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Building a Safer Cockpit

Enhanced and synthetic vision systems (inset) blend GPS information with a topographical database to create a moving digital map of unseen terrain and hazards. (Photograph by Sam Chui)


Wreckage of Northwest Flight 255 crash, August 1987. (Photograph by Melanie Stengel/Corbis)
Northwest 255 had just taken off from Detroit on Aug. 16, 1987, when it began rocking side to side. The plane clipped a building and caught fire before sliding under a railroad embankment and two highway overpasses (right). The crash, which killed all 154 onboard and two bystanders, occurred because the MD-82's pilots did not extend slats on the leading edge and flaps on the trailing edge of the wings to generate extra lift. The manufacturer recommended that airlines modify their MD-80 cockpit checklists; U.S. carriers did so, but not all foreign carriers. In 2008 a Spanair MD-82 crashed in Madrid because of a similar mistake, killing 154—showing that failure to modify procedures in response to crashes, close calls and government advisories can cost lives. Here are other changes in the cockpit that reduce chance of pilot error. —Mark Huber 

1. Make Two-Person Altitude Calls

To prevent planes from dropping below assigned altitudes—which increases the risk of midair collisions—the co-pilot sets the altitude, called "pointing," and the pilot confirms that it is correct. 

2. Retract Speed Brakes

Failing to retract speed brakes—panels that increase wing-surface area—in an aborted landing means an aircraft can't climb quickly. Many airlines require co-pilots to verify speed-brake status if the plane misses a landing. 

3. Know Speed Limits

Flaps, which are extended to allow airplanes to remain aloft at slower speeds during takeoff and landing, can suffer motor damage if they are deployed while the airplane is traveling too fast. In addition to memorizing these speed limits, co-pilots at some airlines are required to call them out as the airplane prepares to land. 

4. Confirm Spoiler Deployment

Like speed brakes, spoilers are wing surfaces that diminish lift and are needed during landing, when an airplane must quickly shed speed. It is the co-pilot's job to confirm that spoilers have been deployed during a landing to prevent the plane from overshooting the runway. 

Building a Safer Airframe

Colgan Flight 3268 loses a wheel while landing at Buffalo. (Photograph by Toronto Sun)


(Illustration by Dogo)
Passengers usually feel relief when their plane touches down. But those peering out the windows of Colgan 3268 this May were horrified to see a wheel rolling away from their airplane during an otherwise routine landing. The end of an axle in a wheel bearing snapped as the Q400 Bombardier screeched across the runway—and as a passenger shot a cellphone video (left) of the chilling event. The airplane safely landed on its remaining tires. Investigators found that the wheel bearing failed after it overheated during the landing. Wheel bearings are just a few of thousands of parts that endure the stress of repeated takeoffs, flights and landings. Maintainers and designers constantly adopt new materials and inspection devices to prevent heavily stressed parts of planes from failing during flights. 


 

1. Wheel Bearings

Wheel bearings support the entire weight of the aircraft on a surface area of a few square inches, and during a landing they accelerate from 0 to 2000 rpm in less than 1 second. Ball bearings made from new ceramic formulas can better resist the temperature changes and physical stresses of these conditions. 

2. Wing Spars

Stress on the wing is borne by the spars. Boeing's 787 Dreamliner is the first civilian airplane to use carbon composites to form spars, but designers added extra metal fasteners to stiffen the wings after tests showed they couldn't handle the FAA's maximum aerodynamic load limits. As with other composite parts, crews use ultrasound to seek early signs of failure. Resin-filled nano- structures embedded in the material could patch cracks as soon as they form. 

2. Wing Skin

Wings endure high pressures while generating lift; stress on the wings' metal skin tends to peak in areas where the wing connects to the fuselage. Wing skin is installed in panels held together with fasteners. Every hole or deformation that interrupts the skin makes it more susceptible to cracking, so maintenance crews inspect areas around the fasteners with ultrasound equipment for signs of weakness. Researchers at Sandia National Laboratories are designing paper-thin pressure sensors that continually monitor for cracks. 

4. Fuselage Skin

Aluminum fuselages are built to handle changes caused by cabin pressurization—which inflates and deflates the body of an airliner as much as a quarter of an inch—but tension stress still spreads across the entire fuselage. Windows, doors and rivet holes magnify this stress. Engineers understand metal fatigue, but new materials like carbon composites pose unique safety issues. Maintenance workers use ultrasound and other non invasive scanners to find deformations and fractures inside composite materials. 

Building a Safer Airport

(Illustrations by Dogo)


Doomed flight 4590 lifts off moments before crashing in Paris, July 2000. (Photograph by Associated Press)
At 2:42 pm on July 25, 2000, Air France 4590 roared down runway 26R at Charles de Gaulle International Airport in Paris, bound for New York with 109 passengers and crew onboard. As the supersonic jet accelerated for takeoff, it ran over a 17-inch-long strip of titanium that had fallen off the thrust reverser of a recently departed DC-10. The metal shredded one of the Concorde's tires, and the flying pieces ruptured and ignited a fuel tank. The plane crashed 2 minutes later, killing all onboard and four people on the ground. Investigators found the runway was unchecked for 12 hours before the crash. The accident highlighted a paradox: Some of the worst threats to aviation, including debris, vehicles and other aircraft, are located on the ground. 

1. Broadcast Tower

The FAA's Airport Surface Detection Equipment-X integrates data from an inbound plane's GPS unit and the transponder signals from ground vehicles and other planes in the air to generate a continuously updated map of all airport traffic. Remote towers capture and relay information from airplanes in flight. ASDE-X, which alerts air traffic controllers to an impending conflict, is already in use at 20 U.S. airports; the FAA plans to install it in 15 more by 2011. 

2. Cockpit Digital Maps

Paper maps keep pilots out of trouble, but they need to be updated regularly. Digital maps of airports and the surrounding areas are more easily amended to include new obstacles and infrastructure. Pilots carry laptop-size computers called Electronic Flight Bags that plug into the cockpit navigation system. New EFBs alert users to update maps using Wi-Fi. 

3. High-Frequency Radar

Detectors use sensitive radar with wavelengths as tight as a millimeter to spot debris as small as a bolt that could cause crashes; some systems have cameras that compare images to a database of common objects, distinguishing grass or paper from more dangerous obstacles. 

4. Runway Status Lights

Modern versions of runway lights—which guide pilots, particularly at night or in bad weather—act like traffic lights: Red means a runway is in use; green means a runway is clear for takeoff, landing or crossing.

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Saturday, July 3, 2010

at 2:55 PM


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James Cameron Talks About Avatar's Blu-ray Release

Today, in a release tied to Earth Day, die-hard fans of James Cameron's Avatar will be able to return to Pandora by purchasing the film's first Blu-ray: A stripped edition with only a menu and the movie—no trailers, no extras—with a more elaborate edition to follow in November. Cameron talks to Popular Mechanics about remastering the film for Blu-ray, the challenges of shooting sports in 3D, and why he doesn't have a 3D TV in his house (yet).

Avatar on Blu-Ray
Q
I got a chance to watch Avatar on Blu-ray, and it looked beautiful. 
AIt looks great on Blu-ray doesn't it? We mastered it with the same colorist who did the digital intermediate on the theatrical release. Same guy, same machine, same color, and we were just able to preserve everything that went into the digital master for the release in the Blu-ray. 
Q
Did you make any other tweaks or adjustments?
AInterestingly enough, we were so rushed to get the film done that we actually improved a few things [on the Blu-ray]. There were also a few things that bothered me and I was like, "Can we fix that?" 
Q
What did you fix?
AOh, just little things. Like maybe someone's face was a little dark or a little light, or we hadn't quite gotten color matching across the shot. But I figure the permanent record of the movie is the Blu-ray. If someone is going to be looking at Avatar 10 years from now, they are going to be looking at it on that. So we might as well get it right once and for all. 
Q
This initial Blu-ray is bare-bones—no trailers, no extras. When can we expect a release with extras, and what goodies will you have on it? 
AWe are going to do the full bells and whistles, multidisk, deluxe box set in November. That's going to have behind-the-scenes stuff, and scenes that were taken out at an earlier stage where you can see them just in their sketched form. Then there will be scenes that were taken out that have been actually completed in CG up to the same level as the rest of the film. That's why the release is being done this week; it's going to take us months to get all of this stuff done. We're actually going to do this in two stages—we're going to do a theatrical re-release of the film in IMAX theaters and digital 3D theaters in August with six minutes of additional footage, and then you'll be able to get the box set in November that has that footage plus a whole bunch more plus all the supplemental stuff. 

One of the things in the supplement that I think is going to be really cool is you'll be able to watch a scene the way we captured it. In other words, it will be cut, but all you'll see is the reference cameras and what the actors are doing with their marker suits on, or you will be able to click and watch it in the CG template, in the way that I see it when I'm working with the virtual camera, and then you will be able to watch it as the finished scene. You'll get to see all the stages of how the film was created. Not for the whole movie but for certain selected scenes in the film. I think that will be really cool. 
Q
Why not do a 3D Blu-ray right away?
AWe will, we will. That technology is out now and we just need more people to buy the players. We are not ready to announce exactly when we're going to do it, but we will be doing it. We haven't done the 3D master for it, although that will only take a day or two.
Q
Blu-ray has been pitched as basically the only format that is capable of creating good 3D because it's the only format that has the space to do it. But is 50 gigs enough to do hi-def and 3D?
AOh yeah. Absolutely. Because they use a stereoscopic algorithm where they aren't actually doing double HD. What they do is they have a full HD image—I'm not sure if it's in the left eye or the right eye—and then they have the delta data between the right eye and the left eye is what is recorded for the other eye. Then it is reconstituted into a double HD picture. It's about 150 percent of the data of a single HD screen. It's actually something that I was talking about 10 years ago, that we should be able to do a stereoscopic compression algorithm and then I didn't do anything with it. And then somebody else came up with it and it actually works beautifully. 
Q
Do you have a 3D television in your house?
ANo. There isn't enough content to run on it yet. Vince Pace and I have a camera company, and we're talking to the networks about providing them with cameras, and that new flow of 3D programming is going to be coming in the next few months and should be really building up by the end of the year. And I haven't been home, by the way, so it doesn't matter what TV I have. I've been in 107 airports in three months. 
Q
Have you made any tweaks to the 3D rig since you used it in Avatar?
AWe're constantly evolving the 3D rigs and upgrading the technology. We're planning a new generation of the camera system for theatrical films as well. So that's an ongoing process. We're on about the third generation now.
Q
Have you seen any footage of the films that have been shot with it? I don't know if you've seen the trailer for the new Resident Evil, but it actually says "shot with the James Cameron/Vince Pace system."
A(laughs) That's a good plug! I haven't seen any of the Resident Evil material, but I've seen some of Tron, and I've seen some of the sports stuff that we've been doing lately. But I think we have the philosophical approach that gets stereo right, and that applies to switched programming like sports, and it applies to theatrical motion pictures. The camera rigs are very flexible; they're great at managing stereo space and at creating good, cuttable stereo—because that's a critical thing, being able to cut rapidly and still have it look good.
Q
There's been a lot of talk about 3D sports, but I once saw a 3D football game that was filmed with a different system, and when the settings weren't right, it was literally painful to watch. 
AVince and I have been involved with, I think, most of the good stereo production that's been done over the last few years. And the Ohio State University football game really proved to the football community that 3D and football worked well together, and it had been done badly before that by a competitor. That had actually been disheartening to the football community, but now they know it can be done right. And the same with basketball, and we just did the Masters tournament and the Final Four. We're basically dominating the sports market right now, and it wasn't easy. We had to go out and do a lot of pro bono work, shooting a lot of sports over the last five or six years at our own expense to figure out how to modify the systems to allow it. And one of the key issues is hyperstereo. You have to be able to go beyond the normal interocular distance in order to film some sports, whether it's a NASCAR race and the car is coming around a corner half a mile away, or it's a football play that's 75 yards away. You have to be able to create stereo that cuts well with a camera that's maybe right along the sidelines that's very close. So the stereo space has to be controlled through interocular to be compatible. We have these sports-oriented rigs that are a little bit different. They use the same basic camera technology, but they're a little bit different than the ones we use for feature film making.
  

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at 2:40 PM


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King Kong Takes on Three Other 3D Universal Rides

How does the new King Kong 360 stand up to other 3D attractions? Here's a look.


Voracious raptors encircle your studio tram car. The carnivorous Vastatosaurus rex spots you as potential prey. Suddenly, a massive, 6000-pound gorilla enters the scene and you're in the middle of an all-out fight. Welcome to Universal Hollywood's King Kong 360 3D, an experience that, aided by the world's largest wraparound screen, will change the face of theme park attractions when it opens this July as part of the larger Studio Tour. King Kong 360 will replace the animatronic King Kong Encounter—destroyed by fire in 2008—with the help of director Peter Jackson and with 3D and technology that will more than double the digital resolution per second of a typical feature film and blast 108 decibels of surround sound. 

But it's not just Kong who's taking theme parks by storm: rapid advancements in 3D technology are ushering in an entirely new era of ride realism. Universal Orlando's Wizarding World of Harry Potter, slated to open this June, combines 3D visuals with robotic technology and live performance in its signature Forbidden Journey dark ride, and park reps are being so secretive, it may be impossible to tell where the tactile ends and the 3D begins. Here is a look at what makes four impressive 3D Universal rides tick. 



Terminator II 3D (Universal Florida, 1996):

 

What It Is: Polarized glasses help propel audiences into the middle of a 12-minute cyber war combining live stage action with advanced 3D film technology; it has Schwarzenegger reprising his title role. 

Game-Changing Tech: Six synchronized projectors cast 70-mm film onto three concavely situated, 50-foot-wide screens, creating one continuous image. It was considered the world's largest 3D installation upon opening. 

Why It Works: The triple screens create a 180-degree arc to pull the 700-seat audience into the picture, while 4D elements—including spraying mists and a custom-built Harley that appears to jump from the stage onto the center screen—amplify the multi-sensory experience. 

The Simpsons Ride (Universal Hollywood & Florida, 2008):

 

What It Is: A simulated roller-coaster ride through Krustyland amusement park aboard one of 24 eight-seat passenger cars, encountering more than 24 Simpsons' regulars—like Sideshow Bob and Groundskeeper Willie—en route. 

Game-Changing Tech: Six minutes of 3D-looking computer-animated digital video project at 60 frames per second onto a pair of newly constructed 80-foot diameter Imax-like dome screens, along with the first-ever simulated 360-degree rollover on a ride. A custom-made fisheye lens takes care of distortion. 

Why It Works: The seamless dome screens optimize immersion, as do passenger cars equipped with 12 surround-sound speakers. The ride's scissor-lift motion-simulator platform spins, tilts, lifts and plummets in complete synchronicity with the digital film. 

Harry Potter and the Forbidden Journey (Universal Florida, 2010):

 

What It Is: After meandering Hogwarts' hallways and rooms on foot, guests board four-person "enchanted benches" for a flight through castle grounds and encounters with deadly dragons, soul-sucking dementors and Daniel Radcliffe on a broomstick. 

Game-Changing Tech: A robotic-arm system akin to those used on car-assembly lines thrusts, twists and lifts passenger cars amid an orchestration of live action and 3D visuals. Virtual cast members from the Potter film franchise accompany riders throughout the scenes. 

Why It Works: Since the ride is situated within the larger Wizarding World of Harry Potter theme park, it's a totally immersive experience. Guests can sample chocolate frogs at Honeydukes sweet shop and sip butterbeer at The Three Broomsticks before even entering Hogwarts. 

King Kong 360 3D (Universal Hollywood, 2010):

 

What It Is: Riders aboard Studio Tour trams are immersed in a 3-minute battle between 35-foot-tall V. rex—Skull Island's fictitious T. rex descendant—and the 30-foot-tall, 6000-pound silverback gorilla. Polarized glasses assist. 

Game-Changing Tech: King Kong has a soundstage the size of a football field; two custom-built, compound-curved, 40-foot-tall, 187-foot-long screens delivering 360 degrees of 3D digital imagery; and 16 hi-def film projectors screening 60 frames per second—the highest resolution possible. 

Why It Works: The darkened soundstage becomes Skull Island, with jungle sounds emanating from 68 speakers in 16 acoustic clusters. Three-dimensional elements envelop riders, while a specially developed pneumatic tram system slides, slips, vibrates and rolls in sync with every V. Rex tail swoosh or King Kong move. 

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at 2:37 PM


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