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PART 1
HYDRAULICS SYSTEM
OBJECTIVES:
On completion of this class you should be able to: 1. 2. 3. Explain the principle of hydraulics. Describe the simple hydraulics systems. Explain the following hydraulics components/ systems:
Hydraulics Fluids Hydraulics Reservoir Hydraulic Filters Hydraulics pump Hydraulics Actuator Accumulator Seals
HYDRAULICS SYSTEM
The theory behind HS equipment is
FLUID PRESSURE.
PRINCIPLES OF HYDRAULICS
The static pressure exerted by a column of liquid is determined by the height of the column and is independent of its volume. Meaning that
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PRINCIPLES OF HYDRAULICS
Neither the shape nor the volume of a container affects the pressure. Only the height of the container has any effects.
PRINCIPLES OF HYDRAULICS
Pascals Law A confined hydraulic fluid exerts equal pressure at every point and in every direction in the fluids.
PRINCIPLES OF HYDRAULICS
PSI = Pounds per Square Inch The pressure produced in a hydraulic cylinder acts at right angles to the cylinder walls = force of hydraulics
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Mechanical advantage may be obtained by using a piston with a small area to force fluid into a cylinder with a larger piston.
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HYDRAULICS TERM
Area
areas of piston heads Unit (sq.in, sq.cm)
Force Amount of push, pull or twist on an object force in hydraulics (force per area)= pressure Unit (pounds per square inc, psi @ kilopascals, kPa)
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HYDRAULICS TERM
Stroke
length measurement of distance a piston moves in a cylinder
Volume
Amount of fluid contained in a reservoirs or displaced by a pump or actuating cylinder Unit (liters, in3)
Fluid
substance that is liquid or gaseous in form
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The relationship between area, pressure, and force is represented by these subdivided circles
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The relationship between volume, area, and distance can also be represented by a segmented circle.
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commanded, must not operate when not commanded and must not fail totally under single failure conditions.
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REQUIREMENTS
The larger an aircraft is the greater the force required to: Move flight control surfaces Extend and retract landing gear Apply brakes Steer the aircraft on the ground
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REQUIREMENTS
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REQUIREMENTS
These requirements together with the type of aircraft determine the design of a hydraulic system. Different aircraft have different hydraulics power configurations. The type of hydraulics applied to aircraft is called power hydraulics because it involves the application of power through the medium of hydraulics. A small aircraft may only have one hydraulics system powering only the brakes Larger aircraft have up to four individual hydraulics system powering
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Utility Systems 1. Undercarriage 2. Wheelbrakes 3. Nosewheel steering 4. Flight Refueling probe 5. Cargo doors 6. Loading ramp 7. Passenger stairs
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Has NO way of replenishing lost fluid As fluid heats up and expands brakes will apply (drag)
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COMPENSATOR PORT
Hydraulics Fluids
HF make possible the transmission of pressure and energy. Act as : Medium to transmit pressure and energy Lubricating medium to reduce friction between moving part
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HYDRAULICS FLUID
Hydraulic Fluids must have the following properties be incompressible have good lubricating properties inhibit corrosion not chemically attack the seals used in the system and must not foam in operation
Major Characteristics of Hydraulic Fluids a low viscosity chemical stability a high flash point and a high fire point
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Hydraulics Fluids
1. 2. 3. 4. 5. 6. 7. 8. 9.
To be suitable as a means of transmitting hydraulic forces, fluids must have certain basic qualities. These are : Low viscosity Not affected by extreme temperature Oiliness (they will act as lubricants) Will not corrode metals (inhibit corrosion) Will not affect the seals (not chemically attack the seals used in the system) Non-toxic or burn to operators Fire resistant (high fire point) Stability (its properties will not change with time) Must not foam in operation
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HYDRAULICS FLUID
There are three types of hydraulics fluid being used in aircraft : Vegetable base Mineral base Phosphate ester-base
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VEGETABLE-BASE FLUID
VBF normally almost colourless (dyed
rubber seals and hoses. It is used in some braking systems but is not often
found in hydraulic power system.
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VEGETABLE-BASE FLUID
Mixture contain castor oil and alcohol based Dyed blue for identification Natural (pure) rubber seals are used System may be flushed with alcohol (Methylated Spirits) Common in older wheel braking systems
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HYDRAULICS FLUID
Type Vegetable Based Fluid MIL-H-7644 Mineral Based Fluid MIL-O-5606 Properties Mixture contain Castor Oil and Alcohol Consist of high quality petroleum oil (kerosene) Colour Blue or bluegreen Characteristics Consider Obsolete. Unlikely to be encountered in modern aircraft. Still be found in older brake system Good lubrication characteristics & less corrosive. Use in systems where the fire hazard is comparatively low. Use in small aircraft for operating brakes, flaps and landing gear. Used extensively by the military services Higher fire resistance
Red
MIL-O-83282
Red
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HYDRAULICS FLUID
Type Phosphate Esterbase fluids MIL-O-8446 (Skydrol-500B-4) Properties Synthetic Phosphate Ester fluid Colour Light Purple Characteristics Fire resistant. Good under higher pressure & temperature Seals, gasket and hoses are made of butyl, silicone rubber or teflon seals. System is flushed with trichloroethlylene.
Always read the aircraft maintenance manual (AMM) and read the instruction plate affixed to the reservoir before adding fluid.
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HYDRAULICS RESERVOIRS
A tank or container to store sufficient hydraulic fluids Have the capability of containing extra fluid Store the unused fluids during certain operation Still have reserve fluids even when the operations used the maximum amounts (standpipes) Provide some means of checking the fluid level and of being replenish (quantity indicating method dipstick @ remote indicating system)
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HYDRAULICS RESERVOIRS
There are two types of reservoirs: 1. Inline reservoirs 2. Integral reservoirs Both can be further classified as a. Unpressurized (vented) b. Pressurized (closed)
Reservoirs are either vented to the atmosphere or closed to the atmosphere and pressurised.
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1. In-Line Reservoir
Separate components in the hydraulics system Has its own housing. Is a stand alone component and is connected with other components in a system by tubing or hose Can be pressurized or unpressurized
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2. Integral reservoir
Combined with the hydraulic pump. Has no housing of its own but is merely a space set aside within some major component to hold a supply of operational fluid. Often found in small aircraft (due to compact arrangement needed)
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a. Vented Reservoir
Aircraft that fly at lower altitudes have vented reservoirs They have some means of checking fluid quantity: Sight glass Dip stick Quantity transmitter The filler cap of a vented system may be opened while the system is operating Fluid level must be adjusted when the system is at rest
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b. Pressurized Reservoir
High altitude aircraft have pressurised reservoirs (Low Atmospheric pressure) Assure a positive feed of fluid to the pump reduces foaming (Because fluid cannot be pulled, it can only be pushed) Three ways of pressurising a reservoir in flight: using variable displacement hydraulic pumps engine bleed air or by the use of hydraulic system pressure acting on a small piston in the reservoir. Means of checking fluid quantity: Sight glass Quantity transmitter & indicator
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HYDRAULIC FILTERS
A filter will remove particles down to 10 microns will provide fluid that is clean enough for almost any hydraulic system. Particles may enter the hydraulics fluid when it is being serviced or during wear of operating components. These contaminants will
i. ii. iii. iv.
damage the seals and cylinder wall causing internal leakage prevent component from seating properly.
Common used filters micronic and porous type. Other type: cuno filetr, differential pressure two stage.
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HYDRAULIC FILTERS
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HYDRAULIC FILTER
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Hydraulics Pump
Pumps
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Hands Pump
Two basic types of hand piston pumps:
1. 2.
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each time its shaft turns (pump will deliver a given volume of fluid) This type is one of the most generally used types
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volume of fluid
OUTLET
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GEAR PUMP
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Gerotor Pump
A combination internalexternal gear pump Consists of :
gear rotor with wide and short height teeth 2. Spur driving gear 3. Pump cover 4. Crescent shaped opening for outlet and inlet **number of gear number
1.
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Gerotor Pump
The six tooth spur type drive gear is turned by the engine and as it turns, it rotates a seven-tooth internal-gear rotor
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Vane-type pump
Constant displacement pump Normally driven by electric motor Consists of sliding vane free to move radially in each slots As the rotor turns around a central steel spacer, the vanes remain in contact with the wall of the pump cavity The vanes form chamber that increase and decrease in volume as the rotor turns
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Multiple-Piston pump
Also called Bent axis piston pump A fixed angle piston pump The pistons are caused to move in and out of the cylinder as rotation occurs The housing is angled so that the piston on one side of the cylinder block are at the bottom of their stroke while those on the other side are at the top. One side draw fluid the other one force the fluid out from the cylinder If the cylinder block is parallel to the axis of the drive shaft, no fluid will be delivered, because there will be no movement of the piston
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Variable-Delivery pump
What is a Variable-displacement Pump? A variable displacement pump does not discharge a constant amount of fluid each revolution, but only the amount of
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HYDRAULICS ACTUATOR
Devices for converting hydraulic pressure to mechanical motion (work)
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ACTUATORS
mechanical or
This demand moves a valve which allows the hydraulic fluid at pressure to enter the actuator and moves the ram (piston) in either direction A mechanical system can be commanded by direct rod, lever or cable connection from pilot control lever to the actuator (Actuating cylinder type) An electrical system can be commanded by means of a solenoid (switch) or motor which is operated by a pilot switch or by a computer output. (Servo actuator)
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HYDRAULICS ACTUATOR
Actuators are classified as : 1. Linear 2. Rotary Common utilize actuator: 1. Actuating cylinder 2. Servo actuator
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ACTUATING CYLINDER
Are used for direct and positive movement Such as:
1. 2.
Retract and extend landing gear Retract wing flaps or slats, spoilers
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1.
The actuating rod reduces area of one side of the piston less force
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Some have a manual unlock mechanism for maintenance operation. Example; i. retract or extension for certain distance ii. Imagine : without lock when relieves the pressure, the piston will move to the neutral position steering
Typically used
gear
Piston is locked at the end of its movement Locked type: Ball type lock Finger type locked Cushion type: Starts its movement slowly Accelerates to full speed Cushioned at the end of its movement
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1. 2. 1.
2. 3.
1.
Rotary Actuators
Simplest form of a rotary actuator is the rackand-pinion type Linear movement of the actuator is converted into rotary action
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Rotary Actuators
737 Flap Power Unit
The piston type rotary hydraulics motor delivers continuous rotary force Similar in operation to the piston-type hydraulic pump. Used to drive Trimable horizontal stabilizers and flaps.
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Rotary Actuators
The vane type rotary hydraulic motor deliver continuous rotary force Similar in operation to the vane type hydraulic pump
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Accumulator
A hydraulic accumulator is an energy storage device. It is a pressure storage reservoir in which a non compressible hydraulic fluid is held under pressure by an external source. That external source can be a spring, a raised weight or a compressed gas. The main reasons that an accumulator is used in a hydraulic systems are so that the pump doesnt need to be so large to cope with extremes of demand, so that the supply circuit can respond more quickly to any temporary demand and to smooth pulsations.
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ACCUMULATOR
A chamber for storing hydraulic fluid under pressure Dampens pressure surges caused by the operation of an actuator Maintains a preset system pressure (in case leaking) Aid the system pump. How? 1. Supplement when several units are operating at the same time & demand beyond capacity. 2. Store power when pump fail to operate (limited)
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Accumulator
Three types off accumulator: 1. Diaphragm Type 2. Bladder type 3. Piston type
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SEALS
Purpose: To prevent leakage and ensure
effective operation
Seal minimize internal linkage and the loss of system pressure (preserve pressure)
because Hydraulics system require various tubing, fittings and seals
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SEAL
Seal minimize internal linkage and the loss of system pressure (preserve pressure)
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SEAL
Classified as : Packings 2. Gaskets
1.
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SEALS (gasket)
Gasket are used when there is no relative movement between surface (such as: engine box) Seal between two stationary parts.
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SEALS (Packings)
Provide seal between two parts of a unit that move relative to each other Packings are used when relative movement does exit (moving parts) Installed in most units that contain moving part such as actuating cylinder, valves and pumps.
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SEALS
Typical shapes of Hydraulic Packing Rings: U-ring : Seals pressure in one direction only U-cup-Ring Seals in one direction only V rings (chevron seal) Seals in one direction only, open end of the V facing the pressure
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SEALS
Pressure
Pressure
To prevent a flow from both directions, two sets of seals must be installed Open and facing the direction from which the pressure applied
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O-RING SEAL
The most common type for sealing Effective in both directions Maybe used as either a gasket or a packing This type of seal fits into a groove in one of the surfaces being sealed Required no adjustment when installed
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Pressure
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Pressure on a properly fitted ring attempts to drive it into the opening between the two surfaces
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> 15000 psi, O-Ring Seal should not be used alone Too high pressure, seal can become over pinched between the moving part & Stationary part destroy the part Backup seal- usually made of Teflon
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Prevent high pressure from pinching the seal the moving part & stationary part (cylinder wall & piston) Additional strength to seal Back-up ring should be place on the side away from pressure
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Use Air or MIL-H-5606 Skydrol hydraulic fluid Fuel system Oil System
Color Code on the O-Ring seal identifies the type of system in which it used Care should be taken installing a new seal Always check the part number Never choose a seal by comparison seals can look alike but may not be Double check by conforming colour code
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Extreme care must be used to prevent the ring being nicked or damaged Use O-ring installation tools Always lubricate the O-Ring before installation
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Installation care same as O-Ring High sufficient pressure in one direction one set sufficient 2 direction require more than one set
Pressure Switches
Electrically operated Electrically control/driven the pumps to maintain system pressure within set limits Pressure correct value, pump stop operation drop, pump operate again Other purpose : to control operation of warning and protective devices warning light when insufficient pressure turn off pump avoid exhausting reservoir Eg: Bourdon tube
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Relief Valves
Purpose ; to limit the maximum pressure can be developed in a hydraulic system Safety valve Pressure relief valves are used as backups to the main pressure regulator Increased pressure unseats the ball allowing pressure to escape (open valve) Adjusting screw increases or decreases the spring pressure on the ball thus adjusting the pressure at which the ball unseats
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Pressure Regulator
pump when it is not needed for operating a unit in the system Also called unloading valve unload the pump when the pressure is not required (continuous pressure can increase the possibility of failure)
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Pressure Reducer
A pressure reducer is used to lower the pressure in specific portion of the hydraulics system To prevent over loading some structures Relieve thermal expansion Pressure reduction is dependent on the size of the bleed hole,
and
The piston ball remains off its seat just enough to maintain the reduced pressure
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Pressure Reducer
Has 3 ports: connect with
1. 2. 3.
Another type of pressure reducer debooster valve Larger area pressure drop!!
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