How To Design an Autopilot

An autopilot is a very complex bit of machinery. Ever think about all the stuff it needs to know and how it does it so well? As a pilot, you were taught that you start a turn before you get to a waypoint, so you don't overshoot. As a computer, how do you know to start a turn before, and how much before?

The FAA has an amazing document, AC 8260.58. I recommend getting the whole PDF, and opening it in a true Adobe reader because this document is interactive, and it is large. This document is full of very well explained math. There are tons of definitions and discussions in here, PLUS there are sample calculators right in the document.Depending on the age of your Adobe reader, you might get some weird document navigation indications.

The document is really about how PBN procedures are designed. PBN procedures assume the aircraft will have an autopilot, so it is interesting to see how the procedures are designed for the limitations of the autopilot.

The drawings in the document are amazing. Look in volume 5 page 9 figures 2-4A and 2-4B, to see how turn errors can be calculated using the radius of the required navigation performance, and bisector lines, and the arc that intersects the edges. The page before (page 4) explains step by step how to make the calculation.

The document is full of acronyms, but they are all explained in volume1 chapter 3. Not all the acronyms are what you might think or are used to in other contexts. In this document CG is "Climb Gradient" not "center of gravity", ATT is "Along Track Tolerance" not that big phone company, etc. It is best to have that chapter book marked to allow you to check back.

The book outlines other tolerances as well. Some of the measurements are metric, while others are nautical miles, and the conversions are part of the calculators in the document. Many of the intermediate values need to be kept in 15 significant digits, and stored in 64bits, with no rounding of intermediate results. There are other common standards that this document relies on, including GPS units calculate the diameter and shape of the earth based on WGS-84 standard.

Much of what is in the document is code that could be copied right into some programs. What code isn't there, is mostly easy to figure out, and could be part of a separate function or method. 

There is a good review of many basic algorithms, including intersections of two arcs, locating a point relative to a locus, and calculating arc length, or sub-arc lengths. 8260.58 might be a good workbook for some advanced STEM type program.

With this reference, building an autopilot should be less searching, and easy implementing.

ICAO vs. 7233-1

We all grew up using the plain old FAA flight plan form (7233-1) that was in the AIM or in the manual we got in ground school. It is the information that the FAA says we need in the order they want it right?

Yes, it is still in the AIM, and it will allow us to get flight following, and all kinds of services. It works in the US.

The 7233 form is in need of updates. This form will still let the FAA know if you have a LORAN equipped aircraft, just use the /I, /C, or /Y. The current set of suffix codes allows the controllers to know if the aircraft is RNP capable, using the /R suffix, but doesn't show how the aircraft meets the requirements, of if the aircraft is RNP10, RNP4 or RNP0.1.

How about that fancy question regarding equipment? If the aircraft GPS equipped, a /G should be filed, or still and older plane with only an ILS and DME, what should be filed. The FAA has plans to change many of the equipment suffix codes August 2013. Mostly the FAA isn't going to care about any performance based navigation (PBN) using the 7233 form. Most of the changes only affect aircraft in the flight levels, that are RVSM capable. The big changes are:

All Mode C transponders (at least, including mode S)

• /Q - RNP (obsolete)
• /W - RVSM no RNAV (no change)
• /Z - RVSM and RNAV with no GNSS (new)
• /L - RVSM GNSS (any GNSS capability is new)
• /J - RVSM DME/DME/IRU (obsolete, similar to /W)
• /K - RVSM FMS with DME (obsolete, similar to /W)

The reality is, and the FAA folks in the know will tell you this, the time has come to retire this old friend. Controllers are like pilots, they grew up on this format, and their flight strips will still use some of this format for a couple years, but mostly, they are being trained on something else.

ICAO form

If you have ever flow to Mexico or Canada you probably had to fill out the ICAO flight plan. Canada calls it the Nav Canada form. It looks intimidating, but it leaves a lot of the guess work out of the above form.

Everything before the "FPL" is not needed. There are links to various instructions for filling out this form. Everything after the remarks (Item 18) is optional. The ICAO has a document 4444 "Rules of the Air and Air Traffic Services" about 4000 pages similar to the FAA AIM for both ATC and pilots. Appendixes 2 and 3 cover the flight plan form, and what text to put where. If the above links are followed the form is easy to deal with. 

The big advantage to using this form is specifying your equipment. If your aircraft has at least one Com radio you put in a V (VHF Radio Telephone), if you have a DME, you put a D, if you can fly in RVSM airspace you put in a W. The suffix is either a C for a mode C transponder, S for mode S transponder or an N for no transponder. Then the suffix beyond that would be for ADS/B. PBN levels can be specified using the R in field 10, but the PBN details must be entered in field 18.


You get to tell the FAA exactly what equipment you want to use for your flight, without interpretation and the FAA will pay attention, and let you use it.

That does mean the air traffic controller may put an aircraft on a GPS approach without asking. That should be a good thing, since it is a little more efficient. You can negotiate the ILS or VOR approach if you prefer still. The ATC computers are reading the flight plan, and offering controllers the most efficient reroute based on capabilities specified.

Going Forward

To start using the ICAO flight plan, most of the flight plan filing services will offer ICAO plans is specified. Select that option, and fill out the plan as before. Specific details for the aircraft will need to be specified when setting up the aircraft, but once set, they will continue to be used for plans going forward.

It would be good it the FAA quit publishing the 7233 form, but that doesn't seem to be in the cards any time soon. There are many publications that still refer to the 7233 form, and they also will need to be changed. We are well past the transition phase, most of the FAA employees are familiar with the ICAO form, and are capable of processing instructions in ICAO format.