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Improvement of Hydraulic system tests in Aircraft Manufacturing by applying Lean techniques

Airbus-Kevin Forster
Cranfield Univ-Philip Webb
  • Technical Paper
  • 2019-01-1901
To be published on 2019-09-16 by SAE International in United States
Lean Manufacturing is generally a challenge across all manufacturing companies. Especially in the aerospace industry where production costs have a significant impact on the overall business success. Additionally, the aircraft Takt time is gradually being reduced to accomplish ramp up requirements. The hydraulic system tests are considered as a production waste (Muda Type I) since it is mandatory but does not add any value to the end customer. Furthermore, due to health and safety aspects, no other production task can be done while the test is being performed. This research project aimed at performing a Kaizen analysis of the hydraulic system test stations to reduce or eliminate idle time while it is taking place. To do so, an extensive literature review has be conducted to provide its research framework. Then, all the project requirements and constraints were identified in order to generate a design specification. As a part of the methodology, several design proposals to accomplish this specification are created. In parallel, a reverse engineering case scenario is used to generate a DMU using a…
 

Recommended Practice Regarding Commercial Aircraft Hydraulic System External Leakage

A-6A1 Commercial Aircraft Committee
  • Aerospace Standard
  • ARP6175
  • Current
Published 2019-04-29 by SAE International in United States
This Aerospace Recommended Practice (ARP) provides a comprehensive and consistent set of guidelines for the definition, recognition, troubleshooting and repair of hydraulic components and systems on in-service commercial aircraft affected by external leakage.
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Flexure Testing of Hydraulic Tubing Joints and Fittings

G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
  • Aerospace Standard
  • ARP1185C
  • Current
Published 2019-04-23 by SAE International in United States
This SAE Aerospace Recommended Practice (ARP) establishes flexure test procedures to determine and classify the fatigue strengths of reconnectable or permanent hydraulic tube joints. The procedure is intended for conducting flexure tests of fittings and joints for hydraulic tubing materials such as AMS 5561 (21Cr-6Ni-9Mn) steel or AMS 4944 (3AL-2.5V) titanium. A mean stress is applied by holding system pressure in the specimens and flexing in a rotary or planar bending test machine.
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HOSE ASSEMBLY, POLYTETRAFLUORETHYLENE, PARA ARAMID REINFORCED, 275 °F, 4000 MAX PSI, FLARELESS, TITANIUM FITTINGS, STRAIGHT TO STRAIGHT

G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
  • Aerospace Standard
  • AS6013B
  • Current
Published 2019-04-17 by SAE International in United States
No Abstract Available.
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HOSE ASSEMBLY, POLYTETRAFLUOROETHYLENE, PARA ARAMID REINFORCED, 275 °F, 4000 PSI MAX, FLARELESS, TITANIUM FITTINGS, STRAIGHT TO 90 DEGREES

G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
  • Aerospace Standard
  • AS6015B
  • Current
Published 2019-04-17 by SAE International in United States
No Abstract Available.
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HOSE ASSEMBLY, POLYTETRAFLUOROTHYLENE, PARA ARAMID REINFORCED, 275 °F, 4000 PSI MAX, FLARELESS, TITANIUM FITTINGS, STRAIGHT TO 45 DEGREE

G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
  • Aerospace Standard
  • AS6014B
  • Current
Published 2019-04-17 by SAE International in United States
No Abstract Available.
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Material Handler Nomenclature and Specifications

MTC C5, Excavators
  • Ground Vehicle Standard
  • J2506_201904
  • Current
Published 2019-04-15 by SAE International in United States
This SAE Standard establishes terminology and the content of commercial literature specifications for self-propelled crawler and wheeled material handlers, pedestal mounted material handlers and their equipment as defined in 3.1. Illustrations used here are not intended to include all existing commercial machines or to be exactly descriptive of any particular machine. They have been provided to describe the principles to be used in applying this document. (Material handlers share many design characteristics with hydraulic excavators and log loaders; primarily 360 degree continuous rotation of the upperstructure relative to the undercarriage or mounting. They differ in their operating application. Material handlers are used for the handling of scrap material and normally utilize grapples or magnets. Hydraulic excavators are used for the excavation of earth, gravel and other loose material utilizing a bucket. Log loaders are used for the handling of logs and trees and normally utilize grapples.)
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Development and Verification of Control Algorithm for Permanent Magnet Synchronous Motor of the Electro-Mechanical Brake Booster

Haoran Zhang, Zhicheng Chen
Jilin University-Jian Wu, Rui He
Published 2019-04-02 by SAE International in United States
To meet the new requirements of braking system for modern electrified and intelligent vehicles, various novel electro-mechanical brake boosters (Eboosters) are emerging. This paper is aimed at a new type of the Ebooster, which is mainly consisted of a permanent magnet synchronous motor (PMSM), a two-stage reduction transmission and a servo mechanism. Among them, the PMSM is a vital actuator to realize the functions of the Ebooster. To get fast response of the Ebooster system, a novel control strategy employing a maximum torque per ampere (MTPA) control with current compensation decoupling and current-adjusting adaptive flux-weakening control is proposed, which requires the PMSM can operate in a large speed range and maintain a certain anti-load interference capability. Firstly, the wide speed control strategy for the Ebooster’s PMSM is designed in MATLAB/Simulink. Then, to quickly verify the development algorithm in more real environment, dual dSPACE hardware tools are used to build a rapid control prototype (RCP) real-time test platform to create operational scenarios, in which MicroAutoBox-II is served as the "controller" and dSPACE HiL simulator is served…
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Accurate Pressure Control Strategy of Electronic Stability Program Based on the Building Characteristics of High-Speed Switching Valve

Jilin University-Zhicheng Chen, Jian Wu, Bing Zhu
Published 2019-04-02 by SAE International in United States
The Electronic Stability Program (ESP), as a key actuator of traditional automobile braking system, plays an important role in the development of intelligent vehicles by accurately controlling the pressure of wheels. However, the ESP is a highly nonlinear controlled object due to the changing of the working temperature, humidity, and hydraulic load. In this paper, an accurate pressure control strategy of single wheel during active braking of ESP is proposed, which doesn’t rely on the specific parameters of the hydraulic system and ESP. First, the structure and working principle of ESP have been introduced. Then, we discuss the possibility of Pulse Width Modulation (PWM) control based on the mathematical model of the high-speed switching valve. Subsequently, the pressure building characteristics of the inlet and outlet valves are analyzed by the hardware in the Loop (HiL) experimental platform. After that, the single closed loop pressure control strategy for the inlet valve and the cascade control strategy for the outlet valve are designed. Finally, the parameters of the control strategy are set and verified through the HiL…
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Modeling, Control, and Adaptation for Shift Quality Control of Automatic Transmissions

H G M Automotive Electronics-Gilbert Cardwell
Ohio State University-Kirti Deo Mishra, Krishnaswamy Srinivasan
Published 2019-04-02 by SAE International in United States
The parameters determining shift quality control in automatic transmissions are determined as part of the calibration of the transmission control. The resulting control system typically has three components: feedforward control, where the control output is determined before a gearshift; feedback control, where the control output is determined during the gearshift based on sensed feedback; and learning control (adaptation), where the feedforward or feedback controller parameters are modified after the current gearshift has ended and before the next similar gearshift begins. Gearshifts involving the same ratio change are referred to here as similar gearshifts, though such gearshifts may involve differences in other variables such as vehicle speed or engine torque. In most automatic transmissions, gearshifts are controlled by hydraulic clutches, and operating conditions for these clutches may vary widely, requiring a dedicated transmission controller involving significant calibration effort.In the current work, novel model-based methods are used to accomplish feedforward control of gearshifts, involving offline calibration of fill and torque phase control parameters and learning control of the fill phase. Towards this end, a physics-based model of…
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