SAE ARP 6200-2014 Test Requirements and Means for Commercial Aircraft Hydraulic Systems.pdf

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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 2014 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/ARP6200 AEROSPACE RECOMMENDED PRACTICE ARP6200 Issued 2014-10 Test Requirements a

5、nd Means for Commercial Aircraft Hydraulic Systems RATIONALE There is a need to provide a document that recommends the tests and their associated test means that are required to demonstrate that a hydraulic system will comply with the applicable regulations of 14CFR Part 25 and EASA CS 25 as well as

6、 determining that the hydraulic system has the correct level of maturity at entry into service (EIS). This document addresses this need. TABLE OF CONTENTS 1. SCOPE 3 1.1 Field of Application 3 2. REFERENCES 3 2.1 Applicable Documents 3 2.1.1 SAE Publications . 3 2.1.2 A4A Publications . 3 2.1.3 EASA

7、 Publications 4 2.1.4 FAA Publications . 4 2.2 Definitions . 4 2.3 Acronyms, Abbreviations, and Symbols . 5 3. TEST MEANS TO BE USED 6 3.1 System Integration Rig 6 3.1.1 Purpose of the Rig 6 3.1.2 Overview of the Rig . 6 3.2 Aircraft Ground Testing . 6 3.2.1 Overview of Adaptations Required . 6 3.3

8、Aircraft Flight Testing 7 3.3.1 Overview of Adaptations Required . 7 4. RECOMMENDATIONS FOR INSTRUMENTATION 7 4.1 General 7 4.2 Measurement Parameters and Locations . 7 5. OVERVIEW OF REQUIRED TESTING 8 5.1 Testing To Demonstrate Compliance with Applicable Airworthiness Regulations . 8 5.1.1 Data Us

9、ed for Certification Purposes 9 5.2 Testing Required To Demonstrate Maturity Prior To Entry into Service . 9 5.2.1 Hydraulic System Endurance Testing . 9 5.2.2 Check of Aircraft Maintenance Manual Procedures . 10 SAE INTERNATIONAL ARP6200 Page 2 of 17 5.2.3 Check Of System Monitoring Devices 10 5.2.

10、4 Trouble shooting . 10 5.2.5 Validation of Master Minimum Equipment List (MMEL) items 10 5.2.6 Review of Installation Zones . 10 6. TEST REQUIREMENTS AND MEANS 10 6.1 Build, System Fill, Air Bleeding, and Servicing . 11 6.2 Visual Inspection of Installations . 12 6.3 Pre-Test Inspections . 12 6.4 P

11、roof Pressure 12 6.5 Functional Test 13 6.6 Functional Test at Elevated System Pressure 13 6.7 Simulated Failures 13 6.8 Endurance . 14 6.9 External Leakage Survey 14 6.10 Pressure Survey 14 6.11 Temperature Survey . 14 6.12 Vibration Survey 15 6.13 Negative Accelerations . 15 6.14 Flammable Fluids

12、16 6.15 Post Test Inspection 16 6.16 Airplane Documents 16 7. NOTES 17 SAE INTERNATIONAL ARP6200 Page 3 of 17 1. SCOPE This SAE Aerospace Recommended Practice (ARP) describes the recommended tests and their associated test means for commercial aircraft hydraulic systems at the system level that are

13、required to demonstrate compliance with the 14 CFR Part 25 and EASA CS 25 airworthiness regulations, and to show that the required level of maturity at the aircraft entry into service (EIS) has been achieved. 1.1 Field of Application This ARP is primarily intended for business and commercial aircraf

14、t that are designed to comply with 14 CFR Part 25 and EASA CS 25 airworthiness regulations. 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 applicable issue of other p

15、ublications 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 regulations unless a speci

16、fic 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. ARP24 Determination of Hydraulic Pressure Drop AS595 Aerospace Civil Type

17、 Variable Delivery, Pressure Compensated, Hydraulic Pump ARP1084 External Hydraulic Leakage for In-Service Components AS4059 Aerospace Fluid Power - Contamination Classification for Hydraulic Fluids ARP4754 Guidelines for Development of Civil Aircraft and Systems ARP4943 Ground Support Equipment Hyd

18、raulic Systems, Design and Installation, Recommended Practices For ARP5376 Methods, Locations and Criteria for System Sampling and Measuring the Solid Particle Contamination of Hydraulic Fluids AS5440 Hydraulic Systems, Military Aircraft, Design and Installation, Requirements For AIR5829 Air in Airc

19、raft Hydraulic Systems ARP5891 Achieving Cleanliness Standards for Aircraft Hydraulic Systems During Manufacture AIR5992 Descriptions of Systems Integration Test Rigs (Iron Birds) For Aerospace Applications 2.1.2 A4A Publications Available from Airlines for America (A4A), 1301 Pennsylvania Avenue, N

20、W, Suite 1100, Washington, DC 20004, Tel: 202-626-4000, www.airlines.org. SPEC 100 Manufacturers Technical Data SAE INTERNATIONAL ARP6200 Page 4 of 17 2.1.3 EASA Publications Available from European Aviation Safety Agency, Postfach 10 12 53, D-50452 Cologne, Germany, Tel: +49-221-8999-000, www.easa.

21、eu.int. Part 21 Certification of Aircraft and Related Products, Parts and Appliances, and of Design and Production Organizations, Commission Regulation (EU) No 748/2012 AMC 25.1435 Hydraulic Systems - Design, Test, Analysis and Certification CS-25 Certification Specifications and Acceptable Means of

22、 Compliance for Large Aeroplanes. PR.TC.00001-002 Type Certification 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 21 Certification Procedures for Products and Parts 14CFR Part 25 A

23、irworthiness Standards: Transport Category Airplanes 8110.4 Type Certification AC 21-16 RTCA, Inc. Document RTCA/DO-160, Environmental Conditions and Test Procedures for Airborne Equipment. Note: AC 21-16 identifies the DO-160 versions that are acceptable for environmental qualifications. AC 25-7 Fl

24、ight Test Guide for Certification of Transport Category Airplanes AC 25-22 Certification of Transport Airplane Mechanical Systems AC 25.1435 Hydraulic System Certification Tests and Analysis TAIL Transport Airplane Issues List 2.2 Definitions AIRPLANE FLIGHT MANUAL (AFM): A formal document containin

25、g limitations within which the aircraft is considered airworthy, and instructions and information necessary to the flight crew members for the safe operation of the aircraft. AIRPLANE MAINTENANCE MANUAL (AMM): A formal document which details the way in which all maintenance tasks carried out on an a

26、ircraft shall be accomplished. CAT I/II APPROACH: A precision instrument approach and landing with specific decision height, visibility, and runway visual range requirements. CYCLE: A cycle is a full travel of service from down to up and a return to the original down position. It is illustrated as a

27、 landing gear transitioning from a down and locked position to an up and locked position followed by a final transition to a down and locked position. EMERGENCY OPERATION: When a hydraulic power system reverts from normal system pressure to emergency system pressure when the normal system pressure i

28、s reduced to an ineffective level. ELAPSED TIME: The time duration taken to complete a prescribed operation from start to finish. SAE INTERNATIONAL ARP6200 Page 5 of 17 ENDURANCE TESTING: A test spectrum designed to validate the durability and maturity of a hydraulic system for a specified period of

29、 time or cycles. The test spectrum may include a range of environmental and external loading conditions. FUNCTIONAL TEST: This is a test to ensure components and systems are in proper working order and their performance conforms to the specification. HYDRAULIC GROUND SUPPORT EQUIPMENT: Hydraulic gro

30、und support equipment provides pressurized fluid to the aircraft hydraulic systems for functional testing or reservoir servicing while the aircraft is on the ground. The equipment may be portable or stationary. HALF CYCLE: A half cycle is completion of 50% of a full travel of service. It is illustra

31、ted as a landing gear transitioning from a down and locked position to an up and locked position. MASTER MINIMUM EQUIPMENT LIST (MMEL): The MMEL is prepared in accordance with applicable operating and flight rules. It is prepared by the airplane manufacturer and identifies which equipment may be ino

32、perative and still permit dispatch. NORMAL SYSTEM: The hydraulic system and components are functioning properly under the specified condition. OPERATIONAL PROFILE: This is the demonstration of all satisfactory functions of a hydraulic system and components during ground, flight, and maintenance oper

33、ations. A flight includes the satisfactory completion of operations from startup to shutdown. POST-TEST INSPECTION: Inspection of components and installations following completion of a test. SYSTEM INTEGRATION RIG: A test rig that utilizes aircraft hydraulic components to duplicate hydraulic system

34、functionality. It may also include aircraft control, monitor, display, and avionics interfaces to assist in validating total system integration. The test rig may apply external loads and environmental conditions to replicate aircraft operational conditions. 2.3 Acronyms, Abbreviations, and Symbols 1

35、4 CFR Title 14 Code of Federal Regulations AC Advisory Circular AGL Above Ground Level AMC Alternate Means of Compliance CS Certification Specification EASA European Aviation Safety Agency ETOPS Extended Range Twin Operations FAA Federal Aviation Administration V1 The maximum speed in the takeoff at

36、 which the pilot must take the first action (e.g., apply brakes, reduce thrust, deploy speed brakes) to stop the airplane within the accelerate-stop distance. SAE INTERNATIONAL ARP6200 Page 6 of 17 3. TEST MEANS TO BE USED 3.1 System Integration Rig 3.1.1 Purpose of the Rig A primary purpose of the

37、rig, also commonly known as an Iron Bird, is validation of system integration. Some of the potential benefits of the system integration rig are to: a. Provide an early means to verify hydraulic component sizing, hydraulic demands and pressure drops, static and dynamic performance, thermal characteri

38、stics, analytical models, and integration with aircraft electrical and avionics systems. b. Provide a means for early identification of manufacturing, installation, servicing, accessibility, and maintainability issues. c. Provide a means for long term endurance tests that would be impractical to acc

39、omplish on a flight test asset. d. Provide an early means to evaluate new technological features and reduce development risk for the aircraft ground and flight test program. e. Provide a means for resolution of issues encountered during aircraft development, certification, and after the aircraft ent

40、ers service if the test bed can be maintained for that purpose. f. Provide a means to collect data for certification credit if an approved certification process can be utilized and there is valid technical justification. 3.1.2 Overview of the Rig AIR5992 provides a description of several historical

41、system integration test rigs used for commercial aircraft development. A common theme of the descriptions is the achieved level of configuration fidelity between the test rig and the eventual production aircraft. Substitutes for actual aircraft hydraulic components, including tube and hose assemblie

42、s, may be utilized initially due to availability constraints. While that may be acceptable for some of the test objectives, there should be a plan to upgrade the substitutes to representative aircraft hardware when it becomes available in order to meet the overall testing goals and objectives. Aircr

43、aft representative control and monitoring systems (hardware and software) and approved software builds (when applicable) should be part of the integration rig configuration. Software tools used to simulate the aircraft operating environment (flight simulation aspects) should be validated, if such to

44、ols are in scope for the project. Each hydraulic component should ideally be located in actual aircraft spatial coordinates. It is desirable that the rig be operational well in advance of the aircraft first flight date. This is to permit adequate time for issue resolution and configuration changes t

45、o be implemented that are deemed essential for first flight readiness. Emergency safety stops should be located around the test rig and in the control room. Alternative means of controlling electrical power supplied to electrical controls, such as a circuit breaker with individual toggle switches, s

46、hould be implemented. This is to prevent inadvertent startup and actuation of test rig hardware during system initialization. The data acquisition system should be capable of recording at high sampling rates. It is beneficial to have hydraulic system user forms with live parameter feeds displayed du

47、ring testing in the control room. 3.2 Aircraft Ground Testing 3.2.1 Overview of Adaptations Required Hydraulic system prime mover adaptations may include hydraulic ground support equipment that is portable or stationary. Aircraft structural supports necessary to permit landing gear retraction/extens

48、ion cycles may be necessary. Adaptations to simulate aircraft conditions such as landing gear “weight on wheels” conditions, wheel speed, and other parameters may be needed in order to test system control, monitor, and warning devices. Equipment necessary to accomplish hydraulic fluid monitoring, sa

49、mpling, and analysis should be available. SAE INTERNATIONAL ARP6200 Page 7 of 17 3.3 Aircraft Flight Testing 3.3.1 Overview of Adaptations Required Adaptations needed to accommodate flight testing and subsequent analysis of flight test data can include the installation of instrumentation and data acquisition and storage equipment. 4. RECOMMENDATIONS FOR INSTRUMENTATION 4.1 General It is recommended that, wherever possible, the same transdu