1、Designation: F 2538 07aStandard Practice forDesign and Manufacture of Reciprocating CompressionIgnition Engines for Light Sport Aircraft1This standard is issued under the fixed designation F 2538; the number immediately following the designation indicates the year oforiginal adoption or, in the case
2、 of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.1. Scope1.1 This practice covers minimum requirements for thedesign and manufacture of reciprocating co
3、mpression ignitionengines for light sport aircraft, Visual Flight Rules (VFR) use.1.2 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and d
4、etermine the applica-bility of regulatory limitations prior to use.2. Referenced Documents2.1 RTCA Documents:2RTCA DO-178 Software Considerations in Airborne Sys-tems and Equipment CertificationRTCA DO-254 Design Assurance Guidance for AirborneElectronic Hardware2.2 FAA Documents:3FAA AC 33.282 Guid
5、ance Material 14 CFR 33.28 Recip-rocation Engines, Electrical and Electronic Control Sys-tems3. Significance and Use3.1 This practice provides designers and manufacturers ofengines for light sport aircraft design references and criteria touse in designing and manufacturing engines.3.2 Declaration of
6、 compliance is based on testing anddocumentation during the design and testing or flight-testing ofthe engine type by the manufacturer or under the manufactur-ers guidance.4. Engine Model Designation4.1 Engine Parts ListA parts list is required for eachengine model qualified in accordance with this
7、practice.4.2 New Engine Model Designations:4.2.1 Each new engine model must be qualified in accor-dance with this practice.4.2.2 Design or configuration changes that impact the in-stallation interface, performance, or operability of the enginerequire a new engine model designation.4.3 Design Changes
8、 of PartsEach design change of a partor component of an engine model qualified to this practiceshould be evaluated relative to the requirements of thispractice.5. Data Requirements5.1 Retained DataThe following data and informationshould be retained on file at the manufacturers facility for aminimum
9、 of 18 years after production is discontinued:5.1.1 Drawings that define the engine configuration,5.1.2 Material and process specifications referenced in theparts drawings, and5.1.3 Engineering analyses and test data prepared for quali-fication with this practice.5.2 Delivered DataThe following data
10、 should be deliv-ered to the airplane manufacturer to support design andoperation of the applicable airplane.5.2.1 An engine performance specification that defines theengine performance under all anticipated operating environ-ments.5.2.2 An installation manual that defines all functional andphysical
11、 interface requirements of the engine. This shouldinclude an engine outline/installation drawing.5.2.3 An operating manual that defines normal and abnor-mal operating procedures and any applicable operating limita-tions; this manual shall include instructions for use of appro-priate engine monitorin
12、g gauges, electronic or otherwise.5.2.4 A maintenance manual that defines periodic installedmaintenance, major inspection, overhaul intervals, and anyother maintenance limitations.5.2.5 If applicable (or if overhauls are authorized by themanufacturer), an overhaul manual that provides instructionfor
13、 disassembling the engine to replace or repair, or both, partsas required to return the engine to airworthy condition that issafe for operation until the next major overhaul.1This practice is under the jurisdiction of ASTM Committee F37 on Light SportAircraft and is the direct responsibility of Subc
14、ommittee F37.70 on Cross Cutting.Current edition approved May 1, 2007. Published June 2007. Originallyapproved in 2007. Last previous edition approved in 2007 as F 2538 07.2Available from RTCA, Inc., 1828 L Street, NW, Suite 805, Washington, DC20036. www.rtca.org3Available from U.S. Department of Tr
15、ansportation, Federal Aviation Adminis-tration, 800 Independence Avenue, SW, Washington, DC 20591. www.faa.gov1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.6. Design Criteria6.1 MaterialsThe materials used in the engine must beadeq
16、uate for the intended design conditions of the engine.6.2 Fire PreventionThe design and construction of theengine and the materials used must minimize the probability ofthe occurrence and spread of fire by:6.2.1 Using fire-resistant lines, fittings, and other compo-nents that contain a flammable liq
17、uid when supplied with theengine, and6.2.2 Shielding or locating components to safeguard againstthe ignition of leaking flammable fluid.6.3 Engine CoolingThe engine design must include pro-visions for cooling; the installation manual must specify engineand component temperature limitations.6.4 Engin
18、e MountingAttach points on the engine musthave data for the correct design of mounting structures to theairframe. The maximum allowable limit and ultimate loads forthe engine mounting attachments and related structure must bespecified.6.5 IgnitionReliable combustion must be achieved in allflight and
19、 atmospheric conditions in which the engine isexpected to operate.6.5.1 Limitations on restart at altitude must be establishedand documented in the operating manual.6.5.2 The use of “glow plugs” or other starting aids must beestablished (if applicable) and documented in the operatingmanual.6.6 Elect
20、ronic Engine Controllers (EEC):6.6.1 Essentially Single Fault ToleranceThe EEC shouldbe designed to accommodate single failures of the electricalcircuit. Loss of any single EEC should not cause significantpower reduction or engine stoppage.6.6.2 The functioning of EECs must not be adverselyaffected
21、by the declared environmental conditions of operationby the manufacturer, including temperature and moisture. Thelimits to which the system has been qualified shall be docu-mented in the installation manual. For protection againstradiated EMI/HIRF, the harnesses or cables should be shieldedfrom each
22、 sensor to each end point and electrically bonded tothe engine. Filter pin connectors should be located at thecontroller housing interface and shunted to ground on the case.Filter pin connectors should have 40 dB attenuation, minimum.For EMI emissions, powerline filters suppress emissions fromthe co
23、ntroller on outgoing signals.6.7 Fuel and Induction System:6.7.1 Fuel LubricityIf fuel system components rely onfuel as a lubricant, their proper function and service life mustbe established for the lowest lubricity fuel that will beencountered in service. This may be demonstrated during thequalific
24、ation tests in Section 7 or by other means such as fuelsystem/component bench tests.6.7.2 FilteringThe type and degree of fuel and air filter-ing necessary to prevent obstruction of air or fuel flow must bespecified.6.7.3 Air LockThe degree of susceptibility to air in thefuel supply lines must be es
25、tablished. If return flow or purgelines are required, their provision must be documented in theinstallation manual.6.8 Lubrication System:6.8.1 The lubrication system of the engine must be designedand constructed so that it will function properly in all flightattitudes and atmospheric conditions in
26、which the engine isexpected to operate. In wet sump engines, this requirementmust be met when only one-half of the maximum lubricantsupply is in the engine.6.8.2 The lubrication system of the engine must be designedand constructed to allow installing a means of cooling thelubricant if required.6.8.3
27、 The crankcase engines must be vented to the atmo-sphere to preclude leakage of oil from excessive pressure in thecrankcase. This venting must have a means to prevent theblockage of the vent by ice.6.9 Vibration GeneralThe engine must be designed andconstructed to function throughout its normal oper
28、ating rangeof crankshaft rotational speeds and engine powers withoutinducing excessive stress in any of the engine parts.6.9.1 The engine must have a crankshaft vibration survey todetermine torsional and bending characteristics from idle speedup to maximum desired takeoff speed. This survey should b
29、edone with a representative propeller and no hazardous condi-tions would be allowed.7. Qualification Tests7.1 Calibration TestEach engine design shall be testedand the characteristics of engine rated power, speeds, and fuelconsumption shall be determined.7.2 Knocking/Misfire TestEach engine shall be
30、 tested onthe lowest cetane number fuel likely to be encountered inservice. Lack of off-load misfiring or excessive cylinderpressure due to delayed combustion (knocking), or both, mustbe demonstrated.7.3 Durability TestingEach engine model must be sub-jected to an engine test that will verify durabi
31、lity by one of thefollowing methods:7.3.1 Accelerated Overhaul TestThis test simulates anengine overhaul interval. A protocol for this test shall incorpo-rate, as a minimum, the following elements:7.3.1.1 At least 100 % of the time at maximum power thatwould occur over the overhaul interval.NOTE 1Fo
32、r calculation, each hour of normal flight would have 5 minof full power.7.3.1.2 At least 10 % of the time at cruise power that wouldoccur over the overhaul interval.7.3.1.3 At least one cycle per hour of test from maximumpower to cruise power and back.7.3.1.4 At least one engine start for each5hofte
33、sting.7.3.1.5 For Air Cooled EnginesDuring operation at maxi-mum power, one cylinder must be maintained within 10F ofthe limiting cylinder head temperature, the other cylindersmust be operated at a temperature not lower than 50F belowthe limiting temperature, and the oil inlet temperature must bemai
34、ntained within 10F of the limiting temperature.7.3.1.6 The engine must be fitted with a propeller thatthrust-loads the engine to the maximum thrust that the engineis designed to resist at each applicable operating conditionspecified in this section.F 2538 07a27.3.1.7 Each accessory drive and mountin
35、g attachment mustbe loaded. During operation at maximum power, the loadimposed by each accessory used only for an aircraft servicemust be the limit load specified by the applicant for the enginedrive or attachment point.7.3.1.8 After completing the accelerated overhaul test, eachengine must be compl
36、etely disassembled and each componentmust conform to the new or overhaul limits established by thedesigner/manufacturer.7.3.2 Endurance Testing by Fleet LeaderIn place of theaccelerated overhaul test in 7.3.1, the engine may completeendurance flight testing.7.3.2.1 The Fleet Leader Test Method is th
37、e operation of themake and model of the engine being developed on a flyingaircraft under the control of the engine manufacturer.7.3.2.2 All engine maintenance must be documented on theengine, and no components may be replaced on the engineduring the test. If components are changed, the test must res
38、tartas0h.7.3.2.3 Periodic inspection must be performed. The flighttests shall subject the engine to all atmospheric conditions forwhich the manufacture states the engine may operate under inthe operating manual required in 5.2.3.NOTE 2Atmospheric conditions in 7.3.2.3 are intended to coveroutside ai
39、r temperatures, density altitudes, and humidity.7.3.2.4 There must be at least one engine start for each 5 hof operation.7.3.2.5 The engine must be fitted with a propeller thatthrust-loads the engine to the maximum thrust that the engineis designed to resist at full power.7.3.2.6 Each accessory driv
40、e and mounting attachment mustbe loaded. The load imposed by each accessory used only foran aircraft service must be the limit load specified by theapplicant for the engine drive of attachment point.7.3.2.7 After completing the Endurance Test, each enginemust be completely disassembled and each comp
41、onent mustconform to the new or overhaul limits established by thedesigner/manufacturer.7.4 Engine Overhaul IntervalThe engine overhaul inter-val shall be reported in the operations manual (see 5.2.3)aseither the overhaul time used to complete the acceleratedoverhaul test in 7.3.1 or 80 % of the tim
42、e accumulated on theengine model fleet leader method from 7.3.2.8. Manufacturing Requirements8.1 The engine manufacturer shall establish inspections andtests necessary to ensure that each article produced conforms tothe design and is in a condition for safe operation, including, asapplicable:8.1.1 I
43、nspections for raw materials, purchased items, andparts and assemblies produced by suppliers, including methodsused to ensure acceptable quality of parts and assemblies thatcannot be completely inspected for conformity and qualitywhen delivered to the engine manufacturers facility.8.1.2 Production i
44、nspection of individual parts and com-plete assemblies, including the identification of any specialmanufacturing processes involved, the means used to controlthe processes, and the final test procedure for the completedengine.8.1.3 A nonconforming materials review system that in-cludes documentation
45、 of parts disposition decisions, and asystem to dispose of rejected parts.8.1.4 A system for informing company inspectors of currentchanges in engineering drawings, specifications, and qualitycontrol procedures.9. Keywords9.1 light sport aircraft; reciprocating compression ignitionengineANNEXA1. COM
46、PRESSION IGNITION ENGINESA1.1 Electronic Engine Control SystemsA1.1.1 Software and Programmable Logic DevicesAnysystem, component, or sub-assembly that utilizes software orfirmware shall demonstrate that the software or firmware hasbeen developed in accordance with best industry practices, andthe so
47、ftware development and verification activities have beenperformed in accordance with RTCA DO-178, methodologies,or an equivalent methodology generally accepted by theaviation industry. Further, the verification levels shall bespecified in the installation instructions, as required, to ensurecompatib
48、ility with safety objectives.A1.1.2 The documentation and verification results shall beavailable for review by the relevant Civil Aviation Authority(CAA), as required.A1.1.3 Complex Electronic HardwareAny system, com-ponent, or sub-assembly that utilizes complex electronic hard-ware shall demonstrat
49、e that the hardware has been developedin accordance with the best industry practices, and the hard-ware design and verification activities have been performed inaccordance with RTCA DO-254, methodologies, or an equiva-lent methodology generally accepted by the aviation industry.Further, the verification levels shall be specified in the instal-lation instructions, as required, to ensure compatibility with thesafety objectives. The documentation and verification resultsshall be available for review by the relevant CAA, as required.A1.2 Study DocumentsA1.2.
