A brake simulator is a hydro-mechanical assembly or digital analog capable of mimicking the mechanical performance of a physical brake assembly. This simulator is designed to predict the brake functionality for Meggitt's line of brake assemblies, ranging from brakes implemented in small personal craft to commuter jets. The assembly must be able to integrate with other aircraft component simulators as well, such as a hydraulic rig. Brake simulators are used in order to collect accurate data without testing the actual brake assembly. Pressure and piston displacement data generated from the simulator will be compared to physical brake test data in order to verify accuracy of the simulated output.

Meggitt Aircraft Braking Systems is in need of a simulator to show brake assembly compliance and mechanical stiffness. The current setup regards two components plumbed together on a table-top with brake assemblies attached for testing. The simulator will eliminate the need for bulky assembly and physical product testing. The simulator’s control system will output hydraulic load data generated from an analogous brake assembly, as well as permit an operator to quickly and easily modify test parameters, such as max pressure and expected brake stiffness.The operator must be able to monitor the system parameters behind a safety enclosure while viewing the test through a sight window. The apparatus must be mobile, and fit through an average 32" door. As such the system must be capable of being transferred by a single operator. Installation must take up to 30 minutes to complete, pressure changes must occur within an 8 hour period, and air must be bled within several minutes for disconnection from the test bed to be conducted properly. The simulator must be able to operate over a range of 0 to 5000 psi and accurately perform roughly 1 million maximum pressure cycles. The simulator's final output will be a graph of hydraulic fluid volumetric change versus developed pressure curve.

Apparatus must comply with the following standards: NEMA, CE, AS4716, AS6235, AS4365, AS4375, and MIL-PRF-5606 or AS1241.

As Meggitt PLC is a US DoD government contractor, elements of this project are subject to restriction. Meggitt is the sole proprietor of IP content as deemed necessary. This proprietary data is not disclosed in this document, nor technical data subject to "ITAR," 22 CFR §125.2 - Export of Unclassified Technical Data. See 'Work Breakdown' below for details.

Project Name

Adjustable Aircraft Brake Simulator (AABS)

Project Number

P18371

Project Family

Aerospace Systems and Technology

Start Term

2175

End Term

2181

Faculty Guide

Harold Paschal

Primary Customer

Kyle Berkowitz, Meggitt USA

Sponsor

Mark Maydew, Meggitt UK

Planning & Execution

Project Photos and Videos

Imagine RIT

Gate Reviews

Problem Definition

Systems Design

Preliminary Detailed Design

Detailed Design

Build & Test Prep

Subsystem Build & Test

Integrated System Build & Test

Customer Handoff & Final Project Documentation (Verification & Validation)

PRP*

Requirements

Schedule

Cost

Risk Assessment

Problem Management

Communication & Minutes**

Use Scenarios

Benchmarking**

Functional Decomposition

Morphological Chart

Pugh Concept Selection

BOM

Mechanical Drawings

Electrical Schematics

Software Diagrams

Facility Layout

Manuals

Mockups

Test Fixtures

Prototyping

Test Plans

Analysis Results

Simulations

Test Results

Design Review Documents

Technical Paper

Poster

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