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A380 Flight Controls Overview A380 Flight Control and Guidance Systems Main Novelties • Aircraft Configuration and Control Surfaces

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A380 Flight Controls Overview A380 Flight Control and Guidance Systems Main Novelties • Aircraft Configuration and Control Surfaces Presented by Xavier Le tron Airbus Flight Controls A380 Flight Controls overview A380 Flight Control and Guidance Systems main novelties • Aircraft configuration and control surfaces • Actuator technology • Power sources for Flight Controls • Flight Control Architecture and Computers • Back-up controls • Flight Control Laws • Conclusion : Flight Tests Findings © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 2 Flight Control Surfaces Trimmable Horizontal Stabilizer Rudders (x2) Flaps (3x2) Elevators (2x2) Slats (6x2) Droop Nose (2x2) spoilers (8x2) Ailerons (3x2) © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 3 Flight Controls: actuator characteristics stall load weight A340/330 stall load Ailerons 13,5 T 35/65 kg 15,7/10 T Spoilers 21/14,5 T25/65 kg 11/8,6 T Elevators 18 T 40/80 kg 10,2 T Rudders 22,5 T 100 kg 9,4 T THSa* 85 T 380 kg 32,5T *: loads on trim screw © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 4 A380 Flight Control and Guidance System : main novelties • Aircraft configuration and control surfaces • Actuator technology • Power sources for Flight Controls • Flight Control Architecture and Computers • Back-up controls • Control Laws © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 5 Primary Flight Control System Actuators : E(B)HA Conventional servocontrol Electro-Hydrostatic Actuator Servovalve Electrical Accumulator (EHA) Pump Accumulator Electronics system (power) Mode Hyd. Mode Motor Hydraulic block selector selector system Servovalve Hydraulic block device device (power) replaced by an electric motor Pump Ram Ram EHA in back-up Servocontrol in Servovalve normal Electrical Accumulator Pump Electronics operation system (power) Motor Mode selector Hydraulic block Hydraulic device system (power) Electrical Back-up Hydraulic Actuator Ram (EBHA) © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 6 Primary Flight Controls equipment status - overview EHA experience • 1989: first prototypes EHA/EMA • 1992 : EBHA aileron first flight on A320 test aircraft (more than 100 fh) • 1993/2000: full qualification process, development of large EHA • 2000/2002: One EHA (inboard aileron) constantly flight tested on A340 MSN 1 (200 FH, 61 flights), in active and stand- by modes, start phases, thermal behaviour... © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 7 Example: A380 EHA aileron Electronic module Hydraulic pump + elec. motor © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 8 Electro-Hydrostatic Actuator features • EHA hydraulically autonomous in flight: • EHA includes a fluid reservoir in order to compensate thermal dilatation and small external seepage • EHA fluid reservoir refilling rare, but possible through a connection between each EHA and one centralised circuit (Filing operation only possible on ground) © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 9 THSA DESIGN MAIN FEATURES Primary Secondary Electric Gearbox Hydraulic End stop Nut Nut Controller Motor Electric Motor Upper Attachment Hydraulic Valve Lower Block Attachment Ballscrew Total length: 2.9 m © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 10 THSA DESIGN MAIN FEATURES A320 A340-600 A380 A320 A380 A340-600 © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 11 A380 Flight Controls: High Lift system A380 High Lift movables and system mechanical components (similar concept as A340 Long Range) Flaps Slats inner, mid and outer flap droop nose Flap PCU Slat PCU SFCC Wing Tip Brake T-gearbox Asymmetry Position Pick-off unit Flaps Lever Motor Control Electronics SFCC 2 Wing Tip Brake © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 12 SystemA380 Flight Architecture Controls: High Lift system • 2 Drooped Nose Devices per wing (INBD wing) to improve aerodynamic performance (lift to drag ratio) • 6 Leading Edge Slats per wing (MIDBD & OUTBD wing) DROOPED NOSE DEVICES : Supported by hinged arms ; driven SLATS : by rotary actuators via link & lever supported by curved tracks ; driven by rotary actuators via rack & pinion © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 13 High Lift main novelties • Electric motor for SLAT PCU: due to 2H/2E concept Output Shaft Hydraulic Motor DC Electrical Motor • Hydraulic Variable Displacement motors: flow consumption • Fail-Safe Control Lever & Sensor: to improve S/F availability (no Clean Wing Landing design objective) © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 14 A380 Flight Control and Guidance System : main novelties • Aircraft configuration and control surfaces • Actuator technology • Power sources for Flight Controls • Flight Control Architecture and Computers • Back-up controls • Control Laws © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 15 A380 Hydraulic and electrical power sources Electrical System 2: Generator 4 Yellow System Generator 3 Reservoir and main generation components (within pylon) Power center 2 Engine Driven Pumps 1 Ground Electric Motor Pump (within pylon) 2 Engine Driven Pumps Emergency System: Power center E.RAT (Flap Track Fairing) Green System 1 Ground Electric Motor Pump (within pylon) 2 Engine Driven Pumps Electrical System 1: Reservoir and main generation components (within pylon) Power center 2 Engine Driven Pumps Generator 2 Generator 1 © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 16 From Blue Hydraulic system to electro-hydraulic actuators System 1 System 2 System 1 System 2 GEN GEN GEN GEN GEN GEN GEN GEN 1 2 3 4 Blue hydraulic circuit 1 2 3 4 BUS BUS BUS BUS replaced by electro-hydraulic BUS BUS BUS BUS actuators BLUE BLUE BLUE ELEC ELEC ELEC PUMP PUMP PUMP Blue Electro-Motor Pumps decentralized within the actuators ELEC ELEC ELEC ELEC ELEC ELEC PUMP PUMP PUMP PUMP PUMP PUMP • Survivability/robustness improvement: good fuse function recovery facility in case of power generation failure good segregation of distribution dissimilarity on surface actuators power supplying Redundancy improvement (2 electrical systems replace 1 hydraulic system) • Reduction of both hydraulic and electrical power consumption © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 17 Electro-hydraulic actuators use • Performances EHA : same performances as adjacent servocontrol, EBHA : same performances in hydraulic mode, reduced deflection rate in electrical mode. • Electrical mode Activation logics: In Normal flight: – No EHA or EBHA operation (damping & hydraulic mode) in case of High surface deflection or deflection rate : – double pressurisation of hydraulic actuators or E(B)HAs Failure cases with possible use of EHA and/or EBHA : – Single or double hydraulic failure, – One engine inoperative, – Total engine flame-out (with electrical RAT), – Engine burst – ... © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 18 A380 Flight Control and Hydraulic System : main novelties • Aircraft configuration and control surfaces • Actuator technology • Power sources for Flight Controls • Flight Control Architecture and Computers • Back-up controls • Control Laws © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 19 A380 Flight Control System Architecture • 2H/2E architecture 4 dissimilar power systems to actuate the moving surfaces Aircraft controllable from one power system robust architecture (engine rotor burst, structural damages …) • Electrical RAT supplying EHA and EBHA in case of total engine flame-out. • No Mechanical Control (Trim Hand Wheel replaced by Switches) • Improvement of Auto-Pilot availability (computers + Control Unit) © AIRBUS S.A.S. All rights document. reserved. Confidential and proprietary 27th September 2007 Page 20 A380 Flight Controls architecture A380 Primary Flight Control System Architecture – Baseline 1a Revised – October 02 Speed brakes, Ground spoilers Speed brakes, Ground spoilers Roll surfaces Roll surfaces Slats SPOILERS SPOILERS G E1 12345678 12345678 AILERONS AILERONS O/B Med I/B G Y E1G E2Y G Y G Y Y G Y G E2Y E1G Y G I/B Med O/B S3 S2 P1 P2 P3 S1 S2 S3 S3 S2 S1 P3 P2 P1 S3 G Y Y E1 G E2 G Y S2 E2 G E1 Y Y G P2 P3 P3 P1 P1 P2 Flaps P2 P1 P1 P3 P2P3 S3 S1 S1 S2 trim S2 S1 S1 S3 B switches B B S3 S1 28VDC1ess 28VDC1 P3 P1 P2 Upper Y P1 S1 B S1 S3 THSA E2 E1 Pedals G Y Rudder G P2 S2 Feel and Vertical E2 Trim Unit THS Stabilizer Lower P1 S1 B ELEVATORS ELEVATORS E1G O/B I/B I/B O/B Rudder Y P3 S3 Electrical Motor. E3 G E2 G E1 E2 Y E1 Y Conventional hydraulic servocontrol. P1 P2 P3 P1 P2P3 P1 P2 EHA, Electro Hydrostatic Actuator. S1 S2 S3 S1 S2S3 S1 S2 BB (Colors on E1, E2 and E3 for representation EBHA, Electrical Backup Hydraulic Actuator. purposes only, no engineering). G GREEN hydraulic system E1 E1 AC power (AC1ess side 1) P1, P2, P3, Prim and Sec Flight Control Computers S1, S2, S3 Command unit : unit A, unit B Y YELLOW hydraulic system E2 E2 AC power (AC2ess
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