ELECTRIC ACTUATION FOR FLIGHT & ENGINE CONTROL: …

1 SAE-ACGSC Mtg 99 Slide 1 ELECTRIC ACTUATION for FLIGHT & ENGINE CONTROL: Evolution & 2, 2007 Boulder Meeting ELECTRIC ACTUATION FOR FLIGHT & ENGINE CONTROL: EVOLUTION & CHALLENGESAmit KulshreshthaMoog CHARRIERH ispano-SuizaSAE-ACGSC Mtg 99 Slide 2 ELECTRIC ACTUATION for FLIGHT & ENGINE CONTROL: Evolution & 2, 2007 Boulder Meeting Rationale for ELECTRIC Powered ACTUATION in Aircraft Reduced Weight ELECTRIC Powered ACTUATION allows the aircraft certification with 3 or, 2 ELECTRIC & 2 Hydraulic compared to conventional aircraft requiring 3 ELECTRIC & 3 Hydraulic A weight saving of ~ 1000 A380 and 400 Lbs for F-35 has been attributed to ELECTRIC ACTUATION due to savings from additional Hydraulic Systems.

2 Weight savings by elimination of a hydraulic system are dependent upon the aircraft size. Improved Performance & Optimization Hydraulic Pump/System is a continuous load on the ENGINE whether Hydraulic Power is used for ACTUATION or, not while ELECTRIC load is on demand/when needed. 25% reduction in peak non-propulsive power usage with 5% reduced fuel consumption: 2000 Lb wt. Reduction for A340 results in fuel savings of 55 Lbs/hr ~ Total 550 Lbs for 10 hr FLIGHT Improved Maintainability & Survivability/Robustness Elimination of a hydraulic system improves reliability significantly due to low MTBF of the hydraulic system~ ENGINE driven pumps, pressure seals and leakage etc.

3 Efficient Segregation & Independence of the ACTUATION Power provides RobustnessDevelopments in enabling technologies- ELECTRIC motors, electronics etc. offer improved performance & optimization with lower maintenance costSAE-ACGSC Mtg 99 Slide 3 ELECTRIC ACTUATION for FLIGHT & ENGINE CONTROL: Evolution & 2, 2007 Boulder Meeting Conventional A330/340 FLIGHT Control- ACTUATION System Source: Airbus/SAE Presentation3 Hydraulic Systems (Y, G & B ) distributed amongst all Actuators SAE-ACGSC Mtg 99 Slide 4 ELECTRIC ACTUATION for FLIGHT & ENGINE CONTROL: Evolution & 2, 2007 Boulder Meeting More ELECTRIC -A380 FLIGHT & ACTUATION Control (2H/2E) SystemA380 More ELECTRIC ACTUATION with 2H/2E allows ~1000 Lbs Wt Saving and use of higher pressure (5000 psi) allowed further ~2000 Lbs resulting in total 3000 Lbs Wt SavingSource: Airbus/SAE PresentationSAE-ACGSC Mtg 99 Slide 5 ELECTRIC ACTUATION for FLIGHT & ENGINE Control.

4 Evolution & 2, 2007 Boulder Meeting ELECTRIC vs Electrohydraulic ActuationVariable-DeliveryConstant-Press ureHydraulic Source270 VDC ElectricalPower Source270 VDC ElectricalPower SourceVariable-SpeedBrushless MotorFlow ControlBy Throttling(Servovalve)Variable-SpeedBrus hless MotorHydraulicCylinderMechanicalTransmis sionFixed-DisplacementPumpHydraulicCylin derVCAEMAEHAM echanical/HydraulicEnergy ConversionMechanical/ElectricalEnergy ConversionMechanical/ElectricalEnergy ConversionRPMFlowRPMV elocityVelocityVelocityFlowMech/HydConve rsionHyd/MechConversionElect/MechConvers ionElect/MechConversionHyd/MechConversio nOil CoolingAir CoolingAir CoolingSAE-ACGSC Mtg 99 Slide 6 ELECTRIC ACTUATION for FLIGHT & ENGINE CONTROL: Evolution & 2, 2007 Boulder Meeting ELECTRIC ACTUATION in Aircraft & ENGINE Control: What Does it Mean?

5 ACTUATION system derives power from aircraft & ENGINE Control and provides required force/moment with a defined displacement within specified time to move a load/controlled element. Typical ACTUATION system in aircraft is run by central hydraulic systems powered by ENGINE driven hydraulic pumps and/or, central ELECTRIC motor driven pumps. ENGINE control is performed by ENGINE fuel based actuators similar to hydraulic servo actuators. ELECTRIC ACTUATION system uses local ELECTRIC power drive driving a mechanical transmission system for Electro-Mechanical Actuators (EMA) or, hydraulic transmission system such as Electro Hydro-static Actuators (EHA) or, Integrated Actuator Package (IAP).

6 RVDT#1 ROLLER SCREW/BALL SCREWELECTRIC MOTORCOMMUTATIONSENSOR-RESOLVERMECHANICA L TRANSMISSIONSENSORINTERFACEAUX POWER28 VDCELECTRONICS MOTOR CONTROL UNIT (EMCU)CONTROLELECTRONICS115/230 VAC,Var FreqBIT & MONITORELECTRONICSPOSITION /VELOCITYCOMMANDEHMM odedeviceRamManifoldElectronicsMotorPump AccumulatorModedeviceRamManifoldElectron icsMotorPumpAccumulatorELECTRIC DRIVEE lectro-Mechanical Actuator (EMA) Electro-Hydro-Static Actuator (EHA)SAE-ACGSC Mtg 99 Slide 7 ELECTRIC ACTUATION for FLIGHT & ENGINE CONTROL: Evolution & 2, 2007 Boulder Meeting Electrical Powered ACTUATION -EMA EMA based design can be made fault tolerant to motor & electronics failures~fail op/fail safe design with combination of control moment or, torque summing at control surface or, speed summing.

7 EMA technology has been successfully deployed in thrust vector controls in launch vehicle/missiles and aircraft hi-lift/ non- FLIGHT critical controls. EMA design require prevention of back driving by adding brakes or, no-backs . Technology capable of 400 deg f temp motor & electronics is enabling its use in severe environment & extended storage life 20+ years. Mechanical linkage between power source ( ELECTRIC motor) & load (control surfaces) & mech. Transmission (ball screw or roller screw are gears with no fluids/leakage but subject to jamming; newer hi torque/low speed may eliminate gear.)

8 Additional work in progress for jam tolerant, failsafe with auto-centering after failures to address ELECTRIC motor failures, loss of lubrication at 55~-65 deg C and mechanical jamming. SAE-ACGSC Mtg 99 Slide 8 ELECTRIC ACTUATION for FLIGHT & ENGINE CONTROL: Evolution & 2, 2007 Boulder Meeting Electrical Powered ACTUATION -EHA Combines advantages of ELECTRIC power & hydraulic ACTUATION ; integrated with conventional hydraulics EHV for EBHA. Transmission linkage between ELECTRIC motor & loads is hydraulic fluid making system immune to jamming. Proven hydraulic ACTUATION with historical data on known failure modes of the system with ability to either disengage failed motor or, lock hydraulic actuator/fluid to prevent flutter depending upon failure.

9 Requires digital control of high power electronics to control ELECTRIC motor torque & speed as needed to meet load requirements. Storage life of 10+ years SAE-ACGSC Mtg 99 Slide 9 ELECTRIC ACTUATION for FLIGHT & ENGINE CONTROL: Evolution & 2, 2007 Boulder Meeting Electrical Powered ACTUATION -IAP Integrated Actuator Package (IAP) Uses ELECTRIC power with swashplate controlled variable displacement pump connected to constant speed motor drive. Eliminates high power motor control electronics with low-power servo control of the swashplate for flow control to hydraulic RAM.

10 Hydraulic transmission linkage between ELECTRIC motor & load eliminates jamming problems. Constant load on pump results in heating of hydraulic fluid requiring cooling of IAP unlike EMA/EHA where ELECTRIC power is consumed only when Mtg 99 Slide 10 ELECTRIC ACTUATION for FLIGHT & ENGINE CONTROL: Evolution & 2, 2007 Boulder Meeting Electro-hydrostatic ACTUATION (EHA) Evolution for Electrical Back-up Hydraulic Actuator: EBHAS ource~Airbus/SAE SAE-ACGSC Mtg 99 Slide 11 ELECTRIC ACTUATION for FLIGHT & ENGINE CONTROL: Evolution & 2, 2007 Boulder Meeting Issues & Perception for EMAs in FLIGHT Controls?