Hydraulics

David Sandells
WHY USE HYDRAULICS
Flight Control Options

In a traditional aircraft, when a pilot exerts a

force on the yoke, a cable or control link
connected to the control surface (such as the
elevator or ailerons) responds accordingly.

Advantages:
Simplicity – Reliability

Disadvantages:
Power

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Flight Control Options

Control surfaces linked to the pilot's control

columns by mechanical pushrods-not cables or
pulleys.
Flight control system is hydraulically actuated by
two independent hydraulic systems. This
redundancy ensures safer flight.
Advantages:
Power
Direct Control

Disadvantages:
Loss of Feel for pilot
Complex routing of push-rods
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Flight Control Options
“Fly-by-wire” technology:
Control Stick & Actuator separately connected to
computer.
Computer processes stick movements and decides what
do with the actuator.
Electrical wires connect components together
Redundancies, load limits, and other factors-is can be
defined by the engineers who develop the aircraft.
Advantages:
Power
Control options
Simpler wiring routing

Disadvantages:
Loss of Feel for pilot
Lack of direct control
Risk of computer faults
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Actuator Locations

Plus many other non-flight control

systems”
e.g.
Cargo Doors
Landing gear
Engine Cowls
Foldable wingtips
Trim devices
ACTUATOR COMPONENTS
 Actuator Components
• For each component
– Name
– Function(s) / Purpose
– Principal stresses
– Key design considerations

A E
C
B
D C
A
 Cylinder Cylinder Barrel

Actuator Components Base/Cap

Piston
Seal Gland
Piston Rod

Cylinder barrel
• Main function: hold cylinder pressure. Normally hoop stress is calculated to optimize the barrel size.

Cylinder base or cap

• Main function: enclose the pressure chamber at one end and provide mounting component support. Cap size is determined
based on the bending and/or torsional stress.

Piston
• Main function: separate the pressure zones inside the barrel whilst sliding within the cylinder. The piston is machined with
grooves to fit elastomeric or metal seals and bearing elements to withstand the pressure difference between the two sides.

Piston rod
• Main function: Transfer the piston force to a moving attachment. Key consideration: withstand buckling & shear stresses,
provide smooth surface for end gland seal.

Seal gland
• Main function: prevent the pressurized oil from leaking externally from the cylinder. Key design consideration: wide enough to
accommodate sealing and load bearing components.

Eye Ends
• Main function: Provide movable joint between actuator and structure. Transfer the actuation forces to the structure.
• Key design consideration: Freely articulating (pin-ended) to minimise side-loading.
Actuator Sectional View
ACTUATOR ATTACHMENTS
 Attachment options
• Actuators need to articulate A B
– Kinematics of the mechanism
– Tolerances of the design
• Out of alignment

• Joints can be characterised by their

degrees of freedom (DoF) The joints A and B in this
A mechanism need to rotate as
B the actuator extends/retracts

Maximum 6 Degrees of freedom

3 Translations
3 Rotations
 Joint Options
• Zero DoF: Bolted/Welded Flange

• One DoF: Clevis Joint

– (Can be 2 DoF if allowed to
rotate around longitudinal axis)

• 3 DoF: Spherical bearing

Spherical bearing provides
3 rotational DoF
 Mounting Options
• Actuator mounting points
– Rod normally connected at the end
– Body connection Trunnion
• End: Clevis or spherical bearing mounting point

• Mid Body: Trunnion or flange

End Clevis

Eye end (spherical

Bearing)

Eye end (spherical

Bearing)
 System Demand
• Each time an actuator moves it
consumes flow

Applied Load

This volume must be filled, regardless of the applied Load

𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒 ∝ 𝑠𝑝𝑒𝑒𝑑
𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 ∝ 𝐹𝑜𝑟𝑐𝑒
Actuation in Demand

https://youtu.be/DV3TrATIAnA
ACTUATION EXAMPLES
Rotary and Linear Actuators
Flap Systems
Slat Systems
Aileron Actuator

US20120181383 A1
Spoiler Actuator

EP0239138 B1
 Thrust Reverser actuator
Clam Shell
Bucket

Translating Cowl

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 Engine Cowls

http://youtu.be/irzcOhjOzAU

US 2012/0125191 A1
Cargo Door Actuator

http://www.sitec-aerospace.com/products/hydraulics.html
TRIMMABLE HORIZONTAL STABILISER
ACTUATOR (THSA)
Trimmable Horizontal Stabiliser Actuator (THSA)
Trimmable Horizontal Stabiliser Actuator (THSA)

United States Patent US6672540

Trimmable Horizontal Stabiliser Actuator (THSA)

http://forum.hardware.fr/hfr/Discussions/Actualite/aviation-campaign-progress-sujet_26595_485.htm
Trimmable Horizontal Stabiliser Actuator (THSA)

United States Patent US6672540

CASE STUDIES
 Case Studies
• During the module we will use 3 design case studies to follow
against the taught content
1. A landing gear extend retract actuation system
2. A cargo door actuation system
3. A nose-wheel steering actuation system
Landing Gear Actuator

https://youtu.be/otz91wHAKzQ
 Landing Gear Actuator
Transitions gear between extended and
retracted state

Harder to lift gear than lower it

Extension firstly by gravity then actuator

helps complete the movement

Flight Safety Risks

Failure to extend (e.g. locked-up or
jammed)
Inadvertent operation in flight
FWD
Managed Risks
Failure to extend gear (alternative
extension methods used)
Failure to retract (land back)
Cargo Door Actuator

https://youtu.be/xCleoApdA7A
 Cargo Door Actuator
Transitions door between closed and
open state

Working against gravity to open the

door

Extension by actuator, retraction by

gravity and operator pressure

Flight Safety Risks

Opening in Flight
Failures that affect other critical
equipment

Acceptable risks
Inability to open/close
Nose Wheel Steering

https://youtu.be/opq1N-gMTaU
 Nose Wheel Steering Actuator
Transitions door between closed and open
state

Working against friction to turn left and right

Equal Loads in both directions

Flight Safety Risks

Inadvertent movement on runway

Managed risks
Inability to steer/taxi
ACTUATOR TYPES
 Single Ended , Single Acting
• Single Acting
– Fluid pushes one way only
– Alternative return force needed
Single Ended, Single Acting
Return Forces Mass

Gravity
 Single Ended, Single Acting
Return Forces
Spring
 Single Ended, Single Acting
• Advantages
– Lighter Weight
– Simpler design
• No sealing on external surface
• Simpler Valves
 Single Ended, Double Acting
• Double Acting -> actuator can extend and retract
• Asymmetric Force Capability:
– Extend force higher than retract
 Single Ended, Double Acting
• Thrust Reversers
• Flap/Slat actuators
 Double Ended , Double Acting
• Double ended means equal areas on both sides of piston
– Equal force capability to extend/retract
 Double Ended , Double Acting
Advantages
• Good for bi-directional control applications with equal loading
in both directions
• Reduces flow consumption
– Control Surfaces
– Nose-Wheel Steering
– Flight Control Surfaces with balanced loads
 Double Ended, Double Acting
• Rudder forces are symmetrical
left/right
• Pilot needs even control feel

Double Ended Rudder Actuator on A10

 Double Ended , Double Acting
Applications
• Nose-Wheel Steering
• Flight Controls

Moving Body
 Internally Double Ended , Double Acting
• Nose-Wheel Steering
• Flight Controls
Fixed Body

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 Choices for Case Studies
Landing Gear Actuator:
Single Ended, Double Acting

Cargo Door Actuator

Single Ended, Single Acting

Nose Wheel Steering

Double Ended, Double Acting