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 there
2、from, 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 p
3、ublication 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: +1 724-776-497
4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/ARP5416A AEROSPACE RECOMMENDED PRACTICE ARP5416 REV. A Issued 2005-03 Revised 201
5、3-01 Superseding ARP5416 Aircraft Lightning Test Methods RATIONALE With the original release of the document, many new test methods were provided to account for aircraft operational experience and changing aircraft technology, including more reliance on electronic data and control systems and increa
6、sing use of composite materials in aircraft structures. As experience is gained with these test methods, some changes and clarifications are needed to ensure consistency across test organizations, particularly regarding high voltage tests and integrated system functional upset tests. Also, ignition
7、source detection methods have historically relied upon the use of Polaroid film as the standard. Since this films source of supply is rapidly disappearing, photographic methods using modern camera technologies needs to be included in the recommended practice. FOREWORD This SAE Aerospace Recommended
8、Practice (ARP) has its origins in the SAE AE-4L Committees “Blue” book issued in 1978 and titled “Lightning Test Waveforms and Techniques for Aerospace Vehicles and Hardware.” Subsequent to the issuance of the “Blue” book, the SAE AE-4L developed MIL-STD-1757 for the United States military dated 198
9、1 and titled “Lightning Qualification Techniques for Aerospace Vehicles and Hardware.” In MIL-STD-1757, the committee placed the test methodology contained in the “Blue” book into a more formalized format. This ARP is a significant refinement and expansion of the basic material from these sources, p
10、roviding a more thorough and updated description of the test techniques. SAE ARP5416A Page 2 of 105 TABLE OF CONTENTS 1. SCOPE 5 2. REFERENCES 5 2.1 Applicable Documents 5 2.1.1 SAE Publications . 5 2.1.2 Federal Aviation Regulations (FAR) . 6 2.1.3 FAA Advisory Circulars (AC) . 6 2.1.4 RTCA, Inc. P
11、ublications 6 2.1.5 EASA Publications 6 2.1.6 EUROCAE Publications 7 2.1.7 ANSI Publications . 7 2.1.8 IEC Publications 7 2.2 Definitions, Abbreviations, and Acronyms 7 2.2.1 Definitions . 7 2.2.2 Abbreviations 10 2.2.3 Acronyms 10 3. LIGHTNING EFFECTS . 11 3.1 Direct Effects . 12 3.2 Indirect Effec
12、ts 13 4. PLANNING OF LIGHTNING EFFECTS TESTS . 14 4.1 Test Object Conformity . 14 4.2 Test Procedure 15 4.3 Measurement Set-Up Calibration . 16 4.4 Test Safety Aspects 16 4.5 Test Set-Up . 16 4.5.1 Test Object Design . 16 4.5.2 Waveform Scaling . 16 4.5.3 Waveform Application . 17 4.5.4 Concurrent T
13、esting . 17 5. DIRECT EFFECTS TEST METHODS 17 5.1 High Voltage Strike Attachment Tests 18 5.1.1 Initial Leader Attachment Test 18 5.1.2 Swept Channel Attachment Test 28 5.1.3 High Voltage Strike Attachment Test on Models 32 5.2 High Current Physical Damage Tests . 36 5.2.1 Arc Entry Test . 36 5.2.2
14、Aircraft Non-Conductive Surfaces Test 39 5.2.3 Conducted Current Test 43 5.3 Induced Transients in External Mounted Hardware . 45 5.3.1 Measurement of Injected Transients in External Hardware 45 5.3.2 Voltage Stress Assessment of Circuit Insulation 48 6. INDIRECT EFFECTS TEST METHODS 50 6.1 Aircraft
15、 Tests . 50 6.1.1 Test Purpose . 50 6.1.2 Test Object 50 6.1.3 Return Conductor Arrangement 51 6.1.4 Measurements 55 6.1.5 Swept Frequency Aircraft Tests 57 6.1.6 Pulse Test . 62 6.2 Tests for Equipment/Systems . 67 6.2.1 Equipment Damage Tolerance Tests . 68 6.2.2 Equipment Functional Upset Tests .
16、 68 SAE ARP5416A Page 3 of 105 6.2.3 System Functional Upset Tests 68 6.3 Wire Bundle Shield Transfer Function Test 74 6.3.1 Wire Bundle Shield Transfer Function Using Lightning Pulse Injection Method 76 6.3.2 Wire Bundle Shield Transfer Function Using Swept Frequency Tests . 78 6.4 Shield/Connector
17、 Current Handling Test 80 6.4.1 Shield/Connector Current Handling Test 80 7. FUEL SYSTEM TEST METHODS 82 7.1 Test Objectives . 82 7.2 Tests and Specimen Types 83 7.2.1 Test Types 83 7.2.2 Specimen Types . 85 7.3 Conduction Tests 85 7.3.1 Conduction Test to Complete Tanks or Complete Tank Subassembli
18、es . 85 7.3.2 Conduction Tests on Fuel Tank Coupon Specimens . 87 7.3.3 Conduction Tests to Fuel System Components . 89 7.4 Direct Strike Tests . 90 7.4.1 Direct Strike Tests on Complete Tanks or Tank Sections 90 7.4.2 Direct Strike Tests on Coupon Specimens . 92 7.4.3 Direct Strike Tests to Externa
19、lly Mounted Fuel System Equipment . 94 7.5 Voltage Breakdown Tests . 94 7.5.1 Voltage Breakdown Tests of Small Gaps . 94 7.6 High Voltage Corona and Streamer Test 97 7.6.1 HV Streamer Test . 97 7.7 Methods for Detection of Ignition Sources 99 7.7.1 Photographic Method 99 7.7.2 Ignitable Mixture (Fla
20、mmable Gas) Test Method 101 8. TEST REPORT . 104 9. NOTES 105 FIGURE 1 INITIAL LEADER ATTACHMENT TEST SETUP A 19 FIGURE 2 LEADER CONNECTION POINT 20 FIGURE 3 INITIAL LEADER ATTACHMENT TEST SETUP B 21 FIGURE 4 INITIAL LEADER ATTACHMENT TEST SETUP B, OF EXTERNALLY MOUNTED EQUIPMENT 22 FIGURE 5 INITIAL
21、 LEADER ATTACHMENT TEST SETUP B, OF EXTERNALLY MOUNTED EQUIPMENT SUSPENDED ABOVE GROUND PLANE 23 FIGURE 6 ARRANGEMENT FOR PROTECTION DEVICE EVALUATIONS TEST SETUP C . 24 FIGURE 7 ARRANGEMENT FOR SWEPT CHANNEL TEST OF LARGE TEST OBJECTS 29 FIGURE 8 ARRANGEMENT FOR SWEPT CHANNEL TEST OF SMALL TEST OBJ
22、ECTS 30 FIGURE 9 TEST ELECTRODE FOR SWEPT CHANNEL TEST . 30 FIGURE 10 TEST SETUP TO DETERMINE INITIAL LEADER ATTACHMENT LOCATIONS ON MODELS NATURALLY OCCURRING LEADER SIMULATION SHOWN 33 FIGURE 11 TEST SETUP TO DETERMINE INITIAL LEADER ATTACHMENT LOCATIONS ON MODELS AIRCRAFT INITIATED STRIKE SIMULAT
23、ION SHOWN 34 FIGURE 12 TEST WIRE POSITIONING 37 FIGURE 13 TYPICAL JET DIVERTING TEST ELECTRODE 38 FIGURE 14 TEST ON TRANSPARENCY MOCK-UP 40 FIGURE 15 TEST ON WINDSHIELD . 40 FIGURE 16 TYPICAL SETUP FOR DAMAGE TEST WITH POWER LEAD LAYOUT 44 FIGURE 17 TYPICAL METAL SKIN INSTALLATION 46 FIGURE 18 LIGHT
24、NING INDUCED VOLTAGE APPEARS AT PITOT HEATER INSULATORS 48 FIGURE 19 INDUCED VOLTAGE MEASUREMENT LOCATIONS 49 FIGURE 20 HELICOPTER GROUND PLANE ARRANGEMENT 53 FIGURE 21 SMALL AIRCRAFT RETURN CONDUCTOR ARRANGEMENT . 54 FIGURE 22 LARGE TRANSPORT AIRCRAFT RETURN WIRE ARRANGEMENT 54 FIGURE 23 SCHEMATIC
25、REPRESENTATION OF MEASUREMENT TYPES . 56 FIGURE 24 SWEPT FREQUENCY TEST SETUP 58 SAE ARP5416A Page 4 of 105 FIGURE 25 TRANSFER FUNCTION EXAMPLE . 61 FIGURE 26 EXAMPLE FOR ESTABLISHING TRANSIENT LEVELS OF STANDARD WAVEFORMS . 62 FIGURE 27 PULSE TEST SETUP . 63 FIGURE 28 TYPICAL CONDUCTOR OPEN CIRCUIT
26、 VOLTAGE DUE TO CURRENT COMPONENT A 66 FIGURE 29 TYPICAL WIRE BUNDLE SHORT CIRCUIT CURRENT DUE TO CURRENT COMPONENT A . 67 FIGURE 30 TYPICAL CONDUCTOR SHORT CIRCUIT CURRENT DUE TO CURRENT COMPONENT A . 67 FIGURE 31 SIMULTANEOUS WIRE BUNDLE INDUCTION - EXAMPLE 73 FIGURE 32 SIMULTANEOUS INJECTION USIN
27、G GROUND INJECTION - EXAMPLE . 73 FIGURE 33 WIRE BUNDLE SHIELD TRANSFER IMPEDANCE EXAMPLE 75 FIGURE 34 WIRE BUNDLE SHIELD TRANSFER FUNCTION PULSE INJECTION TEST SETUP 76 FIGURE 35 SWEPT FREQUENCY WIRE BUNDLE SHIELD TRANSFER FUNCTION TEST SETUP 79 FIGURE 36 HARNESS CURRENT HANDLING CAPABILITY TEST SE
28、TUP - WIRE BUNDLE INJECTION 81 FIGURE 37 HARNESS CURRENT HANDLING CAPABILITY TEST SETUP - GROUND INJECTION . 81 FIGURE 38 DC SPARKOVER VOLTAGE VERSUS GAP AIR PRESSURE MULTIPLIED BY GAP LENGTH 95 FIGURE 39 EXAMPLE OF CONTROLLED ENERGY IGNITION SOURCE . 103 TABLE 1 TYPICAL TEST CURRENT ATTACHMENT CONF
29、IGURATIONS . 52 TABLE 2 EXAMPLES OF APPLICATIONS OF FUEL SYSTEM TESTS . 84 TABLE 3 EQUIVALENT FLIGHT ALTITUDE VERSUS AIR PRESSURE . 96 TABLE 4 102 SAE ARP5416A Page 5 of 105 1. SCOPE This document is one of a set covering the whole spectrum of aircraft interaction with lightning. This document is in
30、tended to describe how to conduct lightning direct effects tests and indirect system upset effects tests. Indirect effects upset and damage tolerance tests for individual equipment items are addressed in DO-160/ED-14. Documents relating to other aspects of the certification process, including defini
31、tion of the lightning environment, zoning, and indirect effects certification are listed in Section 2. This document presents test techniques for simulated lightning testing of aircraft and the associated systems. This document does not include design criteria nor does it specify which items should
32、or should not be tested. Acceptable levels of damage and/or pass/fail criteria for the qualification tests must be approved by the cognizant certification authority for each particular case. When lightning tests are a part of a certification plan, the test methods described herein are an acceptable
33、means, but not the only means, of meeting the test requirements of the certification plan. Each test method is set out in a uniform format, describing the test purpose, test object, test setup, test waveforms (voltage and/or current), measurements and data recording, test procedure and data interpre
34、tation. Guidance is provided on how to select the appropriate test or series of tests, and how the test results can be assessed. Natural lightning is a complex and variable phenomenon and its interaction with different types of vehicles may be manifested in many different ways. It is not intended th
35、at every test described herein be applied to every system requiring lightning verification tests. The document is written so that specific aspects of the environment can be called out for each specific program as dictated by the vehicle design, performance and mission constraints. 2. REFERENCES 2.1
36、Applicable Documents The documents below provide various sources of information relevant to aircraft lightning testing including descriptions of the external lightning environment applicable to aircraft, methods of determining lightning zoning of aircraft, regulatory requirements, and guidance on ce
37、rtifying aircraft by analysis and test. NOTE: Whenever a reference document appears in this Recommended Practice, it carries the minimum revision level of the reference document acceptable to meet the intended requirements. Later versions of the reference document are also acceptable but earlier ver
38、sions are not acceptable. In all cases, other documents shown to be equivalent to the referenced document are also acceptable. 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 (outsid
39、e USA), www.sae.org. ARP4754 Guidelines for Development of Civil Aircraft and Systems ARP5412 Aircraft Lightning Environment and Related Test Waveforms ARP5414 Aircraft Lightning Zone ARP5415 Users Manual for Certification of Aircraft Electrical/Electronic Systems for the Indirect Effects of Lightni
40、ng Report AE4L-76-1 “Lightning Test Waveforms and Techniques for Aerospace Vehicles and Hardware“, (Blue Book), dated June 20, 1978 Report AE4L-81-2 “Test Waveforms and Techniques for Assessing the Effects of Lightning Induced Transients“, (Yellow Book), dated December 15, 1981 SAE ARP5416A Page 6 o
41、f 105 2.1.2 Federal Aviation Regulations (FAR) Available from the U.S. Department of Transportation, Subsequent Distribution Office, Ardmore East Business Center, 3341 Q 75th Avenue, Landover, MD 20785, www.faa.gov. US Code of Federal Regulations 14 CFR Parts 21, 23, 25, 27 Sections x.581, .610, .86
42、7, .899, .901, .903, .954, .1301, .1309, .1316, .1431 and .1529 (as applicable) 2.1.3 FAA Advisory Circulars (AC) Available from the U.S. Department of Transportation, Subsequent Distribution Office, Ardmore East Business Center, 3341 Q 75th Avenue, Landover, MD 20785, www.faa.gov. AC 20-53A “Protec
43、tion of Airplane Fuel Systems Against Fuel Vapor Ignition Due to Lightning”, dated April 12, 1985, Rev B issued June 5, 2006. Contains zoning definitions and procedures that are used for direct effects protection and is used as a guide to describe zoning as it applies to indirect effects. AC 20-136
44、“Protection of Aircraft Electrical/Electronic Systems for the Indirect Effects of Lightning”, dated March 5, 1990, Rev B issued September, 7, 2011 AC 21-16D RTCA Document DO-160D, dated July 21, 1998, Rev G issued June 22, 2011 AC 23.1309-1C “Equipment, Systems, and Installations“, dated March 12, 1
45、999, Rev 1E issued November 17, 2011 AC 25.1309-1A “System Design Analysis“, dated June 21, 1988 AC 27-1B “Certification of Normal Category Rotorcraft“, dated September 30, 1999, Change 3 issued September 30, 2008 AC 29-2C “Certification of Transport Category Rotorcraft“, dated September 30, 1999, C
46、hange 3 issued September 30, 2008 2.1.4 RTCA, Inc. Publications Available from RTCA, Inc., 1150 18th Street, NW, Suite 910, Washington, DC 20036, Tel: 202-833-9339, www.rtca.org. RTCA/DO-160D “Environmental Conditions and Test Procedures for Airborne Equipment“, dated July 29, 1997, including Change
47、 No. 1, dated December, 2000, Change No. 2, dated June, 2001 and Change No. 3, dated December, 2002, Rev G issued December 8, 2010 2.1.5 EASA Publications Available from European Aviation Safety Agency, Postfach 10 12 53, D-50452 Koeln, Germany, Tel: +49-221-8999-000, www.easa.eu.int. CS Parts 21, 2
48、3, 25, 27 Sections x.581, .610, .867, .899, .901, .903, .954, .1301, .1309, .1316, .1431 and .1529 (Parts and Sections as applicable) SAE ARP5416A Page 7 of 105 2.1.6 EUROCAE Publications Available from EUROCAE, 102, rue Etienne Dolet, 92240 Malakoff, France, Tel: +33.1.40.92.79.30, . EUROCAE ED-14D
49、 “Environmental Conditions and Test Procedures for Airborne Equipment“, dated July, 1997, including Change No. 1, dated December, 2000, and Change No. 2, dated June, 2001 and Change No. 3, dated December, 2002, Rev G issued May, 2011 EUROCAE ED-79 “Certification Considerations for Highly Integrated or Complex Aircraft Systems“, dated April, 1997, Rev A issued December, 2010 EUROCAE ED-81 “Certification of Aircraft Electrical/Electronic
