UNIT-I

AIRCRAFT SYSTEMS
(Hydraulic system)
 HYDRAULIC SYSTEMS
• The word hydraulic refers to the power produced in
moving fluids.
• Aircraft Hydraulics is a means of transmitting energy or
power from one place to another efficiently.
• It is a system where liquid under pressure is used to
transmit this energy.
• Modern Hydraulic systems are defined as
The use of confined liquids to transmits power,
multiply force or produce motion efficiently.
 PASCAL’S LAW
• It states that,
a change in the
pressure of an enclosed
incompressible fluid is
conveyed undiminished to
every part of the fluid and
to the surface of its
container.
• In other words, if a pressure
is applied on a confined
fluid, this pressure is
transmitted in all direction
with equal force on equal
area.
Hydrostatic Paradox
The pressure exerted by a column of liquid is determined
by the height of the column and is independent of its volume.
• Neither the shape nor the volume of a container
affects the pressure. Only the height of the column
does this.
 Advantages of Hydraulic Systems
(over other systems for aircraft use)
• It is lighter in weight than alternate existing systems.
• It is reliable; either it works or doesn't.
• It can be easily maintained.
• It is not a shock hazard; it is not much of a fire hazard.
• It can develop practically unlimited force or torque
• It provides smooth and steady movement.
• Installation of hydraulic equipment is simple, items such as
pipe lines between components can go around obstructions
whereas, mechanical systems requires levers, guides or pulleys.
• Variation in speed of operation can be achieved without the
use of gearing.
• Pilot is not subjected to unnecessary fatigue when operating
service as the power for hydraulic actuation is provided by the
pump connected to the aero engine.
 SOME DEVICES OPERATED BY HYDRAULIC SYSTEMS
IN AIRCRAFT

• Retraction and extension of landing gear

• Variable geometry wings (Sweep back wings)
• Opening and closing doors and hatchways
• Automatic pilot and gun turrets
• Shock absorption systems and valve lifter systems
• Braking systems
• Flight control systems, spoilers or flaps
• Bomb bay doors and bomb displacement gears
Hydraulics Systems Principles of Operation
 BASIC HYDRAULIC SYSTEMS
• Open Hydraulic System
 TYPES OF HYDRAULIC SYSTEM
(A)OPEN HYDRAULIC SYSTEM
• Open system develop no pressure except when a
mechanism is being operated: the pressure is then
metered by the selector valve and limited by relief
valve
• Advantage: does not require expensive and
complicated pressure regulator and the power
pump can be single gear pump
• Dis-advantage: operation of only one subsystem at a
time is possible without interference from the other
system
---- Found only in light aircrafts
 BASIC HYDRAULIC SYSTEMS
• Closed Hydraulic Systems
B)CLOSED HYDRAULIC SYSTEM
• Pressure developed may be regulated by pressure
regulator.
• Always have fluid stored under pressure when ever
power pump is operating.
• After the system pressure has reached its predetermined
value the load is automatically removed from pump by
the unloading valve.
• Closed system is one that directs fluid flow to the main
system manifold and builds up pressure in that portion of
system that leads to all selector valves.
Advantage: all the subsystem at a time is possible without
interference of other system
---- Used in all the modern aircraft.
 BASIC HYDRAULIC SYSTEMS
• More modern brake system
 HYDRAULIC FLUID
• The fluid used in aircraft hydraulic systems is one of the system’s
most important parts.
• The fluid must flow with a minimum of opposition. (At all
temperatures)
• Must be incompressible
• Good lubricating properties (Have low freezing and high
boiling point.)
• Inhibit corrosion and not to attack seals (Not affected or
be affected by the materials in the components.)
• Must not foam in operation
• Not to deteriorate or form sludge.
• Should have a high flash point.
 HYDRAULIC FLUID PROPERTIES

• Some of the properties and characteristics

that must be considered.

• Viscosity
• Chemical Stability
• Flash Point
• Fire Point
 HYDRAULIC FLUID PROPERTIES
• Viscosity is the internal resistance to flow.
• Gasoline flows easily (has a low viscosity)
• Tar flows slowly (has a high viscosity)
• A satisfactory liquid for a hydraulic system
must have enough body to give a good seal at
pumps, valves and pistons; but it must not be
so thick that it offers excessive resistance to
flow.
• The average hydraulic liquid has a low
viscosity.
 HYDRAULIC FLUID PROPERTIES
• Chemical Stability is the ability of the liquid to resist
oxidation and deterioration for long periods.
• Excessive temperatures have a great effect on
the life of a liquid.
• Liquids may break down if exposed to air, water,
salt, or other impurities.
• Fire Point is the temperature at which a substance
gives off vapor in sufficient quantity to ignite and
continue to burn when exposed to a spark or flame.
• High fire point is required for desirable hydraulic
fluids.
 HYDRAULIC FLUID PROPERTIES
• Flash Point is the temperature at which a liquid
gives off vapor in sufficient quantity to ignite
momentarily when a flame is applied.
• High flash point is desirable for hydraulic
fluids. Because it indicates good resistance
to combustion and a low degree of
evaporation at normal temperatures.
 TYPES OF HYDRAULIC FLUID
• Vegetable based Fluid
– MIL-H-7644 is composed essentially of castor oil and alcohol.
– It has a pungent alcoholic odour , generally dyed blue colour and
is flammable.
– Used primarily in older aircraft.
• Mineral-base Fluid (Flammable)
• MIL-H-5606 is the most widely used hydraulic fluid in general
aviation aircraft.
• Kerosene-type petroleum product.
• Dyed red for identification
• Odour similar to penetrating oil
• Synthetic rubber seals are used
• Flammable and used at less fire hazard systems.
• Less corrosive and less damaging to certain parts than other
types.
 TYPES OF HYDRAULIC FLUID
• Synthetic Fluid
• Non-petroleum base hydraulic fluid is to provide fire
resistant hydraulic fluid for use in high performance
piston engine and turbine powered aircraft.
• Most commonly used fluid of this type is Skydrol
• Skydrol-500B is a clear purple liquid having low
temperature operating characteristics and low
corrosive side effects.
• Skydrol-LD is a clear purple low weight fluid
formulated for use in large and jumbo jet transport
aircraft where weight is a primary factor.
 HYDRAULIC FLUID CONTANIMATION
• Generally two contaminants
1. Abrasives, including such particles are core
sand, weld spatter, machining chips and rust.
2. Non-Abrasives, including those resulting from
oil oxidation and soft particles worn or shredded
from seals and other organic components.
 HYDRAULIC FILTERS

• It is a screening or straining device used to clean

the hydraulic fluid.
• Prevents foreign particles and avoids
contamination of the fluid.
• If not removed the entire hydraulic system of a/c
fails and leads an emergent condition.
• Filter is rated by the size of the particle it will
remove and are measured in microns.
• Filtering element of stainless wire woven into a
mesh and wrapped around a wire frame
 HYDRAULIC FILTERS
• Filtering element is made of specially treated paper folded
into pleats to increase it surface area.
• These pleated paper is wrapped around a spring steel wire
coil to prevent it from collapsing.
• The materials used for the filter elements depends on the
degree of filtration and may be one of the following:
FELT (a soft thick fabric made from wool or hair that
has been pressed tightly together)
Paper
Brass/steel wire gauze
Aluminum foil
Resin bonded fiberglass cloth
Magnetic element.
 TYPES OF HYDRAULIC FILTERS
• Filter may be classified as follows as per their usage:
TECALEMIT FILTER:
(i) It is of low pressure type.
(ii) Spring loaded relief valve is incorporated which relieves pressure
when the filter gets clogged.
(iii) provided with bypass valve when rotated through 90 deg closes
both inlet and outlet ports thus the container and filtering
element can be remove for servicing without loss of fluid.
(iv) Consists of deeply corrugated felt roll reinforced internally with
wire gauze.
 TYPES OF HYDRAULIC FILTERS
MICRONIC FILTER:
(i)Used in the pressure lines of hydraulic system where
high degree of filtration required.
(ii)Filter houses a bypass valve, a red plastic tell-tale
indicator.
(iii)In the event of clogging the bypass valve opens and
the unfiltered fluid passes to the system.
(iv)At the same time the tell-tale indicator pops out.
HYDRAULIC FILTER-MICRONIC TYPE
 BASIC HYDRAULIC SYSTEMS
• System Components
• Reservoirs
• Pumps
• Selector Valves
• Check Valves
• Hydraulic Fuses
• Accumulators
• Actuators
 RESERVOIR
• To store fluid for supply to the system.
• Stores reserve fluid for emergency operation using
stand pipes.
• Feeds the pump and receives the return fluid
• Provides air space for expansion of the oil due to
temperature changes
• Holds a reserve supply of oil to account for thermal
contraction of oil.
• Provides a place to remove air or foam from liquid.
• Provide a pressure head on the pump, that is, a
pressure head due to gravity and depends upon the
distance of the reservoir above the power pump.
 Construction of Reservoir

•
• Baffles
- they are used to stop the swirling effect of the
return oil from producing a whirlpool
• Filler pipe
- Such a pipe eases the replenishing of the
reservoir liquid. Since liquid seeks its own level, we
put the filler pipe so that its mouth has the same level
as the design level in the reservoir
• Vent
- Initially, vents were introduced because a vent
will not allow a void to form within the tank
• Dipstick
- its job was to measure oil depth
• Cavitation occurs
CAVITATION
when a liquid (such as oil) moves within
tubing or pipes at very fast speeds causing the absolute
pressure of the liquid to drop drastically.
• If the absolute pressure drops below the vapor pressure of the
liquid, cavitations will form
• This phenomenon is more serious in viscous liquids than in thin
liquids
• What are the results of cavitation.
--- it can cause wearing out of parts,
--- it will be heard as noise (sometimes you hear it in your
pipes...it's called line or water hammering),
--- it will cause vibrations in the system,
--- it will cause losses in efficiency of the hydraulic system,
--- it can cause erratic motor operations,
--- it will require replacement of parts much sooner than
designed for.
• To reduce cavitation effects:

The effects of cavitation have been minimized

by employing surge tanks, relief valves and (in water
conduit systems) burst plates.

Other ways to reduce cavitation include:

-- reducing the fluid's velocity, thus increasing fluid

pressure
-- increasing the absolute pressure of the system
-- increasing the pressure head of the suction pumps
-- decreasing sharp bends in the hydraulic system
-- decreasing abrupt changes in tubing cross-section
-- controlling the temperature and vapor pressure of
the system
 TYPES OF RESERVOIR
1.INLINE RESERVOIR
• Has its own housing
• Connected with other components with in system with
tubing or hose.

2.INTEGRAL RESERVOIR
• Has no housing of its own but is merely a space set aside
within some major component.
Eg., Bmc (break mass cylinder)
 IN-LINE RESERVOIR
(a) PRESSURISED RESERVOIR:
• Jet aircraft operating at altitudes where there is not enough air
pressure to have a positive feed to EDP.
• Ensures adequate supply of fluid, free from foaming is always
available at pump inlet.
• Ways of pressurizing are by using engine bleed air, using system
hydraulic pressure.
(b) UNPRESSURISED RESERVOIR:
• Normally used in a/c flying at altitudes below 15,000 feet.
• Used where hyd sys is associated with ground operations such
as brakes
RESERVOIR IN-LINE TYPE
 RESERVOIR
Following are the main parts of reservoir:
– Air breather: equalises the pressure of the air above the
level of the fluid with that of atmospheric pressure.
– Stack pipe: supplies fluid to EDP (engine driven pump)
irrespective of the attitude of the a/c.
– Pressure relief valve: relieves excess pressure in the reservoir
due to thermal expansion.
– Depressurization valve: equalize the pressure in the two
piston areas during servicing.
– Baffles/ fins: keeps the fluid within the reservoir from having
random movement such as vortexing (whirling motion of
fluid) and surging (these can cause fluid to foam and air to
enter the pump along with the fluid).
 SYSTEM COMPONENTS
• Pumps
• Powered Pumps
– Constant displacement moves a specific volume of
fluid each time its shaft turns. They are
a. Gear pump
b. Gerotor pump
c. Vane pump
– Variable displacement does not move a constant
amount of fluid in each revolution, but only the
amount, the system will accept.
 SYSTEM COMPONENTS
• Constant Displacement Pumps
-- Constant-displacement pumps are sometimes called
constant-volume or constant-delivery pumps.
-- They deliver a fixed quantity of fluid per revolution,
regardless of the pressure demands. Since the constant-delivery
pump provides a fixed quantity of fluid during each revolution of
the pump, the quantity of fluid delivered per minute depends
upon pump rotations per minute.
-- When a constant displacement pump is used in a hydraulic
system in which the pressure must be kept at a constant value, a
pressure regulator is required
• Gear Pump
• Gerotor Pump
• Vane Pump
GEAR TYPE POWER PUMP
 GEAR TYPE POWER PUMP
• A gear-type power pump is a constant-displacement pump.
It consists of two meshed gears that revolve in a housing.
The driving gear is driven by the aircraft engine or some
other power unit.
• The driven gear meshes with, and is driven by, the driving
gear.
• Clearance between the teeth as they mesh and between the
teeth and the housing is very small.
• The inlet port of the pump is connected to the reservoir, and
the outlet port is connected to the pressure line.
• When the driving gear turns, as shown in Figure, it turns the
driven gear.
• Fluid is captured by the teeth as they pass the inlet, and it
travels around the housing and exits at the outlet.
GEROTOR PUMP
 GEROTOR PUMP
• A gerotor-type power pump consists essentially of a housing containing
an eccentric-shaped stationary liner, an internal gear rotor having seven
wide teeth of short height, a spur driving gear having six narrow teeth,
and a pump cover that contains two crescent-shaped openings.
• One opening extends into an inlet port and the other extends into an
outlet port. During the operation of the pump, the gears turn clockwise
together
• As the pockets between the gears on the left side of the pump move
from a lowermost position toward a topmost position, the pockets
increase in size, resulting in the production of a partial vacuum within
these pockets.
• Since the pockets enlarge while over the inlet port crescent, fluid is
drawn into them.
• As these same pockets (now full of fluid) rotate over to the right side of
the pump, moving from the topmost position toward the lowermost
position, they decrease in size.
• This results in the fluid being expelled from the pockets through the
outlet port crescent.
VANE-TYPE POWER PUMP
 VANE-TYPE POWER PUMP
• The vane-type power pump is also a constant-displacement pump. It
consists of a housing containing four vanes (blades), a hollow steel rotor
with slots for the vanes, and a coupling to turn the rotor.
• The rotor is positioned off center within the sleeve.
• The vanes, which are mounted in the slots in the rotor, together with the
rotor, divide the bore of the sleeve into four sections. As the rotor turns,
each section passes one point where its volume is at a minimum and
another point where its volume is at a maximum.
• The volume gradually increases from minimum to maximum during the
first half of a revolution and gradually decreases from maximum to
minimum during the second half of the revolution.
• As the volume of a given section increases, that section is connected to
the pump inlet port through a slot in the sleeve. Since a partial vacuum
is produced by the increase in volume of the section, fluid is drawn into
the section through the pump inlet port and the slot in the sleeve.
• As the rotor turns through the second half of the revolution and the
volume of the given section is decreasing, fluid is displaced out of the
section, through the slot in the sleeve aligned with the outlet port, and
out of the pump.
 HYDRAULIC COMPONENTS
• PRESSURE SWITCHES:
Purpose:
(a) It is used in hydraulic systems with electrically driven pumps to
maintain system pressure within set limits.
(b) The pressure switch is set to open the electrical circuit to the pump
motor when system pressure builds up to correct values, causing the
pump to stop.
(c) When the pressure drops to a lower value the switch closes the
circuit to start the pump.
(d) Controls the operation of warning and protective devices. It turns on
light to warn the pilot about insufficient pressure or may turn off a
pump to avoid exhausting reservoir fluid.
 PRESSURE REGULATOR (or)
UNLOADING VALVES
Purpose:
 Designed to maintain a certain range of
pressures within a hydraulic system.
 To relieve the pressure on the pressure pump
when it is not needed for operating a unit.
 Some pressure regulators are also called
unloading valves
 PRESSURE RELIEF VALVE (or)
SAFETY VALVE
Purpose:
• Used to limit the maximum pressure that is being
developed in a hydraulic system.
• It acts as a safety valve.
– During operation, the relief valve remains closed
unless the system pressure exceeds that for which
the valve is adjusted.
– At this time the valve opens and allows the fluid to
flow through a return line to the reservoir.
 SYSTEM COMPONENTS

• Accumulators

• All accumulators consist of a high strength container

divided by some form of movable partition into two
sections, or compartments.

• One compartments connected to the hydraulic

pressure manifold, and the other is filled with
compressed air or with nitrogen.
 SYSTEM COMPONENTS
ACCUMULATORS
Purpose:
 Damps out the pump pulsation and acts as a cushion or
shock absorber by maintaining an even pressure in the system.
 Stores enough fluid under pressure to provide for
emergency operation of certain actuating units.
 Compensate for the temporary drop in supply pressure on
selection of a service thus aiding the power pump.
 To give initial impetus (momentum) to other components
operated.
Hydraulics System Accumulators
• Compressed gas at about one half the system
pressure is let into the accumulator through the
gas valve
• This forces the diaphragm that separates the oil
side from the gas side to "pop" up towards the oil
side
• Then oil is sent through the system
• When the system pressure reaches a point when
it is greater than the pressure of the accumulator,
the diaphragm will deploy (inflate).
• Using Boyle’s Law, the compressed gas will
increase in pressure as its volume decreases
• Therefore when the accumulator is at half volume
of gas, it will be charged at full system pressure.
 SYSTEM COMPONENTS

ACCUMULATORS

Types:

1. BLADDER TYPE
2. DIAPHRAGM TYPE
3. PISTON TYPE
 SYSTEM COMPONENTS

ACCUMULATORS

1. BLADDER TYPE:
It serves the same purpose, but
varies in construction. This unit
consists of a one-piece metal
sphere with a fluid pressure
inlet at top. An opening at
bottom to insert the bladder. A
large screw type plug at the
bottom retains the bladder and
also seals the unit.
 SYSTEM COMPONENTS

ACCUMULATORS

2. DIAPHRAGM TYPE:
Two hollow half ball metal
sections fastened together at
the center line. Between the
two halves is a synthetic rubber
diaphragm which divides the
tank in to 2 compartments.
 SYSTEM COMPONENTS
ACCUMULATORS

3. PISTON TYPE:
Consist of cylinder (b) and piston assembly (e) .
System fluid enters at (a) and forces the piston down against the air charge in
bottom chamber (d) high pressure air valve ( c) is for servicing the unit.
The 2 rubber seals (black dots) prevent leakage between 2 chamber (d and g).
A passage (f) is drilled from the fluid side of the piston to space between the
seals to provide lubrication between the cylinder walls and the piston.
 SYSTEM COMPONENTS
ACCUMULATORS

3. PISTON TYPE:
 SYSTEM COMPONENTS
• Hydraulic Actuators
Hydraulic actuators are devices for converting Hydraulic
Pressure to mechanical motion.

The most commonly utilized actuator is the actuating

cylinder: however, servo actuators and hydraulic motors are
also employed for special application where modified motion
is required.

Actuating cylinders are used for direct positive movement

such as retracting and extending landing gear and the
extension and retraction of wing flaps, spoilers and slats
 SYSTEM COMPONENTS
• Hydraulic Actuators

- Servo actuators are employed in situation where

accurately controlled intermediate positions of units are
required.

- The servo unit feeds back position information to the

pilot’s control, thus making it possible for the pilot to select any
control position required.
 SYSTEM COMPONENTS

• Actuators

• Single-Acting Linear

• Double-Acting Unbalanced Linear

• Double-Acting Balanced Linear

 SYSTEM COMPONENTS

• Single-Acting Linear (Brakes)

 SYSTEM COMPONENTS

• Double-Acting Unbalanced Linear (Landing Gear)

 SYSTEM COMPONENTS

• Double-Acting Balanced Linear (Flight Controls)

 SYSTEM COMPONENTS
• SERVO ACTUATORS
A servo actuator is designed to provide hydraulic power to
aid the pilot in the movement of various aircraft controls.
Such actuators usually include an actuating cylinder, a
multiport flow control valve, check valves, and relief valves
together with connecting linkages.
When the pilot moves a cockpit control in a particular
direction, force is applied to the flow control valve in the
actuator, causing it to direct fluid pressure to the actuating
cylinder.
The piston in the actuating cylinder moves in a direction to
assist the pilot in moving the flight control.
 SYSTEM COMPONENTS
• SERVO ACTUATORS

As the piston moves to the position called for by the

pilot’s control, the linkage between the piston and the flow
control valve moves the flow control valve back to a neutral
position and stops the flow of hydraulic fluid and, therefore
the movement of the piston.
The reverse action takes place when the pilot moves the
cockpit control in the opposite direction.
 AUTOMATIC OPERATING CONTROL VALVES
An automatic operating control valve is one that is designed to operate
without being positioned or activated by any force outside of the hyd. fluid
pressure or flow.
These valves are located in line with the system flow and function to perform
operations such as prevent or restrict flow in a line, allow flow at the proper time,
and change control of components between independent pressure systems.
Types of operating control valves are
1. Orifice or restrictor valves
2. Check valves
3. Orifice check valves
4. Metering check valve
5. Sequence Valve
6. Shuttle valve
7. Hydraulic fuse
8. Priority valve
9. Flow equalizers
 ORIFICE (OR) RESTRICTOR VALVES

The purpose of an orifice or a variable restrictor is to

limit the rate of flow of the fluid in the hydraulic line. In
limiting the rate of flow, the orifice causes the mechanism
operated by the system to move slowly.

Restrictors are used in hydraulic systems to limit the

flow of hydraulic fluid to or from actuators where
speed control of the cylinders is necessary to provide
specific actions. If control in only one direction is
desired, a one-way restrictor is used. If restricted fluid
flow both to and from an actuating cylinder is necessary, a
two-way restrictor is installed.
 CHECK VALVE

It permits the free hydraulic flow in one direction and

prevents flow totally in other direction
 HYDRAULIC FUSES

It is designed to seal off a broken hydraulic line and

prevent excessive loss of fluid.
It permits normal flow in a line; but if the flow increases
above an established level, the valve in the fuse closes the
line and prevents further flow.
HYDRAULIC FUSES
 SPECIAL PROBLEMS
The extreme facility of hydraulic systems present a number of
problems.
• Since hydraulic fluid has no shape, they must be positively
confined throughout the entire system.
• Special consideration to the structural integrity of the system
must be given. i.e strong pipes & containers.
• Leaks must be prevented, a particular problem with the high
pressure involved.
• The constant movement of the fluid in the system results in
friction within the fluid and hence a reduction in efficiency.
• Foreign matter must not be allowed to accumulate in the system.
• Chemical action may cause corrosion of the system components.