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Aircraft Systems: Mechanical, Electrical and Avionics Subsystems Integration, 3rd Edition


Description: This third edition of Aircraft Systems represents a timely update of the Aerospace Series’ successful and widely acclaimed flagship title. Moir and Seabridge present an in-depth study of the general systems of an aircraft – electronics, hydraulics, pneumatics, emergency systems and flight control to name but a few - that transform an aircraft shell into a living, functioning and communicating flying machine. Advances in systems technology continue to alloy systems and avionics, with aircraft support and flight systems increasingly controlled and monitored by electronics; the authors handle the complexities of these overlaps and interactions in a straightforward and accessible manner that also enhances synergy with the book’s two sister volumes, Civil Avionics Systems and Military Avionics Systems.

Aircraft Systems, 3rd Edition is thoroughly revised and expanded from the last edition in 2001, reflecting the significant technological and procedural changes that have occurred in the interim – new aircraft types, increased electronic implementation, developing markets, increased environmental pressures and the emergence of UAVs. Every chapter is updated, and the latest technologies depicted. It offers an essential reference tool for aerospace industry researchers and practitioners such as aircraft designers, fuel specialists, engine specialists, and ground crew maintenance providers, as well as a textbook for senior undergraduate and postgraduate students in systems engineering, aerospace and engineering avionics.


Contents: Foreword
Series Preface
About the Authors
Acknowledgements
List of Abbreviations
Introduction
Systems Integration
Systems Interaction

1 Flight Control Systems
1.1 Introduction
1.2 Principles of Flight Control
1.3 Flight Control Surfaces
1.4 Primary Flight Control
1.5 Secondary Flight Control
1.6 Commercial Aircraft
1.6.1 Primary Flight Control
1.6.2 Secondary Flight Control
1.7 Flight Control Linkage Systems
1.7.1 Push-Pull Control Rod System
1.7.2 Cable and Pulley System
1.8 High Lift Control Systems
1.9 Trim and Feel
1.9.1 Trim
1.9.2 Feel
1.10 Flight Control Actuation
1.10.1 Simple Mechanical/Hydraulic Actuation
1.10.2 Mechanical Actuation with Electrical Signalling
1.10.3 Multiple Redundancy Actuation
1.10.4 Mechanical Screwjack Actuator
1.10.5 Integrated Actuator Package (IAP)
1.10.6 Advanced Actuation Implementations
1.11 Civil System Implementations
1.11.1 Top-Level Comparison
1.11.2 Airbus Implementation
1.12 Fly-By-Wire Control Laws
1.13 A380 Flight Control Actuation
1.14 Boeing 777 Implementation
1.15 Interrelationship of Flight Control, Guidance and Flight
Management

2 Engine Control Systems
2.1 Introduction
2.1.1 Engine/Airframe Interfaces
2.2 Engine Technology and Principles of Operation
2.3 The Control Problem
2.3.1 Fuel Flow Control
2.3.2 Air Flow Control
2.3.3 Control Systems
2.3.4 Control System Parameters
2.3.5 Input Signals
2.3.6 Output Signals
2.4 Example Systems
2.5 Design Criteria
2.6 Engine Starting
2.6.1 Fuel Control
2.6.2 Ignition Control
2.6.3 Engine Rotation
2.6.4 Throttle Levers
2.6.5 Starting Sequence
2.7 Engine Indications
2.8 Engine Oil Systems
2.9 Engine Offtakes
2.10 Reverse Thrust
2.11 Engine Control on Modern Civil Aircraft

3 Fuel Systems
3.1 Introduction
3.2 Characteristics of Fuel Systems
3.3 Description of Fuel System Components
3.3.1 Fuel Transfer Pumps
3.3.2 Fuel Booster Pumps
3.3.3 Fuel Transfer Valves
3.3.4 Non-Return Valves (NRVs)
3.4 Fuel Quantity Measurement
3.4.1 Level Sensors
3.4.2 Fuel Gauging Probes
3.4.3 Fuel Quantity Measurement Basics
3.4.4 Tank Shapes
3.4.5 Fuel Properties
3.4.6 Fuel Quantity Measurement Systems
3.4.7 Fokker F50/F100 System
3.4.8 Airbus A320 System
3.4.9 ‘Smart' Probes
3.4.10 Ultrasonic Probes
3.5 Fuel System Operating Modes
3.5.1 Pressurisation
3.5.2 Engine Feed
3.5.3 Fuel Transfer
3.5.4 Refuel/Defuel
3.5.5 Vent Systems
3.5.6 Use of Fuel as a Heat Sink
3.5.7 External Fuel Tanks
3.5.8 Fuel Jettison
3.5.9 In-Flight Refuelling
3.6 Integrated Civil Aircraft Systems
3.6.1 Bombardier Global Express
3.6.2 Boeing 777
3.6.3 A340-500/600 Fuel System
3.7 Fuel Tank Safety
3.7.1 Principles of Fuel Inerting
3.7.2 Air Separation Technology
3.7.3 Typical Fuel Inerting System
3.8 Polar Operations – Cold Fuel Management
3.8.1 Minimum Equipment List (MEL)
3.8.2 Cold Fuel Characteristics
3.8.3 Fuel Temperature Indication

4 Hydraulic Systems
4.1 Introduction
4.2 Hydraulic Circuit Design
4.3 Hydraulic Actuation
4.4 Hydraulic Fluid
4.5 Fluid Pressure
4.6 Fluid Temperature
4.7 Fluid Flow Rate
4.8 Hydraulic Piping
4.9 Hydraulic Pumps
4.10 Fluid Conditioning
4.11 Hydraulic Reservoir
4.12 Warnings and Status
4.13 Emergency Power Sources
4.14 Proof of Design
4.15 Aircraft System Applications
4.15.1 The Avro RJ Hydraulic System
4.15.2 The BAE SYSTEMS Hawk 200 Hydraulic System
4.15.3 Tornado Hydraulic System
4.16 Civil Transport Comparison
4.16.1 Airbus A320
4.16.2 Boeing 767
4.17 Landing Gear Systems
4.17.1 Nose Gear
4.17.2 Main Gear
4.17.3 Braking Anti-Skid and Steering
4.17.4 Electronic Control
4.17.5 Automatic Braking
4.17.6 Multi-Wheel Systems
4.17.7 Brake Parachute

5 Electrical Systems
5.1 Introduction
5.1.1 Electrical Power Evolution
5.2 Aircraft Electrical System
5.3 Power Generation
5.3.1 DC Power Generation
5.3.2 AC Power Generation
5.3.3 Power Generation Control
5.4 Primary Power Distribution
5.5 Power Conversion and Energy Storage
5.5.1 Inverters
5.5.2 Transformer Rectifier Units (TRUs)
5.5.3 Auto-Transformers
5.5.4 Battery Chargers
5.5.5 Batteries
5.6 Secondary Power Distribution
5.6.1 Power Switching
5.6.2 Load Protection
5.7 Typical Aircraft DC System
5.8 Typical Civil Transport Electrical System
5.9 Electrical Loads
5.9.1 Motors and Actuation
5.9.2 DC Motors
5.9.3 AC Motors
5.9.4 Lighting
5.9.5 Heating
5.9.6 Subsystem Controllers and Avionics Systems
5.9.7 Ground Power
5.10 Emergency Power Generation
5.10.1 Ram Air Turbine
5.10.2 Backup Power Converters
5.10.3 Permanent Magnet Generators (PMGs)
5.11 Recent Systems Developments
5.11.1 Electrical Load Management System (ELMS)
5.11.2 Variable Speed Constant Frequency (VSCF)
5.11.3 270 VDC Systems
5.11.4 More-Electric Aircraft (MEA)
5.12 Recent Electrical System Developments
5.12.1 Airbus A380 Electrical System Overview
5.12.2 A400M
5.12.3 B787 Electrical Overview
5.13 Electrical Systems Displays

6 Pneumatic Systems
6.1 Introduction
6.2 Use of Bleed Air
6.3 Engine Bleed Air Control
6.4 Bleed Air System Indications
6.5 Bleed Air System Users
6.5.1 Wing and Engine Anti-Ice
6.5.2 Engine Start
6.5.3 Thrust Reversers
6.5.4 Hydraulic Systems
6.6 Pitot Static Systems
6.6.1 Innovative Methods of Pitot-Static
Measurement

7 Environmental Control Systems
7.1 Introduction
7.2 The Need for a Controlled Environment
7.2.1 Kinetic Heating
7.2.2 Solar Heating
7.2.3 Avionics Heat Loads
7.2.4 Airframe System Heat Loads
7.2.5 The Need for Cabin Conditioning
7.2.6 The Need for Avionics Conditioning
7.3 The International Standard Atmosphere (ISA)
7.4 Environmental Control System Design
7.4.1 Ram Air Cooling
7.4.2 Fuel Cooling
7.4.3 Engine Bleed
7.4.4 Bleed Flow and Temperature Control
7.5 Cooling Systems
7.5.1 Air Cycle Refrigeration Systems
7.5.2 Turbofan System
7.5.3 Bootstrap System
7.5.4 Reversed Bootstrap
7.5.5 Ram Powered Reverse Bootstrap
7.5.6 Vapour Cycle Systems
7.5.7 Liquid Cooled Systems
7.5.8 Expendable Heat Sinks
7.6 Humidity Control
7.7 The Inefficiency of Present Systems
7.8 Air Distribution Systems
7.8.1 Avionics Cooling
7.8.2 Unconditioned Bays
7.8.3 Conditioned Bays
7.8.4 Conditioned Bay Equipment Racking
7.8.5 Ground Cooling
7.8.6 Cabin Distribution Systems
7.9 Cabin Noise
7.10 Cabin Pressurisation
7.11 Hypoxia
7.12 Molecular Sieve Oxygen Concentrators
7.13 g Tolerance
7.14 Rain Dispersal
7.15 Anti-Misting and De-Misting
7.16 Aircraft Icing

8 Emergency Systems
8.1 Introduction
8.2 Warning Systems
8.3 Fire Detection and Suppression
8.4 Emergency Power Sources
8.5 Explosion Suppression
8.6 Emergency Oxygen
8.7 Passenger Evacuation
8.8 Crew Escape
8.9 Computer-Controlled Seats
8.10 Ejection System Timing
8.11 High Speed Escape
8.12 Crash Recorder
8.13 Crash Switch
8.14 Emergency Landing
8.15 Emergency System Testing

9 Rotary Wing Systems
9.1 Introduction
9.2 Special Requirements of Helicopters
9.3 Principles of Helicopter Flight
9.4 Helicopter Flight Control
9.5 Primary Flight Control Actuation
9.5.1 Manual Control
9.5.2 Auto-Stabilisation
9.5.3 Autopilot Modes
9.6 Key Helicopter Systems
9.6.1 Engine and Transmission System
9.6.2 Hydraulic Systems
9.6.3 Electrical System
9.6.4 Health Monitoring System
9.6.5 Specialised Helicopter Systems
9.7 Helicopter Auto-Flight Control
9.7.1 EH 101 Flight Control System
9.7.2 NOTAR Method of Yaw Control
9.8 Active Control Technology
9.9 Advanced Battlefield Helicopter
9.9.1 Target Acquisition and Designator System
(TADS)/Pilots Night Vision System (PNVS)
9.9.2 AH-64 C/D Longbow Apache
9.10 Tilt Rotor Systems
9.10.1 Tilt Rotor Concept and Development
9.10.2 V-22 OSPREY
9.10.3 Civil Tilt Rotor

10 Advanced Systems
10.1 Introduction
10.1.1 STOL Manoeuvre Technology
Demonstrator (SMTD)
10.1.2 Vehicle Management Systems (VMS)
10.1.3 More-Electric Aircraft
10.1.4 More-Electric Engine
10.2 Stealth
10.2.1 Joint Strike Fighter (JSF)
10.3 Integrated Flight and Propulsion
Control (IFPC)
10.4 Vehicle Management System
10.5 More-Electric Aircraft
10.5.1 Engine Power Offtakes
10.5.2 Boeing 787 (More-Electric) Electrical System
10.5.3 More-Electric Hydraulic System
10.5.4 More-Electric Environmental Control System
10.6 More-Electric Actuation
10.6.1 Electro-Hydrostatic Actuators (EHA)
10.6.2 Electro-Mechanical Actuators (EMA)
10.6.3 Electric Braking
10.7 More-Electric Engine
10.7.1 Conventional Engine Characteristics
10.7.2 More-Electric Engine Characteristics
10.8 Impact of Stealth Design
10.8.1 Lockheed F-117A Nighthawk
10.8.2 Northrop B-2 Spirit
10.8.3 Joint Strike Fighter – F-35 Lightning II
10.9 Technology Developments/Demonstrators
10.9.1 Fault Tolerant 270VDC Electrical Power
Generation System
10.9.2 Thermal and Energy Management Module
10.9.3 AFTI F-16 Flight Demonstration

11 System Design and Development
11.1 Introduction
11.1.1 Systems Design
11.1.2 Development Processes
11.2 System Design
11.2.1 Key Agencies and Documentation
11.2.2 Design Guidelines and Certification Techniques
11.2.3 Key Elements of the Development Process
11.3 Major Safety Processes
11.3.1 Functional Hazard Analysis (FHA)
11.3.2 Preliminary System Safety Analysis (PSSA)
11.3.3 System Safety Analysis (SSA)
11.3.4 Common Cause Analysis (CCA)
11.4 Requirements Capture
11.4.1 Top-Down Approach
11.4.2 Bottom-Up Approach
11.4.3 Requirements Capture Example
11.5 Fault Tree Analysis (FTA)
11.6 Dependency Diagram
11.7 Failure Modes and Effects Analysis (FMEA)
11.8 Component Reliability
11.8.1 Analytical Methods
11.8.2 In-Service Data
11.9 Dispatch Reliability
11.10 Markov Analysis
11.11 Development Processes
11.11.1 The Product Life Cycle
11.11.2 Concept Phase
11.11.3 Definition Phase
11.11.4 Design Phase
11.11.5 Build Phase
11.11.6 Test Phase (Qualification Phase)
11.11.7 Operate Phase
11.11.8 Disposal or Refurbish
11.11.9 Development Programme
11.11.10 ‘V' Diagram
11.12 Extended Operations (ETOPS)

12 Avionics Technology
12.1 Introduction
12.2 The Nature of Microelectronic Devices
12.2.1 Processors
12.2.2 Memory Devices
12.2.3 Digital Data Buses
12.2.4 A 429 Data Bus
12.2.5 MIL-STD-1553B
12.2.6 ARINC 629 Data Bus
12.2.7 COTS Data Buses
12.3 Data Bus Integration of Aircraft Systems
12.3.1 Experimental Aircraft Programme (EAP)
12.3.2 Airbus A330/340
12.3.3 Boeing 777
12.3.4 Regional Aircraft/Business Jets
12.3.5 A380 Avionics Architecture
12.3.6 Boeing 787 Avionics Architecture
12.3.7 COTS Data Buses – IEEE 1394
12.4 Fibre Optic Buses
12.5 Avionics Packaging Standards
12.5.1 Air Transport Radio (ATR)
12.5.2 Modular Concept Unit (MCU)
12.6 Typical LRU Architecture
12.7 Integrated Modular Avionics

13 Environmental Conditions
13.1 Introduction
13.2 Environmental Factors
13.2.1 Altitude
13.2.2 Temperature
13.2.3 Contamination by Fluids
13.2.4 Solar Radiation
13.2.5 Rain, Humidity, Moisture
13.2.6 Fungus
13.2.7 Salt Fog/Salt Mist
13.2.8 Sand and Dust
13.2.9 Explosive Atmosphere
13.2.10 Acceleration
13.2.11 Immersion
13.2.12 Vibration
13.2.13 Acoustic Noise
13.2.14 Shock
13.2.15 Pyroshock
13.2.16 Acidic Atmosphere
13.2.17 Temperature, Humidity, Vibration, Altitude
13.2.18 Icing/Freezing Rain
13.2.19 Vibro-Acoustic, Temperature
13.2.20 RF Radiation
13.2.21 Lightning
13.2.22 Nuclear, Biological and Chemical
13.3 Testing and Validation Process

Index


Author About the Authors Having previously served in the RAF and spent 18 years with Smiths Industries, Ian Moir now runs a successful international independent aerospace consultancy. He has a total of 44 years in the design, development, introduction into service and maintenance of complex integrated systems embracing military and civil applications. Along with Allan Seabridge he has co-authored 3 successful aerospace titles, and currently serves as series editor for the Aerospace series. Allan Seabridge is Head of Flight Systems Engineering with BAE Systems. He has 36 years experience in aerospace systems engineering, business development and research & development, with major projects worked on including Canberra, Jaguar, Tornado, EAP, Typhoon & Nimrod. Both Moir & Seabridge lecture and serve as external examiners for systems engineering, aerospace & avionics courses at Manchester, Loughborough and UCL.


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