Actuator Design Exercise
One of our existing customers has approached Actuation Systems to request a preliminary
design/feasibility study for a demonstrator aircraft project. For this project they have already
determined that they require a hydraulically powered, linear piston-type actuator to actuate an
aircraft spoiler. During operation, the spoiler is either at the fully retracted, or fully extended
position. The customer’s technical requirements are shown below, and they have communicated
that they are looking to minimise size and weight.
Your engineering team lead has produced a partial sketch (attached) and some notes during a
meeting with the customer, and has delegated the task to you. You will need to complete initial
sizing calculations for the actuator based on the information provided. You can then attempt to
optimise your design. Once you have completed this, you will need to determine whether all
requirements can be achieved.
The outcome of your study will need to be presented to your engineering team lead for design
review. At design review, the decisions you have made will be discussed, and analysis approach
reviewed.
The presentation materials can be any format you feel is appropriate for an engineering design
review. The presentation is an informal environment and will be an over the table discussion.
Customer Technical Requirements:
Supply Pressure: 28 ± 0.5 MPa
Return Pressure: 1 ± 0.2 MPa
Available Flow Rate: 5 l/min
Operating Time: 1.2 second maximum
Minimum Extend Force Requirement: 5,400 lbf
Stroke: 4 inches
Your engineering team lead has left the following notes on their recommended approach:
1. Assume an initial rod diameter (D1) of 25mm
2. Calculate the required piston diameter (D2) to meet the minimum force requirement
3. Check the rod and cylinder strength, iterate as required
4. Verify compliance to requirements