CESA – Compañía Española de Sistemas Aeronáuticos

Background

RESEARCH Introduction

System Requirements & Trade-off of Architectures

Elevator Flight Control System

Safety

HUMS – Health and Usage Monitoring

Reliability & Safety Enhanced

Electrical Actuation System

Architectures

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CESA

Founded more than 25 years ago, CESA has

extensive experience in developing, producing

and providing support for mechanical fluid

equipment and systems.

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CESA Shareholders

3 Turnover by Product Line

• Compañía Española de Sistemas Aeronáuticos

C295 Accumulator

EFA Foreplane Actuator

A380 Reservoir

A330 tail boom HOIST and ERAS

A400M Cargo door actuator

E-ELT Support System and

Position Actuator

FT4B Actuator

Background

• CESA participation in European Projects

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Modular Electro Mechanical Actuators for

ACARE 2020 aircraft and helicopters

RESEARCH

Design, development and manufacturing

of an electro-mechanical actuator and

test rig for AiRcrafts Main LandIng Gear

acTuation systems

Advanced Flight Control System –

Design Development and Manufacturing

of an Electro Mechanical Actuator with

associated Electronic Control Unit and

Dedicated test Bench

REliability and Safety Enhanced electrical Actuation System ARCHitectures.

FLIGHT EMA

(e-RUDDER)

ARMLIGHT

Others: GreenAir, SuperSkySense, Fastwing, IND-Dampers, Titalum, Newtiral,

POA, LAMA, ELGAR, NIPSE…

CESA E-Rudder EMA

CESA Armlight EMA

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RESEARCH Introduction

• RESEARCH Consortium

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Coordinator:

University of Moscow

TSagi

RESEARCH Introduction

• RESEARCH

Objective Development of electrical

architectures for Flight Control

Systems capable of controlling flight

control surface on an A/C with the

help of electrically operated

actuators, thus replacing the

hydraulic actuators commonly used

in current A/C designs

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Example of Typical Hydraulic A/C System

Full Electric Flight Control System

Flight Controls

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RESEARCH Introduction

• RESEARCH Workpackage structure

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System Requirements

• Definition of System Requirements • CS-25

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CS 25.393

Loads parallel to hinge line

CS 25.395

Control system

CS 25.397

Control system loads

AMC 25.415

Ground Gust Conditions

CS 25.675

Control Systems, Stops

CS 25.679

Control system gust locks

CS 25.683

Operation tests

CS 25.685

Control system details

CS 25.1309

Equipment, systems and

installations

(…)

• The probabilty of Jamming of at least one Aileron out of neutral shall be less than 1.0E-07 per Flight Hour

Safety

• The mínimum rudder deflection rate shall be 40 degree per second

Speed

• The stall hinge moment for the elevator Surface shall be 4 KNm Force

Examples of System level requirements for Regional Aircraft

Certification specification

requirements for Large Aircrafts 8

Trade-off of Architectures

• Architecture selection

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Selection of Architecture

Performance

Safety Weight

Preliminary Fault Tree Analysis Full

Electric Elevator Flight Control Example

Trade-off architecture main factors

Preliminary Weight estimation example

for Rudder Configurations

Preliminary Force vs Speed assessment for

Aileron configurations

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Elevator Flight Control System

• Final Selection: Elevator Architecture

Both type of actuators can be chosen. From a safety point of view, the implementation of an

anti-jamming device in the EMA makes it a perfect candidate to be selected for its

installation is primary flight control surface as the rudder or elevator while EHA provides the

required damping mode just as the traditional Hydraulic Servoactuator with the proven

safety rating

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Elevator Control Architecture selected for the RESEARCH project

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Safety

• System Safety Assessment Process

(SAE-ARP-4761)

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FHA PSSA SSA

Main Safety Challenge of Electric Elevator

Jamming

REQ. Jamming of at least one Elevator surface out of neutral (CAT)

System Safety Assessment Process

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• Safety features: EMA with anti-jamming

CESA has developed a proprietary anti-

jamming system to avoid catastrophic failure

in EMAs for primary flight controls (and

Landing gear actuation) system. The solution

is a locking device that keep anti-jamming

system locked until a failure or a degraded

performance is detected internally by CBIT

function; afterwards, the auxiliary anti-

jamming system acts extending the actuator

freely

Jamming!!!

Control Loop: Emergency Mode

Electronic Controller (ECU) receives EMA status and send it to

System Controller (SECU)

SECU shares information with the crosschecked SECU

Crosschecked SECU activates

Antijamming system of the EMA failed

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Safety 6

EMA Main parts

HUMS

• Benefits of HUMS

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Identification of faults prior CAT failure

Efficient Proactive

Maintenance On-Condition

Enhanced Safety &

Maintainability

Safety Benefits Maintainability Benefits

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CESA Electromechanical Actuator

prototype with antijamming system for

RESEARCH

HUMS

• Health Usage Monitoring strategy for EMA

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Measurement of Efficiency

• Development and endurance test data recorded to get an “Ideal Efficiency” curve implemented in Control System

• Simulation of degradations: loss of grease, overload in bearings, dust in ballscrew

• Frequency spectrum

Life estimation

• Comparison of health monitoring with “Ideal Curve”

Health Monitoring from Sensors

• Load, current, temperature, etc.

Cycle counter with variables record

• Histogram of performance recorded in each operation

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• HUMS implementation in SECU

Health Monitoring

• Load

• Motor Current

• Temperature

• Vibration

• Position

Test correlations / mathematical algorithms

Prognosis Remaining Useful Life Prediction

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HUMS 7

www.cesa.aero

Thanks for your attention!

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