TECHNICAL REQUIREMENTS

AIRCRAFT POWER DRIVE UNIT FOR WEAPON BAY DOORS

PDU14

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ISSUE STATUS
Affected
Revision Rev. Date Description of Change
Pages
01 29/02/24 Initial version for Contract signing All
02 02/05/24

1. SCOPE
This specification defines the requirements for the design and development of Power Drive Unit
PDU14 (Referred to herein after as the “PDU").
This Specification is an integral PDU development document and should be referenced to
throughout whole development process including all necessary stages - PDR, CDR, etc.

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2. APPLICABLE DOCUMENTS

2.1. GENERAL
The following documents, together with the documents referred to inside them, of the issue and
amendment in effect on the date of contract, form a part of this specification to the extent specified
herein.

2.2. PRECEDENCE
In the event of conflict between documents referenced herein and the contents of this specification,
the contents of this specification shall be considered superseding requirements. The Supplier
CONTRACTOR shall inform of any conflict between documents, when found, to the
CUSTOMER.

2.3. SPECIFICATIONS
Table 2.1 Specifications
Document number Document Title
SAE AS8775 Hydraulic System Components, Aircraft and Missiles, General
Specification for
SAE AS4941B Aerospace – General Requirements for Commercial Aircraft Hydraulic
Components
ARP5384 Specification Guide for Power Drive Units (PDUs)
SAE AS5440A Hydraulic Systems, Aircraft, Design and Installation Requirements for,
MIL-STD-810G Environmental Test Methods & Engineering Guidelines
MIL-PRF-87257B Hydraulic Fluid, Fire Resistant, Low Temperature, Synthetic Hydrocarbon
Base, Aircraft and Missile, Performance Specification
MIL-PRF-5606H Hydraulic Fluid, Petroleum Base, Aircraft, Missile and Ordnance
SAE AS4059F Aerospace Fluid Power – Cleanliness Classification for Hydraulic Fluids
SAE AS33514 Fitting End, Standard Dimensions for Flareless Tube Connection and
Gasket Seal FSC
SAE AS5202A Port or Fitting End, Internal Straight Thread, Design Standard
MIL-B-5087B Bonding, Electrical and Lightening Protection for Aerospace
MIL-I-8500D Interchangeability and Replaceability of Component Parts for Aerospace
Vehicles
MIL-P-514D Plates, Identification, Instruction and Marking, Blank.
SAE AS598A Aerospace Microscopic Sizing and Counting of Particulate Contamination
for Fluid Power Systems
SAE ARP4761 Guidelines And Methods for Conducting The Safety Assessment Process
on Civil Airborne Systems and Equipment

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 3. REQUIREMENTS

3.1. ITEM DEFINITION

3.1.1. Item Definition
The PDU shall conform to the requirements, except as noted in this specification.
Notes:
1. In case of conflict between the texts of this document to ARP5384, the text of this
document takes precedence.
3.1.2. Item Configuration
The PDU is a hydraulic powered, rotating type driver with servovalve speed control valve.

3.2. FUNCTIONAL REQUIREMENTS

3.2.1. Missions
3.2.1.1. Aircraft has two weapon bay compartments, each operated from one PDU;
3.2.1.2. Both PDU powered from one hydraulic pump.
3.2.1.3. PDUs have no mechanical connection and are synchronized by electronic control unit.
3.2.1.4. The developed aircraft has two independent electric power supply systems.
3.2.1.5. Electronic is not included in scope of technical requirements.
3.2.1.6. Weapon bay doors configuration is presented on Figure 3.1.

Figure 3.1 – Weapon bay doors configuration

RIGHT DOOR LEFT DOOR

3500
3043
3000
2874
2500

2000
1984 2243

1500
M [NM]

1000
688
500

0
0 30 60 90 120
-500
-554 -374
-1000 -876
-1035 -1084
-1500
DOOR ANGLE [O]

Figure 3.2 –Door angle – torque graph

(positive – unidirectional for door opening; negative – unidirectional for door closing)
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 Table 3.1 –Door angle – torque

DOOR ANGLE [°] RIGHT DOOR (Nm) LEFT DOOR (Nm)

0 -1035 -554
30 688 1984
60 -374 2243
90 -876 3043
120 -1084 2874

3.2.1.7. Load profiles during doors opening and closing are presented in Figure 3.2 and Table 3.1
3.2.1.8. Weapon bay doors are expected to reach 120o within 3 seconds.
3.2.1.9. GRAs placed after the PDU have a gear ratio of 88.1 and efficiency not less than 0.55.
3.2.1.10. Estimated moment of inertia is _____ kg.m2 connected to the PDU shaft.
3.2.1.11. PDU parameters are given in Table 3.2.

Table 3.2 PDU Parameters

Working
Parameter Units
Condition
Output shaft speed at nominal torque of
rpm 780*
counteracting load
Nominal torque of counteracting load, N*m 45.75
Nominal torque of the unidirectional load N*m 45.75
Maximum torque provided by PDU N*m 75
Torque on the output shaft, held by hydro
N*m 94
mechanical brakes, not less
System pressure bar 207
Pressure in the return line bar 7.5
Ambient temperature
- Operation range -54…93.3
- Requirement strict application in speed °С -20…93.3
- Requirement allowable deviation of -54…-20
15% from speed and torque values
Available space for each PDU mm Mentioned in Figure 3.3
Weight of each PDU kg ≤ 10
Consumed power (both PDUs) kW ≤ 10
Consumed flow rate (both PDUs) lpm ≤ 30
Working fluid MIL-H-5606
*Expected to increase, if total PDU efficiency increases.

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 3.2.2. Operational Phases and Modes
Mode 1 (main operational mode)
Main operation mode is in-flight operation mode. PDU provides required torque and required
rotation speed to aircraft highline. PDU provides supply pressure to uplocks. In main operation
mode, hydraulic power is provided by hydraulic system of aircraft. Control signals provides by
aircraft controller
Mode 2 (ground operating from external hydraulic supply)
Ground operation mode from external hydraulic supply, connected to ground supply ports and
control signals provides by aircraft controller.
Mode 3 (ground manual operating)
Ground manual operating without any electric or hydraulic supply.
Mode 3 (torque holding)
Without electrical command and hydraulic supply PDU shall hold required torque by
hydromechanical brakes.
3.2.3. Duty Cycles
The PDU shall be designed for 2000 hours.
3.2.4. Rated Endurance
Load cyclogram 2 cycles (open/close) in 3 min.

3.2.5. Service Life

3.2.5.1. Design & Operational Service Life
a. Resource of 8000 hours before the first repair and service life for 30 years. – Technical
requirements. The service life is recorded in the PDR document for the UNITs in
accordance with the current documentation of the CONTRACTOR.
b. The design & operational service life shall be achieved under any natural combination
of natural and induced environmental conditions specified herein, and when
performing the duty cycles specified in 3.2.3. of these technical requirements.
c. The PDU shall be so designed that wear-out shall not occur before the above design
service life is achieved.
3.2.5.2. Storage Life
a. Storage life of the PDU shall be 10 calendar years, after which the supplier shall
suggest a maintenance program.
b. Storage life is the period for which the unit may be kept in storage before installation,
and still have the specified design service life, without the need for component or part
replacement, adjustment, or maintenance action.
3.2.5.3. Useful Life
a. The total useful life of the PDU with any combination of operational service and
storage life shall be not less than 30 calendar years.
b. Useful life shall be verified by analysis.

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 3.2.6. Performance
3.2.6.1. Hydraulic System
The hydraulic system in which the component shall be used corresponds in general to Type II (up
to +275°F (+135°C) fluid temperature range), class 3000 PSI hydraulic system characteristics, as
specified in SAEAS5440.
3.2.6.2. Hydraulic Fluid
3.2.6.2.1. General
The PDU shall be capable to operate with Hydraulic fluid: MILPRF5606 or MILPRF87257.
3.2.6.2.2. Fluid Cleanliness
The system must have a filter at the PDU inlet filter of 15 microns absolute.
The PDU shall meet AS4059 Class 7 upon delivery to Customer. The PDU shall meet all
functional and performance requirements up to the limit of AS4059 Class 8.
3.2.6.2.3. Fluid Hydraulic Fluid Temperature Range
The system fluid temperature range is: –54°C to +93.3°C.
PDU shall be capable of operating in temperature range -54°C …-20 °C with 15% reducing of
speed and torque and PDU shall operate without of degradation of parameters in temperature range
-20°C…+93.3 °C.
3.2.6.3. Pressure Conditions
The PDU shall operate in system with following pressure:
Table 3.3 Pressure Value of Modes
Mode Value
Operating 3000psi
Proof 4500psi
Burst 7500psi

3.2.6.3.1. Return pressure

The rated return pressure shall be 7.5 bar
The maximum return pressure shall be 103.5 bar.
3.2.6.4. Output shaft speed
The output shaft speed at nominal counteracting torque at operational mode for nominal fluid
temperature shall be 780±20 rpm.
3.2.6.5. Nominal counteracting torque
The nominal counteracting torque on output shaft shall be not less than 43.75 Nm.
3.2.6.6. Nominal unidirectional torque
The nominal unidirectional torque on output shaft shall be not less than 43.75 Nm.
3.2.6.7. Maximum counteracting torque
The maximal counteracting torque on output shaft shall be not less than 75 Nm.

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 3.2.6.8. Maximum unidirectional torque
The maximal unidirectional torque on output shaft shall be not less than 43.75 Nm.
3.2.6.9. Torque on the output shaft, held by hydromechanical brakes
Torque on the output shaft, held by hydro-mechanical brakes, not less 94 Nm
3.2.6.10. Consumed flow rate and power
Consumed flow rate shall be not more than 30 l/min for both PDU.
Consumed power shall be not more than 10 kW for both PDUs.
3.2.6.11. Motor Shaft Seal Leakage
Shaft seal leakage shall not exceed 1 drop in 2 minutes dynamic and 1 drop in 10 minutes static.
3.2.6.12. Work stroke and position sensor
PDU should contain position sensor with encoder type. Work stroke of PDU shall be 115[TBC]
revolutions. Full stroke shall be operated in 3 sec max.
3.2.6.13. Uplock control
PDU shall has additional hydraulic port for uplocks control with supply pressure and max flow
rate 2.5 l/min.
3.2.6.14. Manual operating
PDU shall has manual operating mode with no load at output shaft. Input torque shall be 2 Nm
max. Manual output for ground operation should be located according to fig. 3.4.
3.2.6.15. Reliability
The PDU shall meet the reliability requirements specified herein, when operated in any mode or
combination of modes and under any natural combination of the loads and environmental
conditions specified herein.
3.2.6.16. Mean Time Between Failure (MTBF)
The PDU shall achieve a MTBF not less than 21000 flight hours.
3.2.6.17. Proof of Reliability Requirements
The reliability requirements of the PDU shall be proved by analysis and/or by activities during the
test and operational phases.
3.2.6.18. Maintainability
3.2.6.18.1. General
a. The maintainability requirements of the PDU shall be those inherent to good design
and good workmanship.
b. The PDU shall be designed with the goal of reducing cost of operation and
maintenance, to minimize the maintenance downtimes and to facilitate the
accomplishment of maintenance actions.
c. The PDU shall be designed for ease of maintenance and accessibility.

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 3.2.6.18.2. Inspection and Overhaul
No scheduled maintenance, unless justified for safety or economic reasons, should be required.
“On-Condition” philosophy shall be applied.
3.2.6.18.3. Qualitative Maintainability Requirements
a. The PDU shall be designed to minimize scheduled maintenance inspections.
b. After installation, no testing or additional adjustment shall be required other than
functional tests.
c. Special skills, techniques or non-standard tools shall not be required for line
maintenance.
d. The PDU shall be designed for ease of maintenance, acceptability and equipment
handling.
e. No Preventive Maintenance Requirements.
f. Reversibility/Connector mismatch restriction - construction incorporate one-way
installation features that make it impossible to install equipment incorrectly.
g. Interchangeability – All parts having the same manufacture’s part number shall be
directly and completely interchangeable with each other with respect to installation
and performance.
3.2.6.19. Interfaces
Mechanical interfaces, mounting pad, direction of rotation, shaft shear section and space envelope
should be agreed with aircraft manufacturer.
3.2.6.19.1. Mechanical Interfaces
Spline shaft shall be ended by spline according to [TBD].
3.2.6.19.2. Hydraulic Ports
The fluid ports shall be equipped with adapters boss connection to tube end. The fitting end shall
be as per [TBD].
3.2.6.19.3. Electrical connectors
Each electrical channel of PDU control should have one electrical connector [TBD]. Connectors
type as per MIL 38999.

3.2.6.19.4. Mounting Pad

Mounting pad: TBD
Max overhung moment on the mounting pad shall not exceed TBD in-lbs (TBD N•m).
3.2.6.19.5. Directional Rotation
The direction of rotation of the PDU drive shaft is both directional, according to polarity of
command signal.

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 3.2.7. Physical Characteristics

3.2.7.1. Envelope
The space envelope at mounting condition should be within the specified volume in Figure 3.3.

Figure 3.3 PDU Maximum volume

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Manual operation mode shaft output shall be located as Figure 3.4.

Figure 3.4 Manual operation mode location

3.2.7.2. Weight
The maximum not-to-exceed dry weight of each PDU shall be under 10kg.

3.3. Additional Requirements

3.3.1. PDU hydraulic schema
PDU should contain pressure and temperature sensors. The principal schema of PDU, the type of
hydraulic motor (fix or variable displacement) shall be chosen and Agreement determined at the
PDR stage.

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