BTEC Unit 28 Turbine Rotary Wing Mechanical and Flight Systems HNC Level 4 Assignment Sample UK

Course: Pearson BTEC Level 4 Higher National Certificate in Aeronautical Engineering

The Pearson BTEC Level 4 Higher National Certificate in Aeronautical Engineering course focuses on the study of turbine rotary wing mechanical and flight systems. This course delves into the complex engineering principles behind helicopters, including mechanical and electrical aspects, integrated flight controls, transmission systems, hydraulic systems, and the importance of Health Usage Monitoring Systems (HUMS) to prevent airframe fatigue failure. By the end of the course, students will gain knowledge and skills in describing airframe control systems, understanding interrelationships between flight systems, analyzing transmission system efficiency, designing hydraulic systems, and implementing strategies to combat airframe fatigue failure.

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Assignment Task 1: Describe the mechanical airframe control systems associated with rotary wing flight and explain the interrelationships between flight systems in modern integrated flight controls.

Mechanical airframe control systems play a crucial role in rotary wing flight, enabling pilots to maneuver and control the helicopter. These systems are responsible for transmitting the pilot’s inputs to the various flight control surfaces and systems. Here are the key mechanical airframe control systems associated with rotary wing flight:

• Cyclic Control: The cyclic control allows the pilot to control the pitch and roll of the rotor blades. It consists of a control stick or yoke that is connected to the rotor hub via mechanical linkages. When the pilot moves the cyclic control, it tilts the rotor disc, causing the helicopter to tilt in the desired direction.
• Collective Control: The collective control is used to control the overall lift produced by the rotor system. It is typically a lever located on the left side of the pilot’s seat. When the collective lever is raised, it increases the pitch angle of all rotor blades simultaneously, generating more lift. Lowering the collective lever decreases the pitch angle, reducing lift.
• Anti-torque Pedals: The anti-torque pedals, also known as the tail rotor pedals, are used to control the yaw of the helicopter. They are connected to the tail rotor via mechanical linkages. When the pilot presses on the pedals, the tail rotor’s pitch changes, generating a lateral thrust that counteracts the torque produced by the main rotor.
• Throttle Control: The throttle control is used to adjust the engine power and, consequently, the rotor speed. It is usually a twist grip or lever located on the collective control. Increasing the throttle setting increases engine power and rotor speed, while decreasing it reduces power and speed.

Modern integrated flight controls aim to enhance the helicopter’s performance and handling through advanced electronic systems. These systems utilize sensors, computers, and fly-by-wire technology to provide additional features and improve safety. The mechanical airframe control systems are interconnected with these flight control systems, allowing for seamless integration and coordinated operation.

For example, in a fly-by-wire system, the pilot’s inputs from the mechanical controls are converted into electrical signals, which are then processed by a flight control computer. The computer interprets the inputs and sends commands to actuator systems that directly control the flight control surfaces, such as the cyclic and collective actuators. This integration provides precise control and allows for stability augmentation, automated flight modes, and envelope protection.

The interrelationships between mechanical airframe control systems and modern integrated flight controls enable pilots to have enhanced control authority, improved stability, and optimized flight characteristics in rotary wing aircraft.

Assignment Task 2: Explain the operation of rotary wing transmission systems and determine the efficiency of transmission system components.

Rotary wing transmission systems are essential for transmitting power from the engine to the rotor system in helicopters. These systems consist of various components that work together to transfer power efficiently and reliably. Here is an overview of the operation of rotary wing transmission systems and how the efficiency of transmission system components can be determined:

• Input Shaft: The input shaft is connected to the engine and receives power from it. It transmits the engine torque to the transmission system.
• Main Gearbox: The main gearbox is the primary component of the transmission system. It receives power from the input shaft and distributes it to multiple output shafts. The main gearbox also allows for speed reduction and torque multiplication to drive the rotor system.
• Tail Rotor Drive Shaft: The tail rotor drive shaft transmits power from the main gearbox to the tail rotor assembly. It ensures that the tail rotor receives the necessary power for anti-torque control.
• Output Shafts: The output shafts are connected to the main gearbox and transmit power to different systems, such as the main rotor assembly, tail rotor, and accessory drives.

Efficiency of transmission system components can be determined by calculating the power losses associated with each component. The efficiency is typically expressed as a percentage and is calculated using the following formula:

Efficiency (%) = (Output Power / Input Power) × 100

To determine the efficiency, the input power is measured or known, and the output power is calculated by multiplying the torque and rotational speed at the output shaft.

Power losses in transmission system components can occur due to factors such as friction, gear meshing, and bearing losses. These losses can be minimized by using high-quality materials, precision manufacturing, efficient lubrication systems, and proper maintenance.

Regular inspection and monitoring of transmission system components are crucial to identify any potential issues or abnormal wear that could affect efficiency. Proper lubrication and maintenance practices, including regular oil changes and component inspections, can help maintain the efficiency and longevity of the transmission system in rotary wing aircraft.

Assignment Task 3: Identify the requirements and system operation of typical rotary wing hydraulic systems and design a hydraulic system to solve a given application.

Typical rotary wing hydraulic systems are used to provide power for various functions and operations in helicopters. These systems use hydraulic fluid under pressure to transmit power and actuate hydraulic devices. Here are the requirements and system operation of typical rotary wing hydraulic systems and the steps involved in designing a hydraulic system for a given application:

Requirements of Rotary Wing Hydraulic Systems:

• Power Generation: The hydraulic system must have a power source, typically a hydraulic pump, to generate the necessary hydraulic pressure.
• Fluid Storage and Supply: The system requires an adequate supply of hydraulic fluid stored in a reservoir. The fluid is supplied to the hydraulic pump to maintain system pressure.
• Distribution and Control: Hydraulic fluid is distributed to various hydraulic actuators and devices through a network of hydraulic lines. The system must have appropriate valves, filters, and control mechanisms to direct and control fluid flow.
• Actuation: The hydraulic system operates various components, such as landing gear, brakes, flight controls, and cargo doors. These components are actuated using hydraulic cylinders or motors.
• Safety and Redundancy: Hydraulic systems should incorporate safety features, such as pressure relief valves and redundant components, to ensure reliable operation and minimize the risk of failure.

Steps to Design a Hydraulic System:

• Define Requirements: Identify the specific requirements of the hydraulic system for the given application, including the desired functions, power levels, operating pressure, flow rate, and safety considerations.
• Select Components: Choose appropriate hydraulic components, such as pumps, valves, cylinders, and reservoirs, based on the requirements. Consider factors such as pressure ratings, flow capacities, size, weight, and compatibility with the hydraulic fluid.
• Determine Hydraulic Circuit: Design the hydraulic circuit, including the routing of hydraulic lines, placement of valves, and arrangement of actuators. Consider the layout constraints, space availability, and ease of maintenance.
• Calculate Power Requirements: Determine the power requirements for each actuator or device to be operated by the hydraulic system. Calculate the required pressure and flow rate based on the desired actuation speed and force.
• Size Hydraulic Components: Size the hydraulic components, such as the pump, based on the power requirements, including pressure and flow rate. Consider safety factors, efficiency, and duty cycle requirements.
• System Integration: Integrate the hydraulic system with the other systems in the helicopter, such as electrical and mechanical systems. Ensure compatibility, proper connections, and effective interoperation.
• Test and Validation: Perform thorough testing and validation of the hydraulic system to ensure its proper operation, reliability, and compliance with safety regulations.

Designing a hydraulic system for a specific application requires a thorough understanding of the hydraulic principles, system requirements, component selection, and integration considerations. It is essential to follow industry standards and guidelines to ensure a safe and efficient hydraulic system in rotary wing aircraft.

Assignment Task 4: Justify the need for Health and Usage Monitoring Systems and the methods used to combat airframe fatigue failure.

Health and Usage Monitoring Systems (HUMS) play a crucial role in monitoring the health, performance, and usage of aircraft, including rotary wing aircraft. These systems provide real-time data on various parameters, enabling early detection of potential issues and supporting proactive maintenance strategies. Here is the justification for the need for HUMS and an overview of methods used to combat airframe fatigue failure:

Justification for HUMS:

• Safety Enhancement: HUMS provides continuous monitoring of critical components, such as rotor systems, engines, transmissions, and structural elements. By detecting anomalies or early signs of failure, HUMS helps prevent catastrophic failures and enhances overall flight safety.
• Condition-Based Maintenance: HUMS allows for condition-based maintenance practices, where maintenance tasks are performed based on actual component health and usage data rather than fixed time intervals. This approach optimizes maintenance schedules, reduces downtime, and lowers maintenance costs.
• Increased Operational Efficiency: By monitoring the health and usage of aircraft systems, HUMS enables operators to optimize their fleet’s operational efficiency. It helps identify trends, assess performance degradation, and make informed decisions regarding aircraft utilization, maintenance planning, and resource allocation.

Methods to Combat Airframe Fatigue Failure:

• Fatigue Life Monitoring: HUMS can monitor and analyze data related to cyclic loads, vibration, stress, and usage patterns. By assessing the fatigue life consumption of critical airframe components, such as the main rotor hub, fuselage, and tail boom, HUMS helps predict fatigue failures and enables timely inspections or replacements.
• Structural Health Monitoring: HUMS incorporates structural health monitoring techniques, such as strain gauges, accelerometers, and acoustic emission sensors, to detect anomalies and damage in airframe structures. These sensors provide continuous data on structural loads, stress levels, and any signs of cracks or damage, facilitating early detection and preventive actions.
• Vibration Analysis: HUMS utilizes vibration sensors to monitor the dynamic behavior of the airframe. By analyzing the vibration signatures, HUMS can identify abnormal vibration patterns that may indicate issues with rotating components, such as bearings, gears, or rotor blades. Early detection of such anomalies allows for proactive maintenance and prevents further damage or failure.
• Usage Monitoring: HUMS tracks various usage parameters, such as flight hours, cycles, and mission profiles, to assess the operational stress imposed on the airframe. This information helps determine the cumulative fatigue damage and enables maintenance planning based on the actual usage conditions.

By combining the data from these monitoring methods, HUMS provides a comprehensive picture of the airframe’s health, usage, and potential fatigue issues. This data-driven approach allows operators to take proactive measures, such as scheduled inspections, repairs, or component replacements, to combat airframe fatigue failure and ensure the continued airworthiness of rotary wing aircraft.

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