1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.Copyright 2011 SAE International All rights reserved. No part of this pub
3、lication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970
4、(outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AIR4543/1AEROSPACEINFORMATIONREPORTAIR4543/1 Issued 2011-12 Aerospace Hydraulics and
5、 Actuation Lessons Learned RATIONALEAIR4543 was published to capture Lessons Learned presented to the technical panels of the SAE Committee A-6, Aerospace Actuation, Control and Fluid Power Systems. This is the first of a series of slash number documents which will contain new Lessons Learned presen
6、ted later than the material contained in AIR4543B. TABLE OF CONTENTS 1. SCOPE 31.1 Further Comment on Document AIR4543 and This Document AIR4543/1 32. REFERENCES 32.1 Applicable Documents 32.1.1 SAE Publications . 32.1.2 ISO Publications 42.1.3 Radio Technical Commission for Aeronautics Documents (R
7、TCA) . 42.1.4 US Government Publications 42.2 Abbreviations, Acronyms, Symbols and Their Definitions 42.3 Definitions . 43. TECHNICAL INFORMATION . 63.1 Systems Lessons Learned 63.1.1 All Systems . 63.1.2 Flight Control Systems 63.1.3 Power Distribution Systems 123.1.4 Utility Control Systems 133.2
8、Actuation Lessons Learned 143.2.1 Electrohydrostatic Servoactuators and Actuators . 143.2.2 Hydraulic Servoactuators and Actuators 183.2.3 Mechanical and Electromechanical Actuation 243.3 Mechanical and Hydromechanical Component Lessons Learned . 273.3.1 Accumulators 273.3.2 Filtration, Filters, and
9、 Fluids 273.3.3 Flight Critical Joint Retention 303.3.4 Manifolds . 303.3.5 Pumps and Motors 303.3.6 Seals . 313.3.7 Tubing, Fittings, Bosses, and Hoses 343.3.8 Valves . 34Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without
10、license from IHS-,-,-SAE AIR4543/1 Page 2 of 48 3.4 Electrohydraulic, Electromechanical and Electronic Component Lessons Learned 343.4.1 Aircraft Sensors . 343.4.2 Computers. 343.4.3 Connectors 343.4.4 Controllers . 343.4.5 Data Buses, Transmitters and Receivers . 343.4.6 Direct Drive Valves 353.4.7
11、 Electrohydraulic Servovalves 353.4.8 Inceptors . 353.4.9 Motors and Generators . 353.4.10 Solenoid Valves 353.4.11 Solenoids 353.4.12 Transducers 353.4.13 Wiring 373.5 Miscellaneous Lessons Learned 373.5.1 Corrosion, Materials, and Processes 373.5.2 Design, Build, Test and Maintenance Procedures .
12、373.5.3 General . 393.5.4 Project Organization . 394. NOTES 424.1 Revision Status . 42APPENDIX A TABLE OF CONTENTS FOR SECTION 3, TECHNICAL INFORMATION, FOR ALL AIR4543 VOLUMES PUBLISHED UP TO AND INCLUDING THIS VOLUME . 43Copyright SAE International Provided by IHS under license with SAENot for Res
13、aleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR4543/1 Page 3 of 48 1. SCOPE This SAE Aerospace Information Report (AIR) contains Lessons Learned from aerospace actuation, control and fluid power systems technologies. The lessons were prepared by engineers from the aer
14、ospace industry and government services as part of the work of SAE Committee A-6, Aerospace Actuation, Control and Fluid Power Systems. Each lesson was presented to the appropriate A-6 technical panel. The technical topics are organized into five sections covering systems, actuation, hydraulic compo
15、nents, electrical components and miscellaneous, each further divided into subsections. The information topics are presented in a concise format of Problem, Issue, Solution and Lesson Learned, often with accompanying descriptive diagrams and illustrations for clarity and understanding. 1.1 Further Co
16、mment on Document AIR4543 and This Document AIR4543/1 AIR4543B contains lessons learned presented to the A-6 Committee during meetings held from 1989 through 1999. This AIR4543/1 document contains lessons presented during the period 2000 through 2010. Subsequent AIR4543/X documents will similarly co
17、ntain material segregated by the date of presentation. The structure of the numbering of the technical topics contained within section 3 of each document will be maintained constant and each new lesson in each new AIR will be numbered consecutively from the material contained in earlier documents.To
18、 help the reader navigate the material, a complete index of all lessons published up until the closing date of this new AIR is included as Appendix A. Each subsequent AIR will similarly contain an updated complete index of all published lessons.NOTES:1. Where known, the year of the activity describe
19、d in each lesson is provided. 2. The allocation of the lessons to the various categories is typically obvious, because of their focused content, but occasionally arbitrary because of mixed content. Text searches are suggested to ensure that all lessons of interest are found. 2. REFERENCES 2.1 Applic
20、able Documents The following publications form a part of this document to the extent specified herein. Unless otherwise specified the applicable issue of the SAE and other publications shall be the issue in effect during the year of the activity described in each lesson. In the event of conflict bet
21、ween the text of this document and the references cited herein, the text of this document takes preference. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Common
22、wealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.ARP1827 Measuring Aircraft Gas Turbine Engine Fine Fuel Filter Element Performance ARP4205 Aerospace Fluid Power - Hydraulic Filter Elements - Method for Evaluating Dynamic E
23、fficiency With Cyclic Flow ARP4386 Terminology and Definitions for Aerospace Fluid Power, Actuation and Control Technologies ARP5007 Development Process - Aerospace Fly-By-Wire Actuation System Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or network
24、ing permitted without license from IHS-,-,-SAE AIR4543/1 Page 4 of 48 ARP5454 Multi-Pass Method for Evaluating Filtration Performance of Fine Lube Filter Elements Utilized in Aerospace Power and Propulsion Lubrication Systems AS4716 Gland Design, O-Ring and Other Elastomeric Seals AS8879 Screw Threa
25、ds - UNJ Profile, Inch Controlled Radius Root With Increased Minor Diameter 2.1.2 ISO Publications Available from American National Standards Institute, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org.ISO 12103-1 Road vehicles - Test dust for filter evaluation - Part 1:
26、 Arizona test dust 2.1.3 Radio Technical Commission for Aeronautics Documents (RTCA) Available from Radio Technical Commission for Aeronautics Inc., 1828 L Street, NW, Suite 805, Washington, DC 20036, Tel: 202-833-9339, www.rtca.org.RTCA/DO-160/ISO7137 Environmental conditions and test procedures fo
27、r airborne equipment 2.1.4 US Government Publications Available from the Document Automation and Production Service (DAPS), Building 4/D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, http:/assist.daps.dla.mil/quicksearch/.MIL-F-8815 Filter and Filter Elements, Fluid Pressure,
28、Hydraulic Line, 15 Micron Absolute and 5 Micron Absolute, Type II Systems; General Specification For 2.2 Abbreviations, Acronyms, Symbols and Their Definitions AC Alternating Current ACCTD A.C. Coarse Test Dust ACFTD A.C. Fine Test Dust AIR Aerospace Information Report APU Auxiliary Power Unit ATP A
29、cceptance Test Procedure BIT Built-In-Test COM Command Channel in Command-monitor Control Architecture CRES Corrosion Resistant Steel CTD ISO Coarse Test Dust DC Direct Current P Differential Pressure EBHA Electrical Back-up Hydraulic Actuator EDM Electrical Discharge Machining Copyright SAE Interna
30、tional Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR4543/1 Page 5 of 48 EHA Electrohydrostatic Actuator EHM Electrohydrostatic Module EHSV Electrohydraulic Servovalve EMA Electromechnical Actuator FAA Federal Aviation
31、 Authority FBW Fly-By-Wire FCC Flight Control Computer FCS Flight Control System Fi, Fo and Fa Pilot Input Force, Output Force and Actuator Force FTD ISO Fine Test Dust GVT Ground Vibration Test HP High Pressure HSTA Horizontal Stabilizer Trim Actuator IBIT Initiated Built-In-Test ICD Interface Cont
32、rol Document ISA International Standard Atmosphere ISO International Stanrdization Organization LVDT Linear Variable Differential Transformer MON Monitor Channel in Command-monitor Control Architecture MSV Mode Select Valve MTD ISO Medium Test Dust NDI Non-destructive Inspection OEM Original Equipme
33、nt Manufacturer OTS Off-The-Shelf PEExtend Pressure PEEK Polyether Ether Ketone Thermoplastic PRRetract Pressure PTFE Polytetrofluoroethylene RTCA Radio Technical Commission for Aeronautics Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking
34、permitted without license from IHS-,-,-SAE AIR4543/1 Page 6 of 48 SOF Safety-Of-Flight Xi and Xo Input Command Displacement and Output Displacement 2.3 Definitions Refer to ARP4386. 3. TECHNICAL INFORMATION 3.1 Systems Lessons Learned 3.1.1 All Systems This subsection addresses lessons generally app
35、licable to systems of all types. No Lessons Learned on this subject submitted for this document. 3.1.2 Flight Control Systems This subsection contains lessons learned from the design and development of aircraft flight control systems and critical control functions for other vehicles. 3.1.2.4 Loss of
36、 All Three Hydraulic Systems from Failure of One Engine PROBLEM: Meeting FAA certification requirements on a three-engine commercial transport aircraft with three or more primary, completely separate, hydraulic systems to cover all phases of flight YEAR OF ACTIVITY: 1989 ISSUE: A massive uncontained
37、 tail engine rotor burst failure caused loss of all three hydraulic systems used for flight control actuation on a commercial transport aircraft. The landing with no control other than engine throttle manipulation resulted in a hull loss with many fatalities. SOLUTION: Enhance the right engine hydra
38、ulic system to sustain minimum acceptable control despite massive tail engine failure. This system has two AC electric auxiliary motor driven pumps to provide “secondary” control and utility power in the event of the loss of all engines. Preclude a complete loss of all fluid in this system by: a. Ad
39、ding a sensor switch in the right system reservoir set to an acceptable minimum fluid level for the operation of the secondary system. b. Adding an electrically operated shutoff valve in the right main hydraulic system supply line and a check valve in the return, with both valves installed forward o
40、f the tail engine and APU fan disk paths. The fast acting shutoff valve is automatically commanded closed and a cockpit alert light illuminated if the reservoir fluid level drops to a minimum design level detected by the switch. Copyright SAE International Provided by IHS under license with SAENot f
41、or ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR4543/1 Page 7 of 48 ILLUSTRATIONLESSON LEARNED Reviewing the extreme failure case required additional protection to be added to the design. If you think you designed for all possible failures, think of the proverb:
42、“If it can happen it will happen.” Copyright SAE International Provided by IHS under license with SAENot for ResaleNo reproduction or networking permitted without license from IHS-,-,-SAE AIR4543/1 Page 8 of 48 3.1.2.5 Effect on Aeroelastic Stability of Changes in Control System Kinematics PROBLEM:
43、The kinematic layout of a manually controlled aileron system was rearranged while the original system gearing ratio was kept unchanged. The effect of the layout modification on the system characteristics was, however, overlooked, and the frequency of the symmetric aileron rotation increased to a lev
44、el such that the wing-aileron flutter mode became unstable. YEAR OF ACTIVITY: 2006 ISSUE: During the development of a new derivative airplane, the kinematic layout of the manually controlled aileron system was rearranged to improve the system maintainability. In the process, the original system gear
45、ing ratio was kept unchanged to retain the similar system characteristics of the existing model, but the effect of the change in the kinematic layout on the overall system stiffness was overlooked. As a result, even with the same system gearing ratio maintained, the aileron control system became muc
46、h stiffer, and the frequency of the symmetric aileron rotation, which affects the airplanes wing-aileron flutter stability, exceeded the acceptable level. The frequency of the symmetric aileron rotation is defined as the natural frequency of the aileron control system at which both left and right ai
47、lerons are rotating in phase. Since the wing-aileron flutter is induced by an aeroelastic coupling of thewing torsion and the symmetric aileron rotation, the frequencies of these two modes must be safely separated under all flight conditions. For manually controlled aileron systems, the frequency of
48、 the aileron symmetric rotation is usually kept lower than the wing torsional frequency. The maximum allowable frequency is determined depending on the aeroelastic design of wings and ailerons. The first illustration shows a schematic of the aileron control system in question, which consists of mechanical elements such as sectors, cables, and linkages. The
