockpit Voice Recorder

The CVR would be better named the cockpit audio recorder as it provides a record of the total audio environment in the cockpit area. This includes crew conversation, radio transmissions, aural alarms, control movements, switch activations, engine noise and airflow noise.

The CVR retains the last 30 minutes of information on tape operating on the endless-loop principle.

Approximately 80% of aircraft accidents involve human factors which, in most cases, means crew performance was a factor. Consequently, the CVR often assists accident investigators to determine why an accident occurred.

The Flight Data Recorder

The FDR records flight parameters. The range and quantity of data recorded varies widely, depending upon the age and size of the aircraft.

The minimum requirement is to record a basic group of five parameters:

  1. Pressure altitude
  2. Indicated airspeed
  3. Magnetic heading
  4. Normal acceleration
  5. Microphone keying.

Microphone keying (i.e. the time radio transmissions were made by the crew) is recorded to correlate FDR data with CVR information.

This basic requirement has existed since the 1960s, and today, modern jet aircraft far exceed this basic requirement, being fitted with FDRs that can record up to 400 parameters covering all aspects of the aircraft operation.

The FDR retains the last 25 hours of aircraft operation on tape and, like the CVR, operates on the endless-loop principle. As FDRs have a longer recording duration than CVRs, they are very useful for investigating both incidents and accidents.

The FDR often tells accident investigators what happened during an accident sequence.

 

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Type: Educational Fact Sheet
Publication Date: 15/11/2000
Last update 23 November 2010