Aircraft Systems

(3 ECTS)

LAB 1
Preliminary design of a hydraulic system

1 Luca Chiabò
Session objective:
Use computational tools for:
• Preliminary design of a basic hydraulic system;
• Preliminary design of an hydraulic accumulator for emergency use.

Tools:
Custom-made Matlab code

Previous knowledge required:

Basic Matlab coding skills
Viscous flows in ducts
Main components of an hydraulic system

2 Luca Chiabò
3 Luca Chiabò
 Exit losses Piston

Load
𝑝𝑝 𝐹𝐿
Distributed
Bend radius Δ𝑝𝐸𝑋 Δ𝑝𝐸𝑁
head losses
Δ𝑝𝐷𝐶𝑉 Entrance losses
Δ𝑝𝑁𝑅𝑉 Δ𝑝𝐹𝐶𝑉
Pump
Δ𝑝𝐵𝑅 Δ𝑝𝑝𝑖𝑝𝑒 Δ𝑝𝐵𝑅
𝑝𝑀
Δ𝑝𝐵𝑅

Bend radius Bend radius

Non return
𝑝𝑇 valves

Direction control
Tank Flow control
valve
valves

4 Luca Chiabò
Task: definition of the structure of the hydraulic system to move linearly a
nominal load. Definition of the components (with their respective size) of
the systems.
Requirements:
• Stroke length of the actuator: 𝑆𝐿 = 1 𝑚
• Nominal load: 𝐹𝑛𝑜𝑚 = 11000 𝑁
• Maximum allowed load: 𝐹𝑚𝑎𝑥 = 16500 𝑁 Operative conditions
• Forward stroke velocity: 𝑉𝐹𝑆 = 900 𝑚𝑚 𝑠
• Return (retraction) velocity: 𝑉𝑅 = 300 𝑚𝑚 𝑠
• Main-line pressure: 𝑝𝑀 = 21𝑀𝑃𝑎
• Tank pressure: 𝑝𝑇 = 0.6𝑀𝑃𝑎
• Distance pump-actuator (pipe length): 𝐿𝑡 = 20𝑚
• Pipe diameter: 𝐷𝑡 = 10𝑚𝑚
• Bend radius: 𝑅 = 30𝑚𝑚 Geometry
• Sharp entrance in the actuator
• Pipes roughness: 𝜀 = 0.002𝑚𝑚
• Fluid density: ρ = 900 𝐾𝑔 𝑚3
2
Fluid Characteristics
• Kinematic viscosity: ν = 1.6 ∙ 10−5 𝑚 𝑠

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 Exit losses Piston

Load
𝑝𝑝 𝐹𝐿
Distributed
Bend radius Δ𝑝𝐸𝑋 Δ𝑝𝐸𝑁
head losses
Δ𝑝𝐷𝐶𝑉 Entrance losses
Δ𝑝𝑁𝑅𝑉 Δ𝑝𝐹𝐶𝑉
Pump
Δ𝑝𝐵𝑅 Δ𝑝𝑝𝑖𝑝𝑒 Δ𝑝𝐵𝑅
𝑝𝑀
Δ𝑝𝐵𝑅

Bend radius Bend radius

Non return
𝑝𝑇 valves

Direction control
Tank Flow control
valve
valves

6 Luca Chiabò
 𝐿𝑜𝑎𝑑
The required movement is linear
𝑝𝑀
linear actuator 𝐴𝑐𝑡𝑢𝑎𝑡𝑜𝑟
𝑝𝑇

3 working conditions:
Static Extraction Retraction

𝑉𝐹𝑆 𝑉𝑅

𝑝𝑀
𝑝𝑝 𝑝𝑝 𝑝𝑝
𝑝𝑇

7 Luca Chiabò
Controls flow and direction (behaves like a switch for an actuator).
Suppose we have a high and a low pressure line, and an input line (pressure,
mechanic, electric, pneumatic). The direction of the flow in the user lines
depends on the direction of the input. The neutral position of the spool is
recovered via a pre-charged spring.

A B

C D
A B A B

C D C D

8 Luca Chiabò
Task: define the piston area (𝐴𝑝 ).
Requirement: the actuator has to be able to stand the maximum load (𝐹𝑚𝑎𝑥 )
using the mean line pressure (𝑝𝑀 ) in static conditions.

Task: define the nominal working pressure (𝑝𝑝 ).

Requirement: the actuator has to be able to move the nominal load (𝐹𝑛𝑜𝑚 ) at
constant velocity.

The force balance equation is:

𝑀𝑥 = 𝑝𝐴𝑝 − 𝐹𝐿 − 𝐹𝑓𝑟 𝑝𝑝 𝐹𝐿

𝑥
Hint: neglect friction forces.

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 Exit losses Piston

Load
𝑝𝑝 𝐹𝐿
Distributed
Bend radius Δ𝑝𝐸𝑋 Δ𝑝𝐸𝑁
head losses
Δ𝑝𝐷𝐶𝑉 Entrance losses
Δ𝑝𝑁𝑅𝑉 Δ𝑝𝐹𝐶𝑉
Pump
Δ𝑝𝐵𝑅 Δ𝑝𝑝𝑖𝑝𝑒 Δ𝑝𝐵𝑅
𝑝𝑀
Δ𝑝𝐵𝑅

Bend radius Bend radius

Non return
𝑝𝑇 valves

Direction control
Tank Flow control
valve
valves

10 Luca Chiabò
In the extraction phase we can estimate the volume flow rate (neglecting
compressibility effects):

𝑄 = 𝐴𝑝 𝑉𝐹𝑆

We know that the head losses in the pipeline and in the valves depend on
the pipe diameter. Considering only distributed head losses:

𝐿𝑡 𝑉𝑡 2 𝐿𝑡 16𝑄2
ℎ𝑓 = 𝑓 =𝑓
𝐷𝑡 2𝑔 2𝑔 𝜋 2 𝐷𝑡 5

It is necessary to estimate the Darcy friction factor.

11 Luca Chiabò
Laminar flows (𝑹𝒆𝑫 < 𝟐𝟑𝟎𝟎): Turbulent flows (𝑹𝒆𝑫 > 𝟐𝟑𝟎𝟎):
64 1 𝜖/𝑑 2.51
𝑓= = −2.0 log +
𝑅𝑒𝐷 𝑓 1/2 3.7 𝑅𝑒𝐷 𝑓 1/2

(Colebrook-White formula)

1.11
1 𝜖/𝑑 6.9
= −1.8 log +
𝑓 1/2 3.7 𝑅𝑒𝐷

(Haaland formula)

Hint: search for a built-in

function in Matlab to solve CW
iteratively.

12 Luca Chiabò
 Exit losses Piston

Load
𝑝𝑝 𝐹𝐿
Distributed
Bend radius Δ𝑝𝐸𝑋 Δ𝑝𝐸𝑁
head losses
Δ𝑝𝐷𝐶𝑉 Entrance losses
Δ𝑝𝑁𝑅𝑉 Δ𝑝𝐹𝐶𝑉
Pump
Δ𝑝𝐵𝑅 Δ𝑝𝑝𝑖𝑝𝑒 Δ𝑝𝐵𝑅
𝑝𝑀
Δ𝑝𝐵𝑅

Bend radius Bend radius

Non return
𝑝𝑇 valves

Direction control
Tank Flow control
valve
valves

13 Luca Chiabò
Bend losses: Entrance/Exit losses:
𝑲𝑩𝑹 𝑲𝑬𝑵 and 𝑲𝑬𝒙

14 Luca Chiabò
 Exit losses Piston

Load
𝑝𝑝 𝐹𝐿
Distributed
Bend radius Δ𝑝𝐸𝑋 Δ𝑝𝐸𝑁
head losses
Δ𝑝𝐷𝐶𝑉 Entrance losses
Δ𝑝𝑁𝑅𝑉 Δ𝑝𝐹𝐶𝑉
Pump
Δ𝑝𝐵𝑅 Δ𝑝𝑝𝑖𝑝𝑒 Δ𝑝𝐵𝑅
𝑝𝑀
Δ𝑝𝐵𝑅

Bend radius Bend radius

Non return
𝑝𝑇 valves

Direction control
Tank Flow control
valve
valves

15 Luca Chiabò
These valves are used to control the volume flow rate over a certain range.
They can be used to reduce the speed of operation of an actuator.
The flow control valves usually exploit the pressure drop of a sudden section
restriction.

Symbol

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 We need to reduce the pressure Use a flow
𝑝𝑀 > 𝑝𝑝
at the entry of the actuator control valve

𝑝𝑝 = 𝑝𝑀 −∆𝑝𝐵𝑅 −ℎ𝑓 𝜌𝑔 − ∆𝑝𝐷𝐶𝑉 − ∆𝑝𝑁𝑅𝑉 − ∆𝑝𝐹𝐶𝑉 −∆𝑝𝐵𝑅 −∆𝑝𝐸𝑋

𝑉𝑡 2 𝑉𝑡 2
∆𝑝𝐵𝑅 = 𝐾𝐵𝑅 𝜌𝑔 = 𝐾𝐵𝑅 𝜌
2𝑔 2
2
𝐿𝑡 𝑉𝑡 𝐿𝑡 16𝑄2
Δ𝑝𝑝𝑖𝑝𝑒 = ℎ𝑓 𝜌𝑔 = 𝑓 𝜌𝑔 = 𝜌𝑓
𝐷𝑡 2𝑔 2 𝜋 2 𝐷𝑡 5
𝑉𝑡 2 𝑉𝑡 2
∆𝑝𝐷𝐶𝑉 = 𝐾𝐷𝐶𝑉 𝜌𝑔 = 𝐾𝐷𝐶𝑉 𝜌 𝐾𝐷𝐶𝑉 = 3.5
2𝑔 2 𝐾𝐷𝐶𝑉 and 𝐾𝑁𝑅𝑉
are data of the
𝑉𝑡 2 𝑉𝑡 2
∆𝑝𝑁𝑅𝑉 = 𝐾𝑁𝑅𝑉 𝜌𝑔 = 𝐾𝑁𝑅𝑉 𝜌 𝐾𝑁𝑅𝑉 = 5.1 problem !!!
2𝑔 2
𝑉𝑡 2 𝑉𝑡 2
∆𝑝𝐸𝑋 = 𝐾𝐸𝑋 𝜌𝑔 = 𝐾𝐸𝑋 𝜌
2𝑔 2

17 Luca Chiabò
𝑝𝑝 = 𝑝𝑀 −∆𝑝𝐵𝑅 −ℎ𝑓 𝜌𝑔 − ∆𝑝𝐷𝐶𝑉 − ∆𝑝𝑁𝑅𝑉 − ∆𝑝𝐹𝐶𝑉 −∆𝑝𝐵𝑅 −∆𝑝𝐸𝑋

Consider a flow control valve with the following

relation between pressure drops and restriction area:

𝑉𝑠 2
∆𝑝𝐹𝐶𝑉 = 𝐾𝑠 𝜌
2
𝑄
𝑉𝑠 = 𝐴 𝐴𝑠 : area of the throat
𝑠
2.8 𝐴𝑡 : area of the pipe
𝐾𝑠 = 𝑉𝑠 : velocity in the throat
𝐴𝑠 2
1+𝐴
𝑡

Task: select the ratio 𝐴𝑠 𝐴𝑡 in order to obtain the drop pressure required at
the FCV.

18 Luca Chiabò
In the retraction stroke (𝑉𝑅 ) the flow is directed to the tank (𝑝𝑇 ).
𝑝𝑇 = 𝑝𝑝 −∆𝑝𝐵𝑅 −ℎ𝑓 𝜌𝑔 − ∆𝑝𝐷𝐶𝑉 − ∆𝑝𝑁𝑅𝑉 −∆𝑝𝐸𝑁 −∆𝑝𝐵𝑅 − ∆𝑝𝐹𝐶𝑉

4𝑄
𝑉𝑡 2
𝑉𝑡 2 𝑄 = 𝐴𝑝 𝑉𝑅 𝑉𝑡 =
∆𝑝𝐵𝑅 = 𝐾𝐵𝑅 𝜌𝑔 = 𝐾𝐵𝑅 𝜌 𝜋𝐷𝑡 2
2𝑔 2
𝐿𝑡 𝑉𝑡 2 𝐿𝑡 16𝑄2 𝑉𝑠 2
Δ𝑝𝑝𝑖𝑝𝑒 = ℎ𝑓 𝜌𝑔 = 𝑓 𝜌𝑔 = 𝜌𝑓 ∆𝑝𝐹𝐶𝑉 = 𝐾𝑠 𝜌
𝐷𝑡 2𝑔 2 𝜋 2 𝐷𝑡 5 2
𝑄
𝑉𝑡 2 𝑉𝑡 2 𝑉𝑠 = 𝐴
𝑠
∆𝑝𝐷𝐶𝑉 = 𝐾𝐷𝐶𝑉 𝜌𝑔 = 𝐾𝐷𝐶𝑉 𝜌
2𝑔 2 2.8
𝐾𝐷𝐶𝑉 = 3.5 𝐾𝑠 =
𝑉𝑡 2
𝑉𝑡 2 𝐴𝑠 2
∆𝑝𝑁𝑅𝑉 = 𝐾𝑁𝑅𝑉 𝜌𝑔 = 𝐾𝑁𝑅𝑉 𝜌 1+𝐴
2𝑔 2 𝑡
𝑉𝑡 2
𝑉𝑡 2 𝐾𝑁𝑅𝑉 = 5.1
∆𝑝𝐸𝑁 = 𝐾𝐸𝑁 𝜌𝑔 = 𝐾𝐸𝑁 𝜌
2𝑔 2
Task: select the ratio 𝐴𝑠 𝐴𝑡 in order to obtain the drop pressure required at
the FCV.

19 Luca Chiabò
20 Luca Chiabò
 Compressed gas Exit losses Piston
accumulator
Load
𝑝𝑝 𝐹𝐿
Distributed
Bend radius head losses Δ𝑝𝐸𝑋 Δ𝑝𝐸𝑁

Δ𝑝𝐷𝐶𝑉 Entrance losses

Δ𝑝𝑁𝑅𝑉 Δ𝑝𝐹𝐶𝑉
Pump
Δ𝑝𝐵𝑅 Δ𝑝𝑝𝑖𝑝𝑒 Δ𝑝𝐵𝑅
𝑝𝑀
Δ𝑝𝐵𝑅

Bend radius Bend radius

Non return
𝑝𝑇 valves

Direction control
Tank Flow control
valve
valves

21 Luca Chiabò
 In this type of accumulator the pressure-
volume law in the work cycle can be derived
using the ideal gas laws. If 𝒱𝑜 and 𝑝𝑜 are the
Gas
volume and pressure of the gas before
charging the accumulator, the gas
transformation can be modeled with the
polytropic transformation:
Oil 𝛾
𝒱0
𝑝 = 𝑝0
𝒱0 − 𝒱𝑜𝑖𝑙

γ is equal to 1.4 for an adiabatic transformation,

and to 1 for an isothermal process.
Usually the charge process is modeled with an isothermal process (slow),
while the discharge is modeled with an adiabatic process (fast).

Tasks: define the pre-charge pressure ( 𝑝𝑃𝐶 ) and the volume of the
accumulator (𝑉𝑎𝑐𝑐 ).
22 Luca Chiabò
Assume that the discharge process can be modeled as a polytropic process
with 𝛾 = 1.3 (nearly adiabatic):
𝑝𝑀
𝛾 𝛾
𝑝𝑀 𝒱𝑡𝑜𝑡 − 𝒱𝑜𝑖𝑙 = 𝑝𝑝 𝒱𝑡𝑜𝑡 𝑝𝑝
𝑝𝑀
𝑝𝑀 = 21𝑀𝑃𝑎
Before After
𝒱𝑜𝑖𝑙 = 𝐴𝑝 𝑆𝐿
discharge discharge
From the polytropic equation, we get:
1
𝑝𝑀 𝛾
𝛾 is a data of the
𝑝𝑝
𝒱𝑡𝑜𝑡 = 𝐴𝑝 𝑆𝐿 1
𝛾
problem !!!
𝑝𝑀
𝑝𝑝
−1

This choice does not account for possible leakages!!!

23 Luca Chiabò
It is actually convenient to choose a larger volume to account for leakages
along the line.

𝒱𝑎𝑐𝑐 = 𝒱𝑡𝑜𝑡 + ∆𝒱𝑜𝑖𝑙 ∆𝒱𝑜𝑖𝑙 ≈ 20%𝒱𝑡𝑜𝑡

It is necessary to size the pre-charge pressure of the accumulator (pressure

before the accumulator is connected to the system).

𝑝𝑔𝐴 = 𝑝𝑀 = 21𝑀𝑃𝑎 𝒱𝐴 = 𝒱𝑡𝑜𝑡 − 𝐴𝑝 𝑆𝐿 𝑝𝑔𝐴

𝑝𝑔𝐵
𝑝𝑃𝐶
𝑝𝑔𝐵 = 𝑝𝑝 𝒱𝐵 = 𝒱𝑡𝑜𝑡 𝑝𝑀
𝑝𝑝
𝑝𝑃𝐶 =? 𝒱𝑃𝐶 = 𝒱𝑎𝑐𝑐
State A State B Pre-charge
𝛾 𝛾
𝑝𝑀 𝒱𝑎𝑐𝑐 − ∆𝒱𝑜𝑖𝑙 − 𝐴𝑝 𝑆𝐿 = 𝑝𝑃𝐶 𝒱𝑎𝑐𝑐

Task: Calculate the 𝑝𝑃𝐶 and 𝒱𝑎𝑐𝑐 . Plot the polytropic relation for 𝒱 varying
between 1lt-5lt and identify on the graph the points A, B and PC.

24 Luca Chiabò
25 Luca Chiabò
 In emergency the pressure of the gas in the accumulator decreases in time,
thus a dynamical analysis of the transient phase has to be performed.

𝑀𝑛𝑜𝑚 𝑥 = 𝑝𝑔 −∆𝑝𝐵𝑅 −ℎ𝑓 𝜌𝑔 − ∆𝑝𝐷𝐶𝑉 − ∆𝑝𝑁𝑅𝑉 − ∆𝑝𝐹𝐶𝑉 −∆𝑝𝐵𝑅 −∆𝑝𝐸𝑋 𝐴𝑝 − 𝐹𝑛𝑜𝑚

𝐿𝑡 𝑉𝑡2 𝐿𝑡 16𝑄2
ℎ𝑓 𝜌𝑔=𝑓 𝐷 2𝑔 𝜌𝑔 = 𝜌𝑓 2 𝜋2𝐷 5 𝐴𝑝
𝑡 𝑡
𝑉𝑡 = 𝑥
𝐴𝑡
𝑉𝑡 2 𝑉𝑡 2
∆𝑝𝐵𝑅 = 𝐾𝐵𝑅 𝜌𝑔 = 𝐾𝐵𝑅 𝜌
2𝑔 2
𝑉𝑡2 𝑉𝑡2
∆𝑝𝐷𝐶𝑉 = 𝐾𝐷𝐶𝑉 2𝑔
𝜌𝑔 ∆𝑝𝑁𝑅𝑉 = 𝐾𝑁𝑅𝑉 𝜌
2
𝑄2 𝑄 2 𝐴𝑡 2 𝑉𝑡2 𝐴𝑡 2 𝑉𝑡 2 𝑉𝑡 2
∆𝑝𝐹𝐶𝑉 = 𝐾𝑠 𝜌 2 = 𝐾𝑠 𝜌 2 2 = 𝐾𝑠 𝜌 2 ∆𝑝𝐸𝑋 = 𝐾𝐸𝑋 𝜌𝑔 = 𝐾𝐸𝑋 𝜌
2𝐴𝑠 2𝐴𝑡 𝐴𝑠 𝐴𝑠 2 2𝑔 2

𝛾 𝛾
𝑝𝑀 𝒱𝐴 = 𝑝𝑔 𝒱𝐴 + 𝐴𝑝 𝑥

Task: solve numerically the second-order non-linear differential equation and determine
𝑥 𝑡 , 𝑥 t , 𝑥 t in emergency
26 Luca Chiabò
Task: solve numerically the second-order non-linear differential equation

Hints: One possible solution is to use the ODE solver “ode45” (Runge-Kutta Method).

𝑡, 𝑦 = 𝑜𝑑𝑒45 @𝑓, 𝑡0, 𝑡𝑓 , 𝑦0

𝑡1 𝑦1 (𝑡1 ) ⋯ 𝑦𝑛 (𝑡1 ) 𝑦1 (𝑡0 )

𝑡= ⋮ 𝑦= ⋮ ⋱ ⋮ 𝑦0 = ⋮
𝑡𝑛 𝑦1 (𝑡𝑛 ) ⋯ 𝑦𝑛 (𝑡𝑛 ) 𝑦𝑛 (𝑡0 )
Example: solve numerically the Damped harmonic oscillator

𝑦1 = 𝑥
𝑑𝑦1
𝑑2𝑥 𝑑𝑥 = 𝑦2
𝑑𝑥 𝑑𝑡
2
+ 2𝛾𝜔 0 + 𝜔02 𝑥 = 0 𝑦2 = 𝑑𝑦2
𝑑𝑡 𝑑𝑡 𝑑𝑡 = −2𝛾𝜔0 𝑦2 − 𝜔02 𝑦1
𝑑𝑡

27 Luca Chiabò
𝑤0 = 5; %angular frequency
𝑔 = 0.35; %damping ratio

%initial conditions
𝑦0 = 𝑧𝑒𝑟𝑜𝑠(1,2); 𝑦0(1) = 1; 𝑦0(2) = 0; %initial position and velocity

𝑡𝑓 = 10; %final time

𝑓 = @(𝑡, 𝑦) [𝑦(2); −2 ∗ 𝑔 ∗ 𝑦(2) − 𝑤0 ∗ 𝑤0 ∗ 𝑦(1)];
𝑡𝑠𝑝𝑎𝑛 = [0 𝑡𝑓];
[𝑡, 𝑦] = 𝑜𝑑𝑒45(𝑓, 𝑡𝑠𝑝𝑎𝑛, 𝑦0);

28 Luca Chiabò
Hydraulic system sizing:
• Size the piston (define the piston area and the nominal working pressure).
• Solve the Colebrook-White formula with an iterative method.
• Estimate the friction head losses in the pipe and the concentrated head losses.
• Size the flow control valves for both forward and return stroke in nominal
conditions (select the area ratio of the valves).
• Size the accumulator for emergency condition (accumulator volume and pre-charge
pressure)
• Plot the ploytropic relation during the discharge process of the accumulator and
identify (on the graph) charged, discharged and pre-charged states.
Dynamical analysis:
• Solve numerically the second-order non-linear differential equation for the piston
position for emergency condition (compute and plot 𝑥 𝑡 , 𝑥 t , 𝑥 t ).

A report developing all the above points should be forwarded before 11:59 PM of
20/10/2020. A template (optional) of the report is available in AG. A PDF version of
the report should be uploaded to the Turnitin assignment “LAB1 - Report” in AG. Well-
commented Matlab codes used must be uploaded to the “Lab1 – Matlab Codes”
assignment in AG. All files should be included in a .zip file with name GR#_LAB1 and
uploaded on AG. (Refer to the group name assigned to your group in the FINAL list
available at AG to name your file appropriately).
29 Luca Chiabò