SERVO HYDRAULIC

TECHNOLOGY
IN FLIGHT CONTROL

Workshop on Innovative Engineering for Fluid Power and Vehicular Systems

ABIMAQ - São Paulo
14-15 May 2012

Mario F. Valdo
 OVER 55 YEARS OF EXPERIENCE
IN MOTION CONTROL

• Founded by Bill Moog, Art Moog and

Lou Geyer in 1951 as "Moog Valve
Company" – based on the first
commercial servo valve

• Founder’s culture of innovation and

persistence still exist today:
─ Collaborative approach
─ "Can-do" mindset
─ Flexible organization
─ Dedicated solutions

Flight Control Technology

 A Global Company

Argentina
Germany
Russia

Australia
India
Singapore

Austria
Ireland
South Africa

Brazil
Italy
South Korea

Canada
Japan
Spain

China
Lithuania
Sweden

Costa Rica
Luxembourg
Switzerland

Denmark
Netherlands
United Arab Emirates

Finland
Norway
United Kingdom

France
Philippines
United States
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Flight Control Technology
GROUPS

MOOG INC.
US$2.33 Billions (FY 2011)

Space & Compo-

Aircraft Industrial Medical
Defense nents
Group Group Devices
Group Group Group
$850 M $629 M $356M $353 M $142 M

36% 27% 15% 15% 7%

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Flight Control Technology
 HIGH PERFORMANCE MOTION CONTROL

Military & Commercial Aircraft

Satellites, Missiles & Launch Vehicles

Defense & Surveillance

Industrial Machinery

Test & Simulation

Infusion Pumps (medical)

Components (slip rings, fiber optic joints, air

moving, resolvers, encoders)
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Flight Control Technology
HIGH PERFORMANCE MOTION CONTROL

Closed loop control of physical variables (servocontrol):

• position
• velocity
• aceleration
• force
• pressure

Servocontrols Technology:

• Electro-hydraulic: servovalves, servopumps

• Electro-mechanical: servomotors

• Electro-pneumatic: proportional pneumatic valves

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Flight Control Technology
AIRCRAFT MARKET - OFFERING

Integrated Flight Control Systems

• Primary Flight Control Systems
• High Lift Systems
• Maneuvering Leading Edge Systems
Critical Control Applications
• Engine Controls
• Active Vibration Control
• Weapons Bay Door Drive
• Braking and Steering
Critical Control Products
• Flight Control Computers & Software
• Cockpit Controls
• Control Electronics & Power Drives
• Actuators – Electrohydraulic, Electromechanical
and Electrohydrostatic
• Related Components

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Flight Control Technology
 AIRCRAFT AXIS OF MOTION

X
Z
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 FLY CONTROL SURFACES

Leading Edge

Trailing Edge
RUDDER

Slats
ELEVATOR

Flap
Wing Tip Trim Tab Spoilers
AILERON
Trailing Edge

Leading Edge

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Flight Control Technology
 ROLL - AILERONS

An animation of an airplane rolling via its ailerons

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 PITCH -ELEVATORS

An animation of an airplane pitching via its elevators

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Flight Control Technology
 YAW- RUDDER

An animation of an airplane yawing with its rudder

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Flight Control Technology
 AIRCRAFT FLIGHT CONTROLS
In the drawing, a red arrow shows the way the control stick is being tilted. Small green
arrows show the swing of the respective control surfaces and indicate the direction of
the forces acting on the cable. The bent wires show the generic routing of control
cables in the aircraft and connect the controls with the control surfaces.
In smaller or older aircraft, the lines represent actual cables that link controls to control
surfaces. In more modern aircraft, a computer take of the pilot inputs and send
commands electronically to control surface actuators.
Control surfaces: A) aileron, C) elevator, D) rudder.
B) control stick
Rudder = yaw (turn around Z)

Ailerons= roll (turn around X)

Elevators = pitch (turn around Y)

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AEROSPACE X INDUSTRIAL COMPONENTS

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Flight Control Technology
NOZZLE-FLAPPER SERVOVALVE

mechanical feedback

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Flight Control Technology
NOZZLE-FLAPPER SERVOVALVE – detailed view

Torque motor

Nozzle-flapper
Orifice

Orifice Q Q
Feedback
wire

Bushing & Spool

Control ports
Actuator (load)

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Flight Control Technology
APPLYING COMMAND.....

I
1- Electric current
generates a 2- The magnetic field
magnetic field… generates torque....

3- Flapper moves to the side...

T T

4- Pressure 4- Pressure
reduces here increases here

A B

5- Spool moves and pulls the feedback wire.....

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Flight Control Technology
 REACHING THE FINAL POSITION
(defined by the current command )

6- When :
I
feedback wire torque =
electric current torque

the flapper gets centralized!

7- Centralized flapper T T
means that pressures
are the same in both
sides of the spool .

A B

8- Spool stays in a position proportional to the current command. 17

Flight Control Technology
JET PIPE SERVOVALVE
Torque motor

Pipe

Receptor
Feedback wire

Bushing & Spool

Control ports
Actuator (load)
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Flight Control Technology
 INTEGRATING A POSITION TRANSDUCER
( to implement electronic spool position loop control and diagnostics)

Integrated or external
electronics to close the spool
position loop

EFB= electrical feedback

(position transducer)

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Flight Control Technology
 EFB SERVOVALVE
SPOOL POSITION CLOSED LOOP

Zero Error
Pressure
amplifier
+ Torque Motor
Flow +
P.D.
command
-
Orifices
Spool Position

Nozzle
flapper

Position Spool
Spool Transducer
P.D.
position
(output)
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Flight Control Technology
 High-flow configuration

Integrated Control
Electronics

Linear Motor

Position Transducer
Spool Spring
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Flight Control Technology
 SPOOL POSITION CLOSED LOOP

Zero Error
amplifier
+
Flow + PWM
P.D.
command
-

Spool Position
Linear
Motor
Spool

Position
Spool Transducer
P.D. Spring
position
(output)
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 LVDT
LINEAR VOLTAGE DISPLACEMENT TRANSDUCER
Voltage
proportional
Fixed body to core position
Secundaries
P
S1
Primary
(syncronous)
Oscilator Demodulator

S2

Fixed amplitude and Core output

[volts]
frequency
P
linear
range
S1 stroke
Core connected [mm]
to the
S2
movable part

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Flight Control Technology
 ACTUATOR POSITION CONTROL CLOSED LOOP

Servoamplifier

ZERO GAINS: P, I, D
Valve
+ P command
+
Position Command + +
I
- +
D

Servovalve
with integrated
spool position transducer
SCALE and electronics

Oscilator
Position feedback =
DC
≈
Demodulator
Actuator
LVDT
Position Transducer
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 ACTUATOR POSITION CONTROL
DIGITAL CLOSED LOOP : Complex Algorithms + Diagnostics + Fieldbus
Digital Controller
TRACKING CONTROLLER

P Flag Handler
Function Blocks

Valve position control

Demand
Pressure F T
with
Demand
I D/A I
D/A force limiting control
T F
Fieldbus PRESSURE
D CONTROL D
Interface A/D
A/D Pa
Ratio
A/D Pb
A/D
TRIGGER Effective (Actual)
D DETECTION Pressure Feedback
Max/Min
Error Window
Flag Pressure Trigger
Gen.r Latched TRUE (T)
when Pressure High
Commands, Max Rate
Supervision
Position
Demand
Servovalve
Limit P

POSITION Position
Feedback
CONTROL
Flight A/D
A/D X
Computer
Flight Pilot commands
envelope
Aircraft real-time data P/V P/V
Position Transducer Pressure Transducers
Flight Control Technology
 REDUNDANCY: the “soul” of modern flight control
In large and military airplanes each flight control surface is either:
• operated by 2 or more actuators in “parallel” (active-bypass-damper modes)
• operated by one actuator with redundant servovalves, transducers, electrical
conections and oil supply connections
• a mix of the above :

Flight Control Actuation System Integrator

for the B-2 Spirit
A quadraplex system controls the B-2’s flight
control surfaces and is comprised of Flight
Control Computers, Actuator Control Electronics,
Servoactuators, Sensors, System Software and
Redundancy Management
4 electronics driving 2 redundant actuators

The B-2 Spirit Actuation System features:

• Quadraplex redundant electrical and hydraulic
systems
• Advanced electronic controls with fault
diagnostics
• 4000 psi Hydraulic system
4 redundant fieldbuses • Redundancy management
connections to the flight
computer 2 oil supply lines per actuator

2 actuators controlling the same surface

REDUNDANCY requires complex “decision” algorithms implemented by the aircraft flight control software
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 NASA – SPACE SHUTTLE
TRUST VECTOR ACTUATORS (Designed in 1973)

4 redundant servovalves,
only one is active
(mechanical-hydraulic selection)

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 REDUNDANCY MODES IN
ELECTROHYDRAULIC ACTUATORS

Damper
Active Bypass
(or blocked)

P T P T P T

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 TYPICAL REDUNDANCY- AILERONS
Active – Active on each surface Active – Standby on each surface

Sized for hinge moment with both active Sized for hinge moment with one active

• Normal mode 1: active , active • Normal mode 2: active, bypass

• First Failure 1: damped , active • First Failure 2: bypass, active

• Second failure1: damped, damped • Second failure 2: damped , damped

Hydraulic Electro-hydraulic actuators

Systems

4B
3B

4A
3A

3 4

2B
1B

2A
1A

1 2
Flight control surfaces

damped = damped or blocked, depending on the flight control design 29

Flight Control Technology

 TIPYCAL REDUNDANCY- ELEVATOR
Active – Active on each surface Active – Standby on each surface

Sized for hinge moment with both active Sized for hinge moment with one active

• Normal mode: active , active • Normal mode: active, bypass

• First Failure: bypass , active • First Failure: bypass, active

• Second failure: damped, damped • Second failure: damped , damped

Electro-hydraulic actuators
Hydraulic
Systems

2B
1B

2A
1A

1 2

Flight control surfaces

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 TYPICAL REDUNDANCY - RUDDER

Electro-Hydraulic Actuators

1A Active – Active - Active

Sized for hinge moment with all active

1B • Normal mode: active, active, active

1 • First Failure: bypass, active, active

1C
• Second failure: damped, bypass, active

• Third failure: damped, damped, damped

Flight control surface

Hydraulic
Systems

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 ELECTRO-HYDRAULIC ACTUATORS - EHA
Features Options
• Low weight • Overload relief
• Manageable failure modes • Multiple modes
• Flexible packaging  Normal servocontrolled operation
• Multiple hydraulic supplies possible  Bypass (to allow other actuators to operate
• Multiple electrical channels possible the control surface)
• Low power consumption to hold load  Damped
Issues  Blocked
• High tare power consumption  Damped - Blocked
• Lower stiffness

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ELECTRO-HYDRAULIC ACTUATORS - EHA

Typical Rudder Actuator Components

• Inlet Filter
• Inlet Check Valve
• Servovalve with monitoring LVDT
• Mode Select Valve (3 way)
• Solenoid Valves to pilot Mode Select Valve
• Damped Check Valves
• Differential Pressure Transducers
• Anti Cavitation Check Valves
• Compensator & Return Relief Valve

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ELECTRO-MECHANICAL ACTUATORS – EMA
Features
• Undesirable failure modes
• Limited packaging flexibility
• Multiple electrical channels possible
• No hydraulics
• Low power consumption when idle
Issues
• High weight
• High stiffness
• No overload relief
• Draws power to hold load stationary (P = R · I2)
Options
• Multiple motors torque or speed summed

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ELECTROHYDROSTATIC ACTUATOR – EHSA
Features Options
• High weight • Overload relief
• Manageable failure modes • Multiple modes
• Flexible packaging  Normal servocontrolled operation
• Multiple hydraulic channels possible  Bypass (to allow other actuators to
• Multiple electrical channels possible operate control surface)
• High power consumption to hold load  Damped
Issues  Blocked
• Low power consumption when stationary  Damped - Blocked
• Lower stiffness

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Flight Control Technology
ELECTROHYDROSTATIC ACTUATOR – EHSA

Transdutor de Posição
Position Transducer
Temposonics
Hydraulic Actuator

Feedback
Realimentação
Control
Surface

Position

Comando de Posição
Position Command
Bidirectional pump
Bomba Bidirecional

M
Servomotor
Brusless servomotor

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Flight Control Technology
 FLY CONTROL ACTUATORS
Kinematic Installation : Simple Triangle

• Actuator body moves

• Hinge generally off surface center

• Envelope must include body motion

• Hydraulic & electrical connections

move with body

• Aircraft structure reacts all actuation

& surface loads

• Application: Ailerons, Rudder,

Elevator, Flaperon, Spoilers

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Flight Control Technology
 FLY CONTROL ACTUATORS
Kinematic Installation : Pillow Block Simple Triangle

• Actuator body moves

• Hinge off surface center
• Envelope must include body motion
• Hydraulic & electrical connections
move with body – but some units built
with swivels on mounting centerline
• Aircraft structure reacts all actuation
& surface loads - with lateral load and
torsion at pillow block mount
• Application: Spoilers

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Flight Control Technology
 FLY CONTROL ACTUATORS
Kinematic Installation : Reaction/Kick Link

• Surface hinge can be centered

• Actuator body motion has additional axial
displacement
• Envelope must include body motion
• Hydraulic (usually hoses) & electrical
connections move with body
• Reaction link reacts major actuation loads –
lighter aircraft structure
• Higher stiffness with lower weight
• Application: Rudder, Elevator, Aileron

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Flight Control Technology
 FLY CONTROL ACTUATORS
Kinematic Installation : Flange Mount with Dog Bone

• Actuator body stationary

• Hinge off surface center

• Effective horn radii reduced

• Lower stiffness design

• Hydraulic & electrical connections fixed –

simplest of all geometries

• Aircraft structure reacts all actuation &

surface loads – lateral loads applied to
actuator and structure

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Flight Control Technology
 Flight Controls For Commercial Aircraft

787 777 767 757

747 737 A380 A350

A340 A330 A320 A319

Citation X Hawker 4000 Challenger 604 Challenger 300

G650 G550 G450 G250

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Flight Control Technology
BOEING 787 PRIMARY FLIGHT CONTROLS
The Moog system controls all the primary flight control surfaces on the airplane. The
system controls 21 flight surfaces and includes a mix of electrohydraulic (EHA) and
electromechanical (EMA) servoactuators and all associated control electronics.
EH servoactuators : Ailerons, Flaperons, Inboard + Outboard Spoilers, Elevator and
Rudder.
EM servoactuators : horizontal stabilizer and mi-board spoilers

Key features :
• Smart actuators with on-board
loop closure electronics
• 5000 psi system operating pressure
• High power motor controllers
• EM actuators with dual load path
and integrated motor drive
• Advanced materials for weight-
performance optimization

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 BOEING 787 PRIMARY FLIGHT CONTROLS
Complete Primary Flight Control Actuation System

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BOEING 787 HIGH LIFT ACTUATION SYSTEM

The Moog systems control the primary and secondary surfaces, horizontal stabilizer,
leading edge slats and trailing edge flaps in response to pilot commands.

The High Lift System includes the complete Flap and Slat Actuation Systems
compromising nearly 450 discrete assemblies including: power drives, electronic controls,
trim controls, geared rotary actuators, rack and pinion roller assemblies, transmissions
shafts, offset gearboxes, sensors and accessory components. The High Lift System
features a number of technical advancements to improve wing aerodynamics. To
decrease system weight a number of advancements were also incorporated, including
the use of advanced composites and increased use of electronic controls.

Key Features of the High Lift System Include:

•Advanced flap trim control
•Composite transmission components
•5000 psi system operating pressure
•Hybrid hydraulic and electric power drive

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BOEING 787 HIGH LIFT ACTUATION SYSTEM
Complete Secondary Flight Control System

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Flight Control Technology
 Boeing 777 High Lift Actuation
Primary and High Lift Actuation Products

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 Boeing 747-8 Lateral Flight Controls
Lateral Fly-By-Wire Flight Control Computers

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 Primary Flight Control for Airbus A350 XWB

Moog is providing 27 discrete actuators and associated control electronics on this

program. This system includes a mix of electrohydraulic (EH) and advanced
electrohydrostatic (EHA) actuators to control the Aileron, Elevator, Rudder and
Spoiler flight surfaces.

Moog products features:

• More electric actuation technology
• On board electronics for actuator power and control
• Highly integrated assemblies to meet challenging envelope constraints

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 Airbus A350XWB Primary Flight Controls
Complete Primary Flight Control Actuation System

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 Airbus A350XWB High Lift Actuation
Trailing Edge Flap Actuation

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 Airbus A380 High Lift Actuation

Leading and Trailing Edge Flight Controls

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 Gulfstream G250 Integrated Flight Control
Complete Primary and High Lift Flight Control Systems

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Gulfstream G650 High Lift Actuation System

Complete Flap Actuation System

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 Bombardier Challenger 300 Flight Controls
Complete Flight Control System

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 Flight Controls For Military Aircraft

F-35 V-22 F/A-18 E/F X-47B

B-2 F-15E F-16 F/A-18C/D

LCA T-50 JAS Gripen F-2

C-5 A400M C-27 CX/PX

UH-60 Lavi IDF Typhoon

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Flight Control Technology
LOCKHEED MARTIN F-35 FLIGHT CONTROLS

The F-35 “power-by-wire” system represents an advancement on the more electric

aircraft topology integrating:
•Self-contained electrohydrostatic (EHSA) actuators to position primary flight surfaces
•Electronic Control Units to remotely drive and control the EHSAs
•Electrically driven PDUs to position the maneuvering leading edge flaps

As the Prime Contract holder,

Moog’s role includes managing the
industry team, integration of the
complete actuation system, and
supplier of critical technologies and
major sub-systems.

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LOCKHEED MARTIN F-35 FLIGHT CONTROLS
Primary and Secondary Flight Control System

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Lockheed Martin F-35B STOVL Lift Fan Actuation
Engine Lift Fan & Swivel Module Actuation Systems

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 Eurofighter Typhoon
Flight Control Actuation and Critical Control Subsystems

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Flight Control Technology
 Airbus A400M Flight Controls

Primary Flight Control Actuation

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Flight Control Technology
 Rotorcraft

V-22

AW129 ATAK

BA609

UH-60

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Flight Control Technology
 V-22 Primary Flight Control Actuation
Design, manufacture and integration of Primary Flight Control Actuators: main rotor
swashplate, flaperon and elevator.
Moog is also providing the vibration control actuation system, bladefold actuation, nose-
wheel steering servovalves, main prop rotor slip ring, hydraulic fluid compensation
module and engine fuel control servovalves.

Key Features:
•5000 psi operating pressure
•Duplex hydraulic/triplex electrical
redundancy on the Swashplate actuators
•Ballistic tolerant Elevator and Swashplate
actuators

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 Bell/Boeing V-22 Flight Control Hardware
Primary Flight Control Actuation and Vibration Suppression Actuation

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 Bell/Agusta BA609 Flight Control Actuation
Primary Flight Control Actuation

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 Agusta Westland AW159 Future Lynx
Primary Flight Control Actuation

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 AgustaWestland AW129 ATAK
Complete Primary Flight Control Actuation

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 Sikorsky H-60

Pitch Trim and Active Vibration Control

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Unmanned Air Systems (UAS)
Unmanned Air Vehicles (UAV)

X-47B
QF-4 Phantom II

BAE Mantis
Hunter RQ-5A

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 BAE Mantis Flight Controls

Primary Flight Control Actuation System

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Northrop Grumman X-47B Flight Controls
Complete Primary Flight Control System System Integrator for X-47B Primary Flight
Control System

The system includes a fully redundant

architecture featuring multifunction system
controllers and modular Electrohydraulic (EHA)
flight control actuators.

The system controller features a high speed

1394 bus interface, redundancy management,
full digital closed loop control for all flight
surfaces and advanced vehicle functionality.
The high dynamic dual tandem EH actuators
position the Aileron, Elevon and Spoiler flight
control surfaces.

The X-47B Primary Flight Control Actuation

System Features:
• Redundant hydraulic and electrical designs
• Modular construction to optimize installation
• High dynamic response
• Full digital loop control

unmanned combat air system

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Flight Control Technology
 OUR VALUE TO CUSTOMERS
Não é possív el exibir esta imagem no momento.

• With motion control application and product know-

We support our how
customers’
success • By jointly developing unique solutions that allow our
customers to differentiate

Não é possív el exibir esta imagem no momento.

• By offering high performance products, services and

We specialize in solutions that solve real world machine challenges
high
performance • Through matching the unique requirements of our
customers

Não é possív el exibir esta imagem no momento.

• Through know-how, capabilities, experience, and open

minds capable of developing a new approach for
We offer demanding motion control applications
expertise
• Ready to support you in addressing your challenges for
your next generation machines or latest project

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Flight Control Technology
THANKS FOR YOUR ATTENTION......
Sales and application Engineering
Carlos Rocha (Drives, slip rings) [email protected] Marcelo Soares [email protected]
Eduardo Rumão (América do Sul) [email protected] Renato Silva [email protected]
Rogério Bressar (Hidráulica [email protected] Haroldo Santana [email protected]
e Testes) Guilherme Lowe [email protected]
Tomás Huertas (Hidráulica) [email protected] Rogério Dantas [email protected]
Fernando Conde [email protected] Jailson Silva [email protected]
Felipe Calil [email protected]
Sales support
Camilla Rossi [email protected] Financial
Carolina Ghellere [email protected] Solange Beletatti [email protected]
Carla Ramos [email protected] Sandra Santos [email protected]

Repairs
Rubens Borges [email protected] Director
Viviane Nascimento [email protected] Mario Valdo [email protected]

MOOG DO BRASIL CONTROLES LTDA

Rua Prof. Campos de Oliveira, 338
C.E.P.: 04675-100 - SÃO PAULO - SP
Tel.: +55-11-3572-0400 – Fax: +55-11-5524-2186
email: [email protected] 72
Flight Control Technology