SAE AIR 4543C-2017 Aerospace Hydraulics and Actuation Lessons Learned.pdf

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1、 _ 6$(7HFKQLFDO6WDQGDUGV%RDUG5XOHVSURYLGHWKDW7KLVUHSRUWLVSX EOLVKHGE6$(WRDGYDQFHWKHVWDWHRIWHFKQLFDO 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 therefrom, LVWKHVROHUHVS

2、RQVLELOLWRIWKHXVHU 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 2017 SAE International All rights reserved. No part of this publication may be reproduced

3、, 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 (outside USA) Fax: 724-776

4、-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:/standards.sae.org/AIR4543C AEROSPACE INFORMATION REPORT AIR4543 REV. C Issued 1992-01 Revised 2010-11 Stabilized 2017-02 Superseding AIR4543B

5、 Aerospace Hydraulics and Actuation Lessons Learned RATIONALE This document has been determined to contain basic and stable technology which is not dynamic in nature. STABILIZED NOTICE This document has been declared “Stabilized“ by the SAE A-6 Aerospace Actuation, Control and Fluid Power Systems Co

6、mmittee and will no longer be subjected to periodic reviews for currency. Users are responsible for verifying references and continued suitability of technical requirements. Newer technology may exist. SAE INTERNATIONAL AIR4543C Page 2 of 111 TABLE OF CONTENTS 1. SCOPE 4 1.1 Further Information Abou

7、t this Revision 4 2. REFERENCES 4 2.1 Applicable Documents 4 2.1.1 SAE Publications . 4 2.1.2 AIA Publications 5 2.1.3 ASTM Documents . 5 2.1.4 FAA Publications . 5 2.1.5 Joint Aviation Authorities Committee Publications 5 2.1.6 US Government Publications 6 2.1.7 Referenced Publications Now Canceled

8、. 6 2.2 Definitions . 7 3. TECHNICAL INFORMATION . 7 3.1 Systems Lessons Learned 7 3.1.1 All Systems . 7 3.1.2 Flight Control Systems 8 3.1.3 Power Distribution Systems 9 3.1.4 Utility Control Systems 18 3.2 Actuation Lessons Learned 19 3.2.1 Electric Servoactuators and Actuators 19 3.2.2 Hydraulic

9、Servoactuators and Actuators. 19 3.2.3 Mechanical Actuation 31 3.3 Mechanical and Hydromechanical Component Lessons Learned . 32 3.3.1 Accumulators 32 3.3.2 Filtration, Filters, and Fluids 36 3.3.3 Flight Critical Joint Retention 43 3.3.4 Manifolds . 43 SAE INTERNATIONAL AIR4543C Page 3 of 111 3.3.5

10、 Pumps and Motors 47 3.3.6 Seals . 57 3.3.7 Tubing, Fittings, Bosses, and Hoses 72 3.3.8 Valves 83 3.4 Electrohydraulic, Electromechanical and Electronic Component Lessons Learned 91 3.4.1 Aircraft Sensors . 91 3.4.2 Computers . 91 3.4.3 Connectors 91 3.4.4 Controllers . 91 3.4.5 Data Buses, Transmi

11、tters and Receivers . 91 3.4.6 Direct Drive Valves 91 3.4.7 Electrohydraulic Servovalves 92 3.4.8 Inceptors . 92 3.4.9 Motors and Generators . 92 3.4.10 Solenoid Valves 93 3.4.11 Solenoids 94 3.4.12 Transducers 95 3.4.13 Wiring 95 3.5 Miscellaneous Lessons Learned . 95 3.5.1 Corrosion, Materials, an

12、d Processes 95 3.5.2 Design, Build, Test and Maintenance Procedures 101 3.5.3 General 111 3.5.4 Project Organization 111 4. NOTES 111 SAE INTERNATIONAL AIR4543C Page 4 of 111 1. SCOPE This SAE Aerospace Information Report (AIR) contains Lessons Learned from aerospace actuation, control and fluid pow

13、er systems technologies. The lessons were prepared by engineers from the aerospace industry and government services as part of SAE Committee A-6, Aerospace Fluid Power, Actuation, and Control Technologies, and were presented to the A-6 during meetings held from 1989 through 1999. The document is org

14、anized into five sections covering systems, actuation, hydromechanical components, electrical components and miscellaneous, each further divided into subsections. The lessons are presented in a concise format of Problem, Issue, Solution and Lesson Learned, often with accompanying descriptive diagram

15、s and illustrations for clarity and understanding. Because of the potential growth in the size of the document as new lessons are published, those presented to the A-6 Committee in 2000 and later years are planned to be released in separate slash number documents, AIR4543/1, AIR4543/2 and so on. 1.1

16、 Further Information About this Revision The attempt has been made to transfer all of the technical information unchanged from the Revision A to this Revision B document. Several spelling and other typos have been corrected and a duplicate of one lesson was deleted. Two other lessons, which have bee

17、n revised and repeat presented to A-6 on dates close to the publication for this revision, have also been deleted and will reappear in the first slash number document. NOTE: 1. The Lessons Learned contained in this document were first published a minimum of 11 years before the publication date. The

18、reader is advised that some may have been overtaken by technology and developing industry practice. 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 e

19、nsure that all lessons of interest are found. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this document to the extent specified herein. The material in this document is informational and historical. Many of the Lessons Learned were originally published many years

20、 before the published date of this revision and the incident dates and relevant issues of the referenced publications are not known. Some of them have been superceded by other standards and this information is provided by parenthetical statements in the body of the document. Both the superceded publ

21、ications and those current at the time of publication are listed below. 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 Practi

22、ce for Cap Seals AIR1569 Handling and Installation Practice for Aerospace Hose Assemblies AMS-P-83461 Packing, Preformed, Petroleum Hydraulic Fluid Resistant, Improved Performance at 275 F (135 C) AMS-R-83485 Rubber, Fluorocarbon Elastomer, Improved Performance at Low Temperatures ARP4150 Procedure

23、for Inspection of Inservice Airborne Accumulators for Corrosion and Damage ARP4378 Aerospace - Accumulator, Hydraulic, Welded Bellows, Factory Precharged ARP4379 Aerospace - Accumulator, Hydraulic, Cylindrical, Piston Separated ARP4553 Aerospace - Accumulator, Hydraulic, Self-Displacing SAE INTERNAT

24、IONAL AIR4543C Page 5 of 111 AS604 Hose Assembly, Polytetrafluoroethylene, Metallic Reinforced, 3000 psi, 400 F, Heavyweight, Hydraulic AS620 Hose Assemblies, Convoluted Polytetrafluoroethylene Metallic Reinforced, High Temperature, Medium Pressure, Aircraft AS1241 Fire Resistant Phosphate Ester Hyd

25、raulic Fluid for Aircraft AS1339 Hose Assembly, Polytetrafluroethylene, Metallic Reinforced, 3000 psi, 400 F, Lightweight, Hydraulic and Pneumatic AS4059 Aerospace Fluid Power - Cleanliness Classification for Hydraulic Fluids AS4623 Hose Assembly, Polytetrafluoroethylene, Para-Aramid Reinforced, 300

26、0 psi, 275 F, Heavy Duty, Aircraft Hydraulic Systems AS4716 Gland Design, O-Ring and Other Elastomeric Seals AS5440 Hydraulic Systems, Aircraft, Design and Installation Requirements For AS8775 Hydraulic System Components, Aircraft and Missiles, General Specification For AS28775 Packing, Preformed, -

27、 MS28775 O-Ring AS83461/1 Packing, Preformed, MS83461 O-Ring AS83461/2 Packing, Preformed, MS83461 Straight Thread Tube Fitting Boss 2.1.2 AIA Publications Available from Aerospace Industries Association, 1000 Wilson Boulevard, Suite 1700, Arlington, VA 22209-3928, Tel: 703-358-1000, www.aia-aerospa

28、ce.org. NAS1638 Cleanliness Requirements of Parts Used in Hydraulic Systems (Inactive for new design) 2.1.3 ASTM Documents 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 F1940 Standard Test Method for P

29、rocess Control Verification to Prevent Hydrogen Embrittlement in Plated or Coated Fasteners 2.1.4 FAA Publications Available from Federal Aviation Administration, 800 Independence Avenue, SW, Washington, DC 20591. Tel: 866-835-5322, www.faa.gov. 14CFR Part 25 Code of Federal Regulations, Part 25 Air

30、worthiness Standards: Transport Category Airplanes 2.1.5 Joint Aviation Authorities Committee Publications Available from Global Engineering Documents, 15 Inverness Way East, Englewood, Colorado, 80112-5776. Tel: 1-800-854-7179 (inside USA and Canada) or 1-303-397-7956 (outside USA), http:/ JAR 25 J

31、oint Airworthiness Requirements, Large Aeroplanes SAE INTERNATIONAL AIR4543C Page 6 of 111 2.1.6 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.mi

32、l/quicksearch/. MIL-DTL-5498 Accumulators, Hydraulic, Cylindrical 3000 psi, Aircraft MIL-F-8815 Filter and Filter Elements, Fluid Pressure, Hydraulic Line, 15 micron absolute and 5 micron absolute, Type II Systems, General Specification for MIL-F-8815/2 Filter, Fluid, Pressure, Hydraulic Line, 3000

33、psi, Absolute 15 Micron, Style B, Non Bypass, -65 Degrees to +275 Degrees F (Inactive for new design.) MIL-F-24402 Filters (Hydraulic), Filter Elements (High Efficiency), and Filter Differential Pressure Indicators, General Specification for MIL-G-5514 Gland Design; Packings, Hydraulic, General Requ

34、irements for (Inactive for new design) MIL-P-25732 Packing, Preformed, Petroleum Hydraulic Fluid Resistant, Limited Service at 275 Deg. F (135 Deg. C) (Inactive for new design) MIL-PRF-680 Degreasing Solvent MIL-PRF-5606 Hydraulic Fluid, Petroleum Base; Aircraft, Missile and Ordnance (Inactive for n

35、ew design) MIL-PRF-6083 Hydraulic Fluid, Petroleum Base, for Preservation and Operation MIL-PRF-17331 Performance Specification, Lubricating Oil, Steam Turbine and Gear, Moderate Service MIL-PRF-46170 Hydraulic Fluid, Rust Inhibited, Fire Resistant, Synthetic Hydrocarbon Base, NATO Code No. H-544 MI

36、L-PRF-81836 Cleanliness Requirements of Parts Used in Hydraulic Systems MIL-PRF-83282 Hydraulic Fluid, Fire Resistant Synthetic Hydrocarbon Base; Aircraft, MIL-PRF-87257 Hydraulic Fluid, Fire Resistant Synthetic Hydrocarbon Base; Aircraft MIL-R-25988 Rubber, Fluorosilicone Elastomer, Oil- and Fuel R

37、esistant, O-Rings MS27595 Retainer, Packing Backup, Continuous Ring, Polytetrafluoroethylene (Inactive for new design) MS28774 Retainer, Packing Backup, Single Turn, Polytetrafluoroethylene (Inactive for new design) 2.1.7 Referenced Publications Now Canceled The following documents are referenced in

38、 the legacy Lessons Learned contained in this document. In each case they were valid when the Lesson was first published but should now be disregarded since they have been canceled and usually superceded. The superceding documents are provided in the body of the Lesson through parenthetical notes an

39、d listed in the preceding subsections. NOTE: 7KHRULJLQDOUHIHUHQFHVKDYHEHHQUHWDLQHGVRWKDWWKHUHDGHUFDQDFFHVVWKHDXWKRU VLQWHQWLIDQRIWKHOHVVRQVare found to conflict with the superceding document. Canceled SAE Publications AIR4150 Inspection of Inservice Airborne Accumulators for Corrosion and Damage SAE

40、 INTERNATIONAL AIR4543C Page 7 of 111 Canceled Government Specifications and Standards MIL-H-5440 Hydraulic Systems, Aircraft, Design and Installation Requirements for MIL-H-8775 Hydraulic System Components, Aircraft and Missiles, General Specification For MIL-P-83461 Packing, Preformed, Petroleum H

41、ydraulic Fluid Resistant, Improved Performance at 275 deg F (135 deg C) MIL-P-87175 Packing, Preformed, Petroleum Hydraulic Fluid Resistant, Phosphonitrilic Fluoroelastomer MIL-R-83485 Rubber, Fluorocarbon Elastomer, Improved Performance at Low Temperatures MS28775 Packing, Preformed, Hydraulic, +27

42、5 deg F (“O“ Ring) P-D-680 Dry Cleaning and Degreasing Solvent 2.2 Definitions Refer to ARP4386. 3. TECHNICAL INFORMATION 3.1 Systems Lessons Learned 3.1.1 All Systems This subsection addresses lessons generally applicable to systems of all types. 3.1.1.1 Biased Trade Studies PROBLEM: Trade Studies

43、Biased by Omissions ISSUE: Trade studies often fail to assess all influences on the air vehicle. Frequently in such trade studies the following issues are not compared: a. Cooling b. Power transmission c. Power conversion ILLUSTRATION: Distributed hydraulic packages: SAE INTERNATIONAL AIR4543C Page

44、8 of 111 Centralized hydraulic system SOLUTION: Conduct the trade study from the point of original power generation (usually the engine) to the point of final utilization. 3.1.2 Flight Control Systems 3.1.2.1 Effect of JAR/FAR 25.671 Requirement PROBLEM: Spoiler surface operation not compliant with

45、JAR/FAR 25.671 requirement. ISSUES: a. Noncompliance with JAR/FAR 25.671. The reference -$5)$5 is to paragraph 25.671 from 14CFR Part 25 and JAR 25 Ed. b. A single failure of a flight control surface attachment point could cause a catastrophic event. c. The center or outboard ground lift spoiler pan

46、el could deploy, following the failure of the eye end attachment point for example, such that an inadvertent rolling moment could not be controlled. ILLUSTRATION: SOLUTION: Reroute hydraulic supplies to the lift spoilers and link the center and outboard panels. SAE INTERNATIONAL AIR4543C Page 9 of 1

47、11 ILLUSTRATION: 3.1.2.2 Failure of all Four Hydraulic Systems PROBLEM: Failure of all four hydraulic systems due to blowout of the aft bulkhead. (Normal flight control was lost and the airplane crashed into a mountain.) ISSUES: a. The bulkhead was replaced and mistakenly fastened with a single row

48、of rivets rather than the required double row. b. The released cabin air over pressurized the fin, causing failure of the hydraulic lines. SOLUTION: a. The access port from the tail section (aft of the bulkhead) was closed. b. A hydraulic fuse was installed in one of the four hydraulic pressure lines leading to the fin. 3.1.2.3 Flight Control Attachmen