AEROFIL - New Concept of High Pressure Hydraulic Filter for Aeronautics Preserving Environment
Overview
Background & policy context:
In Aeronautics, hydraulics energy is currently used for brakes, engine reverse system and flaps command. To significantly reduce weight, the major changes in the future will be: either an increase in the hydraulics pressure from 3000 Psi to 5000 Psi; or, an hybrid architecture electrical / hydraulics known as the EHA concept (Electrical Hydraulics Actuator), envisaged with possible increase of hydraulics pressure. For large aircrafts, the increase of pressure is studied in details and is planned in the future aircrafts. In parallel, the EHA concept may be used either in redundancy or complementary. For middle range aircraft, the EHA concept is nowadays preferred but the increase of pressure may be used in the future. The high-pressure technology is already applied in middle range military aircraft, and its civil application appears promising, stanting with the A380. In both cases, one of the key elements of the hydraulics circuit is the filtration function. Today most hydraulics filtration systems use renewable cartridges that are thrown away after use without the possibility of the incinerability or recycling. It is a highly polluting process, bearing in mind that hydraulics fluids are very chemically aggressive and hazardous to human health.
This project consists of working on future filtration requirements : use of more ecological material, improvement of cartridge lifetime and an increase in working pressure. The proposed approach is firstly to understand the physical mechanism of filtration by simulation. Theoretical models are proposed and then compared with experiments to obtain a high degree of confidence. New materials are studied, adapted and tested to fulfil performance requirements, most particularly incinerable conditions. Manufacturing processes are investigated for availability, cost impact and environmental constraints, and finally mock-ups are manufactured and tested to validate the technologies.
Objectives:
The research objectives of the AEROFIL project related to:
- fluid mechanics of porous media modelling and characterisation of filtration system with very high pressure (up to software development and validation);
- ester Phosphate characteristics for High pressure;
- synthetic media with an increase in autonomy;
- composite or polymer elements characteristics;
- polymer meshes characteristics
The project was expected to produce the following deliverables:
- ester Phosphate characteristics vs Pressure and temperature;
- precise definition of a filtration system compatible with very high pressure hydraulic systems, increasing lifetime by a factor of 2 and incinerable;
- for this filtration system:
- mechanical design software
- fluid dynamics simulation software
- mock ups
- economical and environmental Life cycle analysis
Methodology:
The work on the project encompassed the following tasks:
Task 1: Needs and Concept description
The goal of this task is to define the requirements for the filter and the resulting requirements on the different components. It also includes the choice of a reference equipment for comparison between former and new technologies
Task 2: Material and technology
It consists in research and development work in new material needed for the conception and the manufacturing of the different components included in the filters in order to fulfil the Scientific and technological objectives of the project.
Task 3: Simulation
This task covers all activities to develop a numerical tool for simulation of flow across the filter. It includes all activities related to the modelisation of the flow and of particles deposition during contamination process, and afterwards, actual development of the sofware and validation by comparison with real data.
Task 4: Simulation tool validation on existing filter technologies
Task 5: Filter mock-up
Activities related to the design, procurement and manufacturing of a filter element prototype using the new technologies.
Task 6: Experimental testing
Testing of the filter element performances on a test bench and comparison between the former and new technologies
Task 7: Simulation tool refinement based on new technologies testing
Comparison of numerical results with test results, and refinement of numerical data
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