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 2013 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/ARP5796AEROSPACERECOMMENDEDPRACTICEARP5796 Issued 2013-07 Flight Critical Control Va
5、lves, Military Aircraft RATIONALEThis aerospace recommended practice is issued to establish more uniform and technically efficient processes for the design, qualification and manufacture of Flight Critical Control Valves (FCCVs). FORWARDThe primary application of FCCVs has been for helicopter flight
6、 critical control servoactuators which are used to continuously control rotor blade pitch. The single FCCV controls multiple servoactuator power stages to simplify redundancy management, minimize installation envelope and minimize weight. Although this specification is primarily focused on helicopte
7、r application, it may be used for design guidance on other types of flight control servoactuators (e.g., fighter aircraft, missile, unmanned aircraft), hydraulic system switching valves and mission critical utility system control valves. TABLE OF CONTENTS 1. SCOPE 42. REFERENCES 52.1 Applicable Docu
8、ments 52.1.1 SAE Publications . 52.1.2 U.S. Government Publications 62.1.3 ASTM Publications 72.1.4 Industry Standards 72.2 Applicable References 72.3 Definitions . 72.3.1 CONTRACTOR . 72.3.2 CRITICAL CHARACTERISTIC (CC) 72.3.3 CRITICAL SAFETY ITEM (CSI) 72.3.4 FLIGHT CRITICAL CONTROL VALVE (FCCV) .
9、 82.3.5 MODULATION (MOD) PISTON 82.3.6 ACTUATOR POWER STAGE CYLINDER . 82.3.7 PERFORMANCE 82.3.8 PROCURING ACTIVITY . 82.3.9 SUPPLIER 82.4 Acronyms and Their Definitions 83. REQUIREMENTS . 93.1 General Design . 93.1.1 Design Process . 103.1.2 Hydraulic Fluid 10SAE ARP5796 Page 2 of 41 3.1.3 Performa
10、nce Over Temperature . 103.1.4 Pressure 113.1.5 Stability 143.1.6 Erosion 143.1.7 Contamination . 153.2 Detailed Design Requirements . 153.2.1 Pressure Balanced Sleeve Design . 153.2.2 Spool Sleeve Clearance . 153.2.3 Seal Design Considerations 163.2.4 FCCV Filtration 173.2.5 Chip Shear Design Consi
11、derations. 173.2.6 FCCV Operating Force . 183.2.7 FCCV Input Driving Force. 183.2.8 Maximum FCCV Load . 183.2.9 Pressure Balance Grooves . 193.2.10 Metering Lands . 193.2.11 Sleeve Lands 193.2.12 Threads . 193.2.13 Passages 193.2.14 Body Deflection . 193.2.15 Sleeves . 193.2.16 Press Fit Components
12、203.2.17 Spool Bores . 203.2.18 Multiple Concentric Components 203.2.19 Springs 203.2.20 Position Transducer Integration 213.2.21 Modulation (mod) Pistons . 213.2.22 Endurance . 213.2.23 Unbalanced FCCV Spool End Areas 213.2.24 Unbalanced Actuator Piston Area . 213.2.25 Multiple System FCCV Design 2
13、23.2.26 Spool Integrity . 243.2.27 Spool and Sleeve Material 243.2.28 Non Destructive Test and Inspection (NDI) 253.2.29 Demagnetization . 253.2.30 Aircraft Level Built-in-Test Monitoring . 253.2.31 Secondary Retention 263.2.32 Reverse Installation 263.2.33 Disassembly 264. QUALITY ASSURANCE PROVISI
14、ONS 264.1 Quality System 264.1.1 First Article Inspection . 264.2 General Requirements 274.3 Analysis Requirements . 274.3.1 System Safety Engineering . 274.3.2 Reliability . 284.3.3 Maintainability Analysis . 284.3.4 Producibility Analysis 294.3.5 Finite Element Analysis (FEA) 294.3.6 Configuration
15、 Control 294.3.7 Seal Analysis . 294.3.8 Spool/Sleeve Clearance Measurement Tolerance . 304.4 Critical Safety Item Program (CSIPRG) 304.4.1 Critical Safety Item (CSI) 314.4.2 Critical Characteristic (CC) . 314.4.3 Documentation 314.4.4 Controls . 32SAE ARP5796 Page 3 of 41 4.4.5 Disposition of Non-c
16、onforming Parts 324.4.6 Inspection 324.4.7 Serialization and Traceability 334.4.8 Assembly Process. . 334.5 Test Requirements 334.5.1 Acceptance Test . 334.5.2 Qualification Tests. 354.6 In-Process Component Storage and Preservation . 414.7 Cleaning of Components and Assemblies 415. PREPARATION FOR
17、DELIVERY . 416. NOTES 41SAE ARP5796 Page 4 of 41 1. SCOPE This SAE Aerospace Recommended Practice (ARP) provides guidance in the design, development, qualification test, process control and production acceptance test for flight critical control valve (FCCV) design used in military flight control ser
18、voactuators where loss of single valve control could cause a catastrophic failure resulting in death, permanent total disability, and/or financial loss exceeding a defined contractual limit. The FCCV, which is one element of a flight control actuator servo control loop, is a variable position contro
19、l valve which modulates fluid into and out of the servoactuator power stage cylinders. The FCCV may be mechanically driven by either a mechanical flight control system as shown in Figure 1 or hydraulically driven from electro-hydraulic servo valve (EHSV) modulation control flow as shown in Figure 2.
20、 This type of control valve is not an EHSV or a direct drive valve (DDV). The FCCV is used in military hydraulic systems which conform to AS5440. PilotMechInputMechBoostedOutputDual Parallel Actuator Power StagesFlight CriticalControl ValveP1 R1 P2R2FIGURE 1 - HYDRO-MECHANICAL SERVOACTUATOR FLIGHT C
21、RITICAL CONTROL VALVE LVDTEHSV ALVDTEHSV BSOV ASOV BEHSV CSOV CBypass / Shutoff CBypass / Shutoff A and BLVDTLVDTsLVDTsControl ValveReturn 1ModPistonsSupply 1Return 2Supply 2Dual Tandem ActuatorEHSV: Electro-hydraulic ServovalveSOV: Shut Off ValveLVDT: Linear Variable Differential TransformerFlight
22、CriticalControl ValveFIGURE 2 - FLY-BY-WIRE (FBW) SERVOACTUATOR FLIGHT CRITICAL CONTROL VALVE SAE ARP5796 Page 5 of 41 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The
23、applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and
24、 regulations unless a specific exemption has been obtained. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.AIR1243 Anti Blow-By Design Practice for Cap Se
25、als ARP1383 Aerospace - Impulse Testing of Hydraulic Components AS4059 Aerospace Fluid Power - Cleanliness Classification for Hydraulic Fluids ARP4386 Terminology and Definitions for Aerospace Fluid Power, Actuation and Control Technologies AIR4543 Aerospace Hydraulics and Actuation Lessons Learned
26、AS4716 Gland Design, O-ring and Other Elastomeric Seals ARP4904 Capability Guidelines for Computer Controlled Test Equipment for Hydraulic Components AIR5273 Actuation System Failure Detection Methods AS5440 Hydraulic Systems, Military Aircraft, Design and Installation, Requirements For ARP5580 Reco
27、mmended Failure Modes and Effects Analysis (FMEA) Practices for Non-Automobile Applications ARP5941 Aerospace Fluid Power - Contamination Sensitivity - Considerations for Establishing Test Procedures for Flight Control Actuators AS8775 Hydraulic System Components, Aircraft and Missiles, General Spec
28、ification For AS9017 Control of Aviation Critical Safety Items AS9100 Quality Management Systems - Requirements for Aviation, Space and Defense Organizations AS9102 Aerospace First Article Inspection Requirement AMS2700 Passivation of Corrosion Resistant Steels AMS2759/5 Heat Treatment Martensitic C
29、orrosion-Resistant Steel PartsAMS3216 Fluorocarbon (FKM) Rubber, High-Temperature-Fluid Resistant Low Compression Set 70-80 AMS3218 Fluorocarbon (FKM) Rubber, High-Temperature-Fluid Resistant Low Compression Set 85-95 SAE ARP5796 Page 6 of 41 AMS5630 Steel, Corrosion-Resistant, Bars, Wire and Forgin
30、gs, 17Cr - 0.52Mo (0.95 - 1.2C) (440C) AMS7259 Rubber: Fluorocarbon (FKM) High Temperature/Fluid Resistant Low Compression Set/85 to 95 Hardness For Seals in Fuel Systems and Specific Engine Oil Systems AMS7276 Rubber: Fluorocarbon (FKM) High-Temperature-Fluid Resistant Low Compression Set For Seals
31、 in Fuel Systems and Specific Engine Oil Systems AMS-P-83461 Packing, Preformed, Petroleum Hydraulic Fluid Resistant, Improved Performance at 275F (135C) AMS-R-83485 Rubber, Fluorocarbon Elastomer, Improved Performance at Low Temperatures JA1000 Reliability Program Standard JA1000-1 Reliability Prog
32、ram Standard Implementation Guide 2.1.2 U.S. Government Publications Unless otherwise recommended, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DoDISS) and supplement thereto, cited in the solicitation.Specifications
33、are available from the the Standardization Document Order Desk, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, http:/assist.daps.dla.mil/quicksearch/2.1.2.1 Active Specifications MIL-STD-882 Department of Defense Standard Practice: System Safety MIL-PRF-6083 Hydraul
34、ic Fluid, Petroleum Base, For Preservation and OperationMIL-PRF-46170 Hydraulic Fluid, Rust Inhibited, Fire Resistant, Synthetic Hydrocarbon baseDI-SAFT-80101 Subsystem Hazard Analysis Report MIL-PRF-83282 Hydraulic Fluid, Fire Resistant, Synthetic Hydrocarbon Base, Aircraft, Metric, NATO Code Numbe
35、r H-537MIL-PRF-87257 Hydraulic Fluid, Fire Resistant; Low Temperature, Synthetic Hydrocarbon Base, Aircraft and Missile Standards2.1.2.2 Cancelled Specifications The following publications are provided for information purposes only and are not a part of this SAE Aerospace Technical Report. The subsc
36、ribing agency may use these documents as guidance or invoke them as necessary. MIL-STD-756 Reliability Modeling and Prediction MIL-STD-785 Reliability Program for Systems and Equipment Development and Production MIL-STD-1629 Procedures for Performing a Failure Mode and Criticality Analysis ISO 10012
37、-1 Quality assurance requirements for measuring equipment - Part 1: Metrological confirmation system for measuring equipment ANSI Z540-1 Calibration Laboratories and Measuring and Test Equipment General Requirements SAE ARP5796 Page 7 of 41 2.1.2.3 Regulations AMCOM 702-7 Flight Safety Parts/New Sou
38、rce Testing Program Management. Note: This regulation is approved for public release and is available from the U.S. Army Aviation and Missile Command (AMCOM), Redstone Arsenal, AL 35898-5000. 2.1.2.4 Handbooks PR11-515 Joint Aeronautical Commanders Group Public Release, Aviation Critical Safety Item
39、 Management Handbook2.1.3 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org.ASTM E1417 Standard Practice for Liquid Penetrant Testing ASTM E1444 Standard Practice for Magnetic Particle Testing
40、ASTM D1744 Test Method for Water in Liquid Petroleum Products by Karl Fischer Reagent 2.1.4 Industry Standards Available from Electronic Industries Alliance, 2500 Wilson Boulevard, Arlington, VA 22201-3834, Tel: 703-907-7500, www.eia.org.EIA 649 Configuration Management Standard 2.2 Applicable Refer
41、ences “Aircraft Flight Control Actuation System Design”, E.T Raymond and C.C. Chenoweth, SAE Publication 2.3 Definitions General definitions for terminology used within this document may be found in ARP4386. The following definitions are unique to this document. 2.3.1 CONTRACTOR The company or other
42、 organization on contract to the Government Procuring Activity, to design, develop, manufacture and qualify a flight critical control valve. The Contractor typically writes a servoactuator specification and sub-contracts thedetail design of the servoactuator and flight critical control valve to a Su
43、pplier. 2.3.2 CRITICAL CHARACTERISTIC (CC) Any feature throughout the life cycle of a critical safety item (e.g., dimension, tolerance, finish, material or assembly, manufacturing or inspection process, operation field maintenance, depot overhaul requirement) that if nonconforming, missing, or degra
44、ded may cause the failure or malfunction of the critical safety item. 2.3.3 CRITICAL SAFETY ITEM (CSI) Any part, assembly, or installation that contains a characteristic which failure, malfunction, or absence of could cause a catastrophic failure resulting in death, permanent total disability, and/o
45、r financial loss exceeding a defined contractual limit. Within industry, a critical safety item is sometimes referred to as a flight critical part or a flight safety part. SAE ARP5796 Page 8 of 41 2.3.4 FLIGHT CRITICAL CONTROL VALVE (FCCV) An assembly which contains one or more critical safety items
46、 used to meter hydraulic fluid into and out of redundant force summed servoactuators. Figure 1 and 2 show examples of FCCVs used in a hydro-mechanical servoactuator and a fly-by-wire servoactuator, respectively. Wherever this ARP uses the terminology “flight critical control valve”, it should be int
47、erpreted to mean all of the functional elements of the control valve assembly which can affect its performance. This includes but is not limited to the inlet screen, spool, sleeve, body manifolds, modulation pistons, spring assemblies, seal assemblies and integral sensors.2.3.5 MODULATION (MOD) PIST
48、ON Hydraulic pistons used to drive the servoactuator control valve as shown in Figure 2. The mod pistons are typically controlled by electro-hydraulic servovalves (EHSVs). 2.3.6 ACTUATOR POWER STAGE CYLINDER The piston and cylinder assembly which converts the hydraulic power from one hydraulic syste
49、m into usable mechanical output power. Multiple power stages can be arranged in parallel as shown in Figure 1, or in tandem (series) as shown in Figure 2. 2.3.7 PERFORMANCE Wherever this ARP uses the term “performance” it should be considered as the functional design and test capabilities of the FCCV as defined under the Performance Tests section of the Acceptance Test section. 2.3.8 PROCURING ACTIVITY The Government age
