Hydraulics and Landing Gear DREAMLINER Systems Dean Hefilinger Boeing commercial Aviation Services May June 2005 Presented to: ABDEING 787 Engineering Maintenance Conference Proprieta The information contained herein is proprietary to The Boeing Company and shall not be reproduced or disclosed in whole or in part or used for amy eason except when such u ssesses direct written authorization from The Boeing Company
Hydraulics and Landing Gear Systems Dean Hefflinger Boeing Commercial Aviation Services May-June 2005 Presented to: 787 Engineering & Maintenance Conference
Agenda DREAMLINER a 5000 psi Hydraulics System Configuration Update Hydraulic Architecture ■ System Interfaces Component Installations Landing Gear Actuation System Overview Landing Gear Actuation System ■ Steering System Boeing Propriet
Boeing Proprietary Agenda ◼ 5000 psi Hydraulics System Configuration Update ◼Hydraulic Architecture ◼System Interfaces ◼Component Installations ◼ Landing Gear Actuation System Overview ◼Landing Gear Actuation System ◼Steering System
Hydraulic System DREAMLINER Architecture Overview 5,000 psi Hydraulic System Hydraulic System Distribution Reduced weight Volume integration by Partners Proven Left, Center and Right independent system architecture Control and indication Hydraulic Power Generation Integrated into Common Core System(Ccs) Four 27 gpm Electric Induction Motor Flight crew interfaces similar to 777 umps Common motor controllers for electric Two 25 gpm Engine Driven Pumps Motor Pumps One 19 gpm Ram Air Turbine Boeing Propriet
Boeing Proprietary 5,000 psi Hydraulic System • Reduced weight • Proven Left, Center and Right independent system architecture Hydraulic Power Generation • Four 27 gpm Electric Induction Motor Pumps • Two 25 gpm Engine Driven Pumps • One 19 gpm Ram Air Turbine Hydraulic System Architecture Overview Control and Indication • Integrated into Common Core System (CCS) • Flight crew interfaces similar to 777 • Common motor controllers for Electric Motor Pumps Hydraulic System Distribution • Volume integration by Partners
Hydraulic System DREAMLINER Architecture Left System Center System Right System 25 27/37g 27/37gpm27/37gpm10-19gp 25 gpm 27/37 gpm Electric Electric Electric Electric Motor Motor Moto Motor Pump Pump Pump Turbine Engine Pump (EMP) (EMP) (EMP) (RAT) (EMP) Ailerons Left Wing Left Wing Flaperons Left Wing Right Wing Right Wing Left Wing Right Wing: #8 Right Wing: #9 Left Wing: #3 Left Wing: #1 Left Wing: #2 Right Wing: #12 Right Wing: #14 Right Wing: #13 Elevator Left elevator Left Elevator Right Elevator Right Elevator Rudder PCU PCU PCU Thrust Left Engine Right Engine Edge Flaps ydraulic Motor Edge Flap Hydraulic Motor Nose Landing Normal Gear& Steering Reserve Main Landing Left Right Boeing Proprieta
Boeing Proprietary Hydraulic System Architecture Ailerons Flaperons Inboard Spoilers Outboard Spoilers Elevator Rudder Thrust Reversers Trailing Edge Flaps Leading Edge Flaps Nose Landing Gear & Steering Main Landing Gear Left Engine Engine Driven Pump (EDP) Electric Motor Pump (EMP) Left Wing Right Wing Left Wing: #3 Right Wing: #12 Left Wing Left Elevator Electric Motor Pump (EMP) Electric Motor Pump (EMP) Ram Air Turbine (RAT) Right Wing Left Wing Right Wing Left Wing: #7 Right Wing: #8 Left Wing: #1 Right Wing: #14 Left Elevator Right Elevator PCU Hydraulic Motor Hydraulic Motor Normal Reserve Left & Right PCU Left System Center System Right System 25 gpm 27/37 gpm 27/37 gpm 27/37 gpm 10-19 gpm Right Engine Engine Driven Pump (EDP) Electric Motor Pump (EMP) Right Wing Left Wing Left Wing: #6 Right Wing: #9 Left Wing: #2 Right Wing: #13 Right Elevator PCU 25 gpm 27/37 gpm Left Engine Right Engine
Hydraulic System DREAMLINER Architecture(cont 5000 psi operating pressure Saves weight on fluid, tubing, reservoirs Utilize low density bms 3-11 fluid, currently classified as Type IV Class 1, Type V Grade A or B Hydraulic Interface Function (HYDIF)software: Part of Common Core System(ccS) Common hydraulic pumps on EDPs and EMPs Electric Motor Pumps(EMPs) Flooded Induction Motor- cooled by hyd fluid from pump case drain (change from dc motors 27/37GPM@5000psi Motor controller for starting controlling motor speed Brake System is not hydraulic Boeing Propriet
Boeing Proprietary Hydraulic System Architecture (cont.) ◼ 5000 psi operating pressure ◼Saves weight on fluid, tubing, reservoirs ◼Utilize low density BMS 3-11 fluid, currently classified as Type IV Class 1, & Type V Grade A or B ◼ Hydraulic Interface Function (HYDIF) software: Part of Common Core System (CCS) ◼ Common hydraulic pumps on EDPs and EMPs ◼ Electric Motor Pumps (EMPs) ◼Flooded Induction Motor – cooled by hyd fluid from pump case drain (change from DC motors) ◼~27/37 GPM @ 5000 psi ◼Motor controller for starting, controlling motor speed ◼ Brake System is not hydraulic
Hydraulic System DREAMLINER Architecture(cont New controlled system operating temperature to approximately:100°-160°F Temperature control maintained by a bypass valve and fuel tank heat exchanger in each system Bypass valve is a mechanical thermostat type device located on the case drain filter module Bypass valve is designed for two positions Closed: flow through the heat exchanger(only Open a percentage of flow bypassing the heat exchanger Boeing Propriet
Boeing Proprietary Hydraulic System Architecture (cont.) ◼ New controlled system operating temperature to approximately: 100 – 160F ◼ Temperature control maintained by a bypass valve and fuel tank heat exchanger in each system ◼Bypass valve is a mechanical thermostat type device located on the case drain filter module ◼Bypass valve is designed for two positions: • Closed: flow through the heat exchanger (only) • Open: a percentage of flow bypassing the heat exchanger
Hydraulic System DREAMLINER Architecture(cont No bleed air used for hydraulic power ■ Bootstrap Reservoir Chosen because bleed air not available for reservoir pressurization Change from traditional air-over-oil configuration Bootstrap system utilizes hydraulic system pressure to pressurize reservoIr Proven design on Douglas model airplanes DC-10,MD-11 717.DC-8,DC-9.MD-80.MD-90 Boeing Propriet
Boeing Proprietary Hydraulic System Architecture (cont.) ◼ No bleed air used for hydraulic power ◼ Bootstrap Reservoir ◼Chosen because bleed air not available for reservoir pressurization ◼Change from traditional air-over-oil configuration ◼Bootstrap system utilizes hydraulic system pressure to pressurize reservoir ◼Proven design on Douglas model airplanes • DC-10, MD-11 • 717, DC-8, DC-9, MD-80, MD-90
Hydraulic Systems DREAMLINER Bootstrap Reservoir Schematic Pressure AutoBleed Transduc Valve ATm Return High pressure(Red) Am PressReli ef 5000psi Samplevalve ■ Low pressure High Pressure (Blue) Cty ransduc AltExtend MLG Te Transd EMP 1 EMP 2 Boeing Propriet
Boeing Proprietary Hydraulic Systems Bootstrap Reservoir Schematic ◼ High pressure (Red) 5000psi ◼ Low pressure (Blue)
Hydraulic System DREAMLINER Architecture(cont Ground test that require 5000 psi pressure Landing gear retraction RAT functional tests(GsE) High pressure hydraulic leakage checks Flaps/slats operation(hydraulic mode-priority valve Primary flight controls actuation confidence test Hydraulic Power Options for Ground Tests ■ APU generator Three or Four external ground power sources TWo external ground power sources can provide limited hydraulic power in maintenance mode ■5000 psi ground cart Boeing Proprieta
Boeing Proprietary Hydraulic System Architecture (cont.) ◼ Ground test that require 5000 psi pressure: ◼Landing gear retraction ◼RAT functional tests (GSE) ◼High pressure hydraulic leakage checks ◼Flaps/slats operation (hydraulic mode – priority valve) ◼Primary flight controls actuation confidence test ◼ Hydraulic Power Options for Ground Tests: ◼APU generator ◼Three or Four external ground power sources ◼Two external ground power sources can provide limited hydraulic power in maintenance mode ◼5000 psi ground cart
Hydraulic System DREAMLINER Transport Elements System Pressure Tubing ■ Titanium,T-3-2.5 Requires thicker wall tubing Qualification to 5080 psi for industry commonality Threat zones will use 21-6-9 CRES tubing ( thrown tread area, pressure dome, etc.) Return Pressure tubing Thin wall titanium. Ti-3-25 Aluminum inside the fuel tanks Boeing Propriet
Boeing Proprietary Hydraulic System Transport Elements ◼ System Pressure Tubing ◼Titanium, Ti-3-2.5 • Requires thicker wall tubing • Qualification to 5080 psi for industry commonality ◼Threat zones will use 21-6-9 CRES tubing (thrown tread area, pressure dome, etc.) ◼ Return Pressure Tubing ◼Thin wall titanium, Ti-3-2.5 ◼Aluminum inside the fuel tanks