Incident: CV-22 Osprey Clutch Slippage Grounds Air Force Special Operations Command

Published Date: 2022-08-17

Postmortem Analysis
Timeline 1. The software failure incident involving the clutch slipping in the CV-22 Ospreys occurred in the last six weeks prior to the article being published on August 17, 2022 [131579]. Therefore, the software failure incident likely happened around June-July 2022.
System unknown
Responsible Organization 1. The software failure incident involving the clutch slipping in the CV-22 Osprey aircraft was caused by a design flaw in the clutch inside a gearbox connecting one of the aircraft’s two engines to its rotors, as reported by AFSOC spokeswoman Lt. Col. Becky Heyse [131579].
Impacted Organization 1. Air Force Special Operations Command (AFSOC) [131579]
Software Causes 1. Unknown
Non-software Causes 1. Slip in the clutch inside a gearbox connecting one of the aircraft’s two engines to its rotors, causing power to shift over to the other engine. 2. Pilot error, as mentioned in the Marine Corps investigation report that pilot error killed four Marines in Norway [131579].
Impacts 1. The software failure incident involving the clutch slipping in the CV-22 Osprey aircraft led to the grounding of all 52 Ospreys by the Air Force Special Operations Command (AFSOC) until further notice to ensure the safety of the Airmen [131579]. 2. The incidents caused damage to the gearboxes and engines of the aircraft, requiring replacements that cost in excess of $2.5 million for repairs [131579].
Preventions 1. Implementing thorough software testing procedures during the design and development phase to identify any potential issues related to the clutch engagement software [131579]. 2. Conducting regular maintenance and inspections on the software systems controlling the clutch engagement to detect any anomalies or malfunctions before they lead to safety incidents [131579]. 3. Enhancing the data analysis capabilities to accurately identify the root cause of the software-related issues, whether they are mechanical, design, or software-related, to implement targeted preventive measures [131579].
Fixes 1. Conduct a thorough engineering data analysis to accurately identify the root cause of the hard clutch engagements in the CV-22 Ospreys [131579]. 2. Implement risk control measures based on the identified root cause to prevent future incidents [131579].
References 1. AFSOC spokeswoman Lt. Col. Becky Heyse [131579] 2. Breaking Defense [131579]

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization, unknown (a) The software failure incident related to the clutch slipping in the CV-22 Osprey aircraft has occurred multiple times within the Air Force Special Operations Command (AFSOC). The article mentions that there have been four safety incidents involving the clutch issue since 2017, with two incidents occurring in the last six weeks [131579]. (b) The article does not provide information about similar incidents happening at other organizations or with their products and services.
Phase (Design/Operation) design (a) The article mentions that the clutch inside a gearbox connecting one of the aircraft’s two engines to its rotors is slipping, causing power to shift over to the other engine as part of a design feature to keep the aircraft flying in the event of a partial engine failure. The AFSOC spokeswoman mentioned that they have been unable to gather enough engineering data analysis to accurately identify the root cause of the issue, whether it's mechanical, design, software, or a combination of those factors [131579]. (b) The incidents of clutch engagements impacting the CV-22 Ospreys have not caused any injuries or deaths so far, attributed to the skill and professionalism of the Air Commandos who operate the aircraft. However, if the aircrew were unable to control the aircraft during such incidents, it could result in a loss of control and uncontrolled landing of the aircraft, indicating potential risks during operation [131579].
Boundary (Internal/External) within_system The software failure incident related to the grounding of the CV-22 Ospreys by the Air Force Special Operations Command (AFSOC) is primarily within the system. The article mentions that the clutch inside a gearbox connecting one of the aircraft’s two engines to its rotors is slipping, causing power to shift over to the other engine as part of a design feature to keep the aircraft flying in the event of a partial engine failure [131579]. Lt. Col. Becky Heyse mentioned that the incidents have not caused any injuries or deaths so far, attributing it to the skill and professionalism of the Air Commandos who operate the CV-22 [131579]. Additionally, Heyse stated that the AFSOC has been unable to gather enough engineering data analysis to accurately identify the root cause, whether it's mechanical, design, software, or a combination of those factors [131579].
Nature (Human/Non-human) non-human_actions (a) The software failure incident related to non-human actions: - The article mentions that the clutch inside a gearbox connecting one of the aircraft’s two engines to its rotors is slipping, causing power to shift over to the other engine as part of a design feature to keep the aircraft flying in the event of a partial engine failure [131579]. - It is highlighted that the incidents have not caused any injuries or deaths so far, largely due to the skill and professionalism of the Air Commandos who operate the CV-22 [131579]. (b) The software failure incident related to human actions: - The article does not provide specific information indicating that the software failure incident was directly caused by human actions.
Dimension (Hardware/Software) hardware (a) The software failure incident related to hardware: - The article mentions that the clutch inside a gearbox connecting one of the aircraft’s two engines to its rotors is slipping, causing power to shift over to the other engine as part of a design feature to keep the aircraft flying in the event of a partial engine failure [131579]. - The AFSOC has been unable to gather enough engineering data analysis to accurately identify the root cause of the incidents, whether it's mechanical, design, software, or some combination of those factors [131579]. (b) The software failure incident related to software: - The article does not specifically mention any software-related issues contributing to the failure incident.
Objective (Malicious/Non-malicious) non-malicious (a) The articles do not mention any indication of a malicious software failure incident. The reported issue with the CV-22 Ospreys is related to a mechanical problem with the clutch inside a gearbox connecting one of the aircraft's engines to its rotors, causing power to shift over to the other engine. The focus is on safety incidents and the need to determine the cause of the hard clutch engagements to ensure the safety of the Airmen operating the aircraft [131579]. (b) The software failure incident related to the CV-22 Ospreys is described as a non-malicious failure. The AFSOC spokeswoman mentioned that they have been unable to gather enough engineering data analysis to accurately identify the root cause, whether it's mechanical, design, software, or a combination of those factors. The incidents have not caused any injuries or deaths so far, thanks to the skill and professionalism of the Air Commandos operating the aircraft [131579].
Intent (Poor/Accidental Decisions) unknown The articles do not provide specific information about a software failure incident related to poor decisions or accidental decisions. The focus of the reported incidents is on the mechanical issue with the clutch inside the gearbox of the CV-22 Osprey aircraft, which is causing safety concerns and leading to the grounding of the aircraft for investigation and repairs.
Capability (Incompetence/Accidental) unknown The articles do not mention any software failure incident related to development incompetence or accidental factors.
Duration unknown The articles do not provide specific information about the duration of the software failure incident related to the clutch issues in the CV-22 Ospreys. The focus of the articles is on the safety incidents caused by the clutch slipping in the aircraft's gearbox, leading to power shifts and potential loss of control. The investigation mentioned in the articles is primarily concerned with determining the root cause of the mechanical issue rather than specifically addressing the duration of the software failure incident. Therefore, the duration of the software failure incident being permanent or temporary is unknown based on the information provided in the articles [131579].
Behaviour other (a) crash: The software failure incident in the article did not involve a crash where the system lost state and did not perform any of its intended functions [131579]. (b) omission: The software failure incident did not involve omission where the system omitted to perform its intended functions at an instance(s) [131579]. (c) timing: The software failure incident did not involve timing issues where the system performed its intended functions too late or too early [131579]. (d) value: The software failure incident did not involve the system performing its intended functions incorrectly [131579]. (e) byzantine: The software failure incident did not involve the system behaving erroneously with inconsistent responses and interactions [131579]. (f) other: The behavior of the software failure incident in the article is related to mechanical issues with the clutch inside a gearbox connecting one of the aircraft’s two engines to its rotors, causing power to shift over to the other engine. The incidents were due to hard clutch engagements, and the root cause could be mechanical, design, software, or a combination of those factors [131579].

IoT System Layer

Layer Option Rationale
Perception None None
Communication None None
Application None None

Other Details

Category Option Rationale
Consequence property, delay, non-human, theoretical_consequence (a) death: People lost their lives due to the software failure - There is no mention of any deaths resulting from the software failure incident related to the clutch issues in the CV-22 Ospreys [131579]. (b) harm: People were physically harmed due to the software failure - The article does not mention any physical harm to individuals due to the software failure incident with the CV-22 Ospreys [131579]. (c) basic: People's access to food or shelter was impacted because of the software failure - The article does not mention any impact on people's access to food or shelter due to the software failure incident with the CV-22 Ospreys [131579]. (d) property: People's material goods, money, or data was impacted due to the software failure - The software failure incident with the CV-22 Ospreys resulted in damage that costs in excess of $2.5 million to repair, indicating a financial impact in terms of property damage [131579]. (e) delay: People had to postpone an activity due to the software failure - The grounding of all 52 CV-22 Ospreys due to the software failure incident would result in a delay in their operations until the issue is resolved [131579]. (f) non-human: Non-human entities were impacted due to the software failure - The software failure incident affected the CV-22 Ospreys, which are aircraft, but there is no mention of any other non-human entities being impacted [131579]. (g) no_consequence: There were no real observed consequences of the software failure - The software failure incident with the CV-22 Ospreys led to safety incidents and the grounding of all aircraft, indicating real consequences [131579]. (h) theoretical_consequence: There were potential consequences discussed of the software failure that did not occur - The article mentions that so far, the incidents have not caused any injuries or deaths, highlighting potential consequences that have not materialized due to the professionalism of the Air Commandos operating the aircraft [131579]. (i) other: Was there consequence(s) of the software failure not described in the (a to h) options? What is the other consequence(s)? - The article does not mention any other specific consequences of the software failure incident beyond those related to financial costs, operational delays, and potential safety risks [131579].
Domain transportation, government (a) The failed system in the incident was related to the transportation industry, specifically affecting the Air Force Special Operations Command's CV-22 Ospreys [131579]. The CV-22 Osprey is a tiltrotor aircraft used for special operations and transportation purposes.

Sources

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