AS0403 Aircraft Systems & Instruments

S.Raj Kumar
Assistant Professor
Department of Aerospace Engineering
School of Mechanical Engineering
SRM University, Chennai, India.
Email: aerozsraj@ymail.com
 UNIT I

AIRCRAFT SYSTEMS

May 22, 2017 Aircraft Systems and Instruments 2

 Hydraulic System
Hydraulics :
Greek word for water
Study of behavior of water at rest and in motion
Current context the meaning has been expanded to include
the physical behavior of all liquids, including hydraulic
fluid.
Early aircraft had hydraulic brake systems
Invent of aircraft sophistication newer systems with
hydraulic power were developed.

May 22, 2017 Aircraft Systems and Instruments 3

 Advantages:

Light Weight

Ease of Installation

Simplification of Inspection

Minimum Maintenance requirements

100% efficient with negligible loss due to fluid friction

May 22, 2017 Aircraft Systems and Instruments 4

 Applications:

Landing Gear

Wing Flaps

Speed and Wheel Brakes

Flight Control Surfaces

May 22, 2017 Aircraft Systems and Instruments 5

 Hydraulic Fluid:

Primarily used to transmit and distribute forces to various units to be

actuated

Liquids are Incompressible

Pascals Law : Confined hydraulic fluid exerts equal pressure at every

point and in every direction in the fluid.

May 22, 2017 Aircraft Systems and Instruments 6

 Selection of Hydraulic Fluids:

Working Conditions

Service required

Temperatures expected inside and outside the system

Pressure the liquid must withstand

Possibilities of corrosion and other conditions

May 22, 2017 Aircraft Systems and Instruments 7

 Criteria For Selection:
Viscosity :
Internal resistance to flow

Viscosity decrease with increase in temperature

Satisfactory liquid must have enough body to give a good seal

at pumps, valves and pistons, but not so thick that it offers
resistance to flow, leading to powerloss and higher operating
temperatures which will lead to excessive wear of parts.

It is measured with viscosimeter (or) viscometer (Saybolt

Universal Viscosimeter)

May 22, 2017 Aircraft Systems and Instruments 8

 Criteria For Selection:
Chemical Stability :
Ability to resist oxidation and deterioration for long periods

All liquids tend to undergo unfavorable chemical changes under severe operating
conditions
Excessive temperatures have a great effect on the life of a liquid
Localized hot spots occur on bearings, gear teeth or at the point where liquid
under pressure is forced through a small orifice.
Small metals such as zinc, lead, brass and copper have a undesirable chemical
reaction on certain liquids resulting in formation of sludge, gums and carbon (or)
other deposits which clog openings, causes valves and pistons to stick or leak and
give poor lubrication to moving parts.

May 22, 2017 Aircraft Systems and Instruments 9

 Criteria For Selection:
Flash Point:
Temperature at which the liquid gives off vapour in sufficient quantity to ignite momentarily
or flash when a flame is supplied.

High flash point is desirable for hydraulic fluids because,

It indicates good resistance to combustion

Low degree of evaporation at normal temperature.

Fire Point:
Temperature at which a substance gives off vapour in sufficient quantity to ignite and
continue to burn when exposed to a spark or flame.

High fire point is required of desirable hydraulic fluids.

May 22, 2017 Aircraft Systems and Instruments 10

 Types of Hydraulic Fluids
To assure proper system operations
To avoid damage to non-metallic components of hydraulic system
Use the type specified in aircraft manufacturers maintenance manual (or)
instruction plate affixed to the reservoir or unit being serviced.

Types:
Vegetable Base Hydraulic Fluid
Mineral Base Hydraulic Fluid
Phosphate ester base Hydraulic Fluid

May 22, 2017 Aircraft Systems and Instruments 11

 Vegetable Base Hydraulic Fluid

Composed of caster oil and alcohol

Pungent alcoholic odor and generally dyed blue

Used in older aircrafts (Brake Systems)

Natural rubber seals are used with this type of fluid

If contaminated with petroleum base (or) phosphate ester base fluids, the
seals will swell, break down and block the system

Fluid is Flammable

May 22, 2017 Aircraft Systems and Instruments 12

 Mineral Base Hydraulic Fluid
Processed from Petroleum

Odor similar to penetrating oil and is dyed red

(Neoprene)Synthetic rubber seals are used with this type of fluid

Do not mix with other types

Fluid is Flammable

In small aircraft, Wheel brakes, Flaps and Landing gear are operated using
these fluids. Used on World War II aircrafts.

Less Corrosive and Less Damaging(Braco)

May 22, 2017 Aircraft Systems and Instruments 13

 Phosphate Ester Base Fluids
In 1946, United Airlines DC-6 flying from San Francisco to Denver
experienced Hydraulic fire that rapidly destroyed the wing and the aircraft
crashed shot of the runway.
Today's larger aircraft use phosphate ester base non flammable fluids such
as Skydrol.
They are approximately seven times as expensive as mineral base fluids.
Specially designed to operate at very high loads and temperature.
Touchy stuff (Make sure reservoir cap is fastened)
Old fluid smells sour and colour darkens
Drain old fluid, flush with Varsol or Stoddard solvent and replace with
fresh fluid.

May 22, 2017 Aircraft Systems and Instruments 14

 Phosphate Ester Base Fluids
Intolerant of contamination , fluids has to be inspected with a microscope.
When system component fails, drain the fluid, flush the system and refill
with fresh fluid.
Contaminated fluid eat the seals and grind the surfaces.
Used in most transport category aircraft and are very fire resistant
Not Fire Proof, under certain conditions fluids will burn.
They are coloured Purple.
Butyl synthetic rubber (or) Teflon Flurocarbon resin seals, gaskets and
hoses
Fire resistant fluids will soften or dissolve many types of paints, lacquers
and enamels.

May 22, 2017 Aircraft Systems and Instruments 15

 Performing Work with a Liquid

May 22, 2017 Aircraft Systems and Instruments 16

 Simple Hydraulic System

Requirements:

Reservoir

Pump

Valve Mechanism

Pipes (or) Hoses

Actuating Cylinder

May 22, 2017 Aircraft Systems and Instruments 17

 Hydraulic System Components
Hydraulic Reservoirs
Inline Reservoir
Pressurized
Unpressurized

Integral Reservoir

Hydraulic Filters
Micronic Type (3m)-treated paperelement
Porous Metal Type (5m)-metal particles joined sintering

May 22, 2017 Aircraft Systems and Instruments 18

 Hydraulic System Components Contd..

Heat Exchanger
Equipped with Temperature operated Bypass valve

Hydraulic Pumps
Heart of the hydraulic system
Various methods are employed to power a pump ( Electricity,
Bleed air from a turbine engine or even by a hand)

May 22, 2017 Aircraft Systems and Instruments 19

 Hydraulic System Components Contd..

Classification of Hydraulic Pumps:

Hand Driven Pump
Single-acting Hand Pump
Double-acting Piston Displacement Pump

May 22, 2017 Aircraft Systems and Instruments 20

 Hydraulic System Components Contd..

Power Driven Pump

Constant Delivery Pump
Variable Delivery Pump

Pumping Mechanism
Gears
Gerotors
Vanes
Pistons

May 22, 2017 Aircraft Systems and Instruments 21

 Pumping Mechanism

May 22, 2017 Aircraft Systems and Instruments 22

 Hydraulic System Components Contd..
Ram Air Turbine (RAT)
Air Turbine
Speed Governing Device
Variable Volume Pump

Pressure Control Devices

Pressure Switches
Pressure Regulators
Relief Valves (Thermal Relief Valve)
Pressure Reducing Valves

May 22, 2017 Aircraft Systems and Instruments 23

 Hydraulic System Components Contd..
Accumulators
Diaphragm
Bladder
Piston

Selector Valves
Rotary Valve
Poppet
Spool (or) Piston
Open-Center System

May 22, 2017 Aircraft Systems and Instruments 24

 Automatic Operating Control Valves

Orifice (or) Restrictor Valve

Check Valve
Orifice Check Valve
Metering Check Valve
Hydraulic Fuse
Sequence Valve
Shuttle Valve
Priority Valve
Flow Equalizers

May 22, 2017 Aircraft Systems and Instruments 25

 Hydraulic System Components Contd..
Hydraulic Actuators
Hydraulic Plumbing Components
Prevent leakage and Preserve pressure in the system

Seals (Packings and Gaskets)

Packings : Installed in parts containing moving parts (Actuating
Cylinders, Valves and Pumps)
Gaskets: Seal between two stationary parts
O ring seal commonly used for sealing pistons and rods
Identification of O-ring usage using Colour Codes
Red Fuel System : Blue Hydraulic System ; Yellow Oil System

May 22, 2017 Aircraft Systems and Instruments 26

 Hydraulic System
Classified into two major sections
Power Section

Actuating Section

Power Section :
Provides fluid flow
Regulates and limits pressure
Carries fluid to various selector values in the system

May 22, 2017 Aircraft Systems and Instruments 27

 Hydraulic System

Actuating Section
Contains various operating units such as wing
flaps, landing gear, brakes, boost systems and
steering mechanisms.

Power Section may be further classified as

Open System
Closed System

May 22, 2017 Aircraft Systems and Instruments 28

 Open System
It has fluid flow but no appreciable pressure in the system
whenever the actuating mechanisms are idle.
Selector valves are always connected in series with each other,
whereby the pressure line goes through each selector valve.
Pressure developed by the pump is controlled by one of the
three valves:
Open-center valve
Power-control valve
Pump-control valve

May 22, 2017 Aircraft Systems and Instruments 29

 Open System

It develops no pressure except when a mechanism is being

operated; the pressure is then metered by selector valve and
limited by a relief valve.

Advantages:

It does not require expensive or complicated pressure

regulators.
The power pump can be a simple gear pump, although
a fixed displacement piston pump may be used

May 22, 2017 Aircraft Systems and Instruments 30

 Open System
Disadvantages:

Operation of only one subsystem at a time is possible

without interference from other systems.
Transport-category aircraft require more complex
systems, which may have several units operating at the
same time.

Uses:
Light, general aviation aircraft.

May 22, 2017 Aircraft Systems and Instruments 31

 Basic Open-Center System

May 22, 2017 Aircraft Systems and Instruments 32

 Closed System

It directs fluid flow to the main system manifold and

builds up pressure in that portion of the system that leads
to all selector valves.

Two basic types:

Constant-volume pump and a pressure regulator
Variable-volume pump

May 22, 2017 Aircraft Systems and Instruments 33

 Closed System

Constant-volume pump and a pressure regulator:

To control pressure at working range .

To unload the pump when there is no flow requirement.

Pressure builds up in the system manifold.

May 22, 2017 Aircraft Systems and Instruments 34

 Closed System

Variable-volume pump:

Directs the flow to the system manifold

Output of the valve is controlled by an integral control

valve.

The valve reduces the pump flow to zero when no units are
operating in the system and pressure is built up in the
storage chambers, called accumulators.

May 22, 2017 Aircraft Systems and Instruments 35

 Closed System

Any number of subsystems may be incorporated in a closed

system

Selector valves are arranged in parallel

Based on system pressure the fluid is directed either to the system

or to the reservoir by the pressure regulator.

System pressure is maintained between kick-out and kick-in

settings of the regulator when the actuating mechanisms are not in
operation.

May 22, 2017 Aircraft Systems and Instruments 36

 Closed System

Accumulator: It stores fluid under pressure, Stabilizes system

pressure, ensures smooth operation of the regulator.

Relief valve safeguards the system if the regulator fails.

Multiple power pumps are used in multiengine aircrafts, where

they can be driven by separate engines.

May 22, 2017 Aircraft Systems and Instruments 37

 Closed System with Dual Pumps

Closed System with Dual Pumps

May 22, 2017 Aircraft Systems and Instruments 38

 Closed- Center System

May 22, 2017 Aircraft Systems and Instruments 39

 Aircraft Brake Systems

Mode of Actuation:

Mechanical (Older Small Planes)

Hydraulic (Sub system or Independent)

Pneumatic (In case of Hydraulic failure)

May 22, 2017 Aircraft Systems and Instruments 40

 Independent Brake System

May 22, 2017 Aircraft Systems and Instruments 41

 Power Boost Brake System

May 22, 2017 Aircraft Systems and Instruments 42

 Debooster Valve

May 22, 2017 Aircraft Systems and Instruments 43

 Aircraft Pneumatic System

Used Primarily as emergency source of pressure.

Principle of Operation is same with one exception AIR in a
pneumatic system is compressible therefore pressure can reduce
gradually.
In hydraulic system : Pressure drops from accumulator pressure
to zero pressure when pump is not operating.
Entire system, including air storage bottles can store air
pressure, in hydraulic system only accumulator stores fluid
under pressure.

May 22, 2017 Aircraft Systems and Instruments 44

 Aircraft Pneumatic System

Air must be kept clean by means of filters and also kept free
from moisture and oil droplets (or) vapours.

Liquid separators and Chemical driers are used.

Moisture in the system may freeze in low temperatures at high

altitudes, resulting in serious system malfunction.

No return lines, air is dumped overboard saves tubing, fittings

and valves.

May 22, 2017 Aircraft Systems and Instruments 45

 Aircraft Pneumatic System

System utilized in Fairchild F-27 aircraft

Used to operate : Landing Gear Retraction and Extension,

Nose wheel centering, Propeller Brakes, Main wheel brakes
and Passenger entrance door retraction.

Source of Power :
Primary System
Emergency System

Fokker F - 27
May 22, 2017 Aircraft Systems and Instruments 46
 Pneumatic System Components:
Power Section located in each engine nacelle:
Gear Box driven Compressor
Bleed Valve
Unloading Valve
Moisture Seperator
Chemical Drier
Back Pressure Valve (Right Side Only)
Filter
Shuttle Valve
Disk Type Relief Valve
Ground Charging Connection for Ground maintenance (or) Initial Filling.
May 22, 2017 Aircraft Systems and Instruments 47
 Pneumatic System

May 22, 2017 Aircraft Systems and Instruments 48

 Aircraft Landing-Gear System
Configuration

Conventional Geared Aircraft

Tricycle Landing Gear

May 22, 2017 Aircraft Systems and Instruments 49

 Classification

Non - Absorbing Landing Gear

Rigid Landing Gear
Shock-Cord Landing Gear
Spring-Type Gear

Shock-Absorbing Landing Gear

Spring - Oleo
Air- Oleo
Fixed Gear
Retractable Gear
Hulls and Floats
May 22, 2017 Aircraft Systems and Instruments 50
 Landing-Gear Components
Trunnion
Struts
Torque Links
Truck or Bogie
Drag Link or Drag Strut
Side Brace Link or Side Strut
Overcenter Link or Downlock
Swivel Gland
Shimmy Dampers
May 22, 2017 Aircraft Systems and Instruments 51
 Landing-Gear Components contd..

May 22, 2017 Aircraft Systems and Instruments 52

 Hydraulic Landing Gear Retraction System

May 22, 2017 Aircraft Systems and Instruments 53

 Landing Gear System
(Retractive Mechanism)

Electrically Operated Landing Gear System

May 22, 2017 Aircraft Systems and Instruments 54
 Reference:

Aircraft Maintenance and Repair, Kroes, Watkins and Delp, Sixth

Edition, Tata McGraw Hill Education Pvt Ltd.
Page Nos: 341 378 ; 395 401; 404 414; 417 420; 452 456

Airframe and Powerplant Mechanics, Airframe HandBook, U.S

Department of Transportation (FAA) 15A
Page Nos: 349 - 351

May 22, 2017 Aircraft Systems and Instruments 55