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Aerospace

Airbus A380

The world's only twin-deck, four-aisle airliner


The airlines' solution to growing demand for
air travel
More fuel-efficient than your car
A dedicated three-deck 150 ton long-range
freighter

Airbus A380 System Overview


Eatons Aerospace Product
Capabilities

The Airbus A380: The largest,


most advanced and efficient
commercial airliner ever conceived.
The A380 Family starts from a
baseline passenger aircraft
with a capacity of 555 passengers in three classes over a
range of up to 8,000
nm/14,800 km. Larger and
longer range members of the
family are anticipated in the
basic design concept.
Designed in close collaboration with major airlines, airport and airworthiness
authorities, the A380 brings
new standards of comfort and
better economics in an aircraft
that is more environmentally
responsible. Whilst doing all
of this, it allows growth and
reduced congestion from
today's airports with minimum change. Most importantly, the A380 introduces competition to the large aircraft
sector, completing the Airbus
product portfolio.
While offering all the advantages of a completely new
design, the A380 will extend
the unique benefits of Airbus
family commonality into the
very large aircraft sector.
Thanks to the same cockpit
layout, procedures and handling characteristics through
fly-by-wire, pilots will be able
to transition to the A380 from
other Airbus aircraft with only
minor additional training.
The A380 can be powered by
Trent 900 engines from Rolls-

Royce or GP7200 engines


from The Engine Alliance (a
joint venture between
General Electric and Pratt &
Whitney).
The A380, which will seat 555
passengers in a typical threeclass interior layout, will enter
airline service in 2007.
While meeting the most stringent international certification
requirements, the A380 embodies the very latest technologies
for materials, systems and
industrial processes. Offering
about a third more seating and
far more available floor space
than its closest competitor, the
A380 will deliver an unparalleled
level of comfort, with wider
seats and aisles, open spaces
for passengers to stretch their
legs and access to lower-deck
amenities. The A380's modern
technology and economies of
scale provide 15% lower seatmile costs than today's most
efficient aircraft. Consequently,
the A380 will offer passengers
luxury travel at much more
affordable prices.
The A380 will carry more passengers further allowing for
growing passenger numbers
and helping to ease an increasingly congested environment. It
will achieve this without increasing the number of air traffic
movements and without negatively impacting the environment thanks to significantly
reduced noise and emissions
levels. In addition, thanks to
new generation engines and
advanced wing and undercar-

riage design and technology, the


A380 will not only comply with
current noise limits but will be
quieter than today's largest airliner, meeting strict local regulations such as QC2 for departure
at London airports. The A380
will generate half the noise level
at take-off and carry 35 per cent
more passengers than its competitor over distances such as
from London to Singapore.
And the A380's environmental
friendliness does not stop at
noise reductions. The economic
fuel consumption of the A380 around 13 per cent lower fuel
burn than its closest competitor
- will also help reduce the
impact of exhaust gases on the
atmosphere. Indeed, the A380
will be the first long-haul aircraft
to consume less than three
liters of fuel per passenger over
100 kilometers (95 miles per
imperial gallon) - a fuel burn
comparable with the best of
small modern turbo-diesel cars.
While offering all the advantages of a completely new
design, the A380 will extend
the benefits of Airbus family
commonality to the very large
aircraft sector. Thanks to the
same cockpit layout, procedures
and handling characteristics,
pilots will be able to make the
transition to the A380 from
other Airbus fly-by-wire aircraft
with minimal additional training.

economical solution to growing


air traffic and airport congestion.
The only alternative, an increase
in frequencies of existing aircraft, would not only require billions of dollars of investment by
airports (in new runways, terminals and even airports) but
would also contribute to greater
congestion and a significantly
increased impact on the environment. Airbus' analysis of this
issue has been irrefutably confirmed, both implicitly, through
industry-wide participation in
the program from its outset,
and explicitly, through the
already immense success of
the A380 on the market. To
date, eleven customers have
announced firm commitments
for a total of 129 A380s, including 17 freighter versions.
The A380 Family starts from a
baseline passenger aircraft with
a capacity of 555 passengers in
three classes, and a range of up
to 15,000km (8,000nm). The
freighter version, the A380F, will
carry a payload of 150 tons
(330,000lbs) over 10,400km
(5,600nm).

Working with some 60 major


airports to ensure airport compatibility and a smooth entry
into service, the Airbus A380
provides the smartest and most

EATON CORPORATION AEROSPACE C5-37A June 2006

A380 Hydraulic System Block Diagram


The Airbus A380 hydraulic system consists of two hydraulic
systems (Green & Yellow). A
third hydraulic system used on
previous Airbus aircraft is
replaced by an electro-hydraulic
system made of a combination
of Electro Hydraulic Actuators
(EHA) and Electrical Backup
Hydraulic Actuators (EBHA).

aircraft can be dispatched normally with one off-line EDP


while using the remaining seven
pumps.
On this aircraft the Electro
Motor Pump (EMP) will be used
for ground purpose only and are
located by couple in the inner
pylon.

For the first time in civil aircraft


history the A380 will use a high
pressure 5000 psi- hydraulic system. The fluid remains a standard phosphate-ester type as
used on most civil aircraft.
The A380 hydraulic system integrates a total of eight Engine
Driven Pumps (EDP). This architecture allows to have one EDP
as a go item which means the

LOB:
LIB:
LMB:
RMB:
ROB:
RIB:
PV:
PMV:

Left Outboard
Left Inboard
Left Medium
Right Medium
Right Outboard
Right Inboard
Priority Valve
Pressure
Maintaining Valve
Gen: Electrical Generator
EDP: Engine Driven Pump
EMP: Elec. Motor Pump

Electric System 1 Electric System 2

Green System

Gen
Gen1

Gen

Gen2

Eng. 1
EDP

APU

Eng. 2

EDP

EDP

Yellow System

RAT

EDP

Gen3

Gen4

Eng. 3

Eng. 4

EDP

EDP

EDP

EDP

Isolationcontactor (RAT)

EMP
EMP
EMP

Thrust Reversers
Ailerons

LIB & RIB


LOB & ROB

Spoilers

2, 4, 6, 8 (L&R)

Rudder

Slats/Flaps
Braking

LEHGS

BPS

EMP

LMB & RMB

LIB & RIB

LOB & ROB


LMB & RMB

5 (L & R)

1, 3, 5, 7 (L &R)

6 (L & R)

LOB & LIB

THS

Eng. 3 T/R

Upper & Lower

Upper & Lower

Elevators

Eng. 2 T/R

LIB & ROB

Pitch trim

PMV

Slats & Flaps

PMF

Lower

Upper

Upper & Lower


ROB & RIB

LOB & RIB


Pitch trim

PMV

Slats

PMF

Pitch trim
2
Flaps

Body Gear
B k
BPS

Wing Gear Brakes


BPS
PV

Landing Gear actuation

Wing Gears
(ERS)
Nose Gears (ERS)

PV
Body Gears (ERS)
PV

Wheel steering
Back Up
Hand pump

Nose Wheel
St
i
Cargo Doors

EATON CORPORATION AEROSPACE C5-37A June 2006

Body Wheel
St
i

LEHGS

Eatons Airbus A380 Components

CFRP Transmission Shafts


Hydraulic Sliding Unions
Trent 900 EBU
Fire Shut-Off Valve
Engine-Driven Pump
Chip Collectors
Sight Gauge
Ground Service Panel
Monitoring & Control
Protection Units (MCPU)

APU Pump
Trim Tank Check Valve
HTP Ducting
Supplemental
Cooling System

HP Air Ground Connector


Slat Drive System
CFRP Main Deck Struts
CFRP Upper Deck Struts
GR7200 EBU
QDM
Carbon Main Breaking Seals
Flexible Hose Assemblies
Rynglok Fittings

Cabin Water Drain


Valve
Trim Pumps
Flexible Hose Assemblies
Rynglok Fittings
Wing Transfer Fuel Pumps

Feed Fuel Pumps


Pressure Holding Valves
Fuel Transfer Jet Pumps
EBH Accumulators
Wing Transfer Fuel Pump

EATON CORPORATION AEROSPACE C5-37A June 2006

Ground Service Panel


Eaton's Ground Service Panel is
situated in the hydraulic bay of
the A380 aircraft and integrates
eleven different equipment packages, which are used to monitor
and maintain the two hydraulic
systems. The main components
of the system include the pressure and level gauges used to
monitor the reservoir air-pressurization and fluid levels, a hand
pump used to refill the hydraulic
reservoir, and some valves used
to control the fluid and the air
pressurization during the refilling
operation of the hydraulic reservoirs.

Reservoir
Green Circuit

Reservoir
Yellow Circuit

Reservoir
Air Pressure
Gauges

Reservoir
Level Adjustment
Indicator

Reservoir
Air Pressurisation
Valve

Reservoir Filling
Selector Valve
Green & Yellow System
Pressure Gauges
RSVR Filling Filter

Hand Pump, Handle


& filling coupling

Reservoir Air
Depressurisation
Switches

Reservoir Filling
Protection Coupling

Filling Hose
Ground Pressure
Supply

Engine Driven Pump

Fire Shut-Off Valve (FSOV)

AC Motorpump

Motor Switching Unit (MSU)

On the A380 there are eight Eaton


Vickers brand Engine Driven
Pumps (EDP) which provide the
main hydraulic power for the 5000
psi system. Each EDP is powered
by the engine accessory gear box
and delivers a rated flow of 160
l/min (42 gpm) at 3775 rpm. The
pump integrates an 11 piston rotating group coupled with a spherical
type attenuator, a boost impeller,
an electrical de-pressurization
valve, and a scavenge pump. The
pump also includes a clutch mechanism which allows disconnection
of the pump from the engine gear
box in flight or on the ground.

The A380 is fitted with four Fire


Shut-Off Valves. The valves are
used to shut-off the hydraulic
line at the pump inlet in the
event of major system or engine
failure.

The 21,3 kw 5,000 psi AC


Motorpump is the largest developed to date for an aircraft. Each
Eaton Vickers brand AC
Motorpump is powered by 115
VAC 400 Hz constant frequency
and can deliver a max flow of
38 l/min (10 gpm) with a constant horse power characteristic.
The unit is controlled by two
particular subsystems, the
Monitoring and Control
Protection Units (MCPU) and
Motor Switching Units (MSU).
There are four AC Motorpumps
per aircraft.

There are two Eaton Vickers


brand Motor Switching Units per
A380 aircraft. Each MSU comprises two Eaton power contactors, carrying electrical power to
two Electro Motor Pumps. The
contactors of the MSU are controlled by the Motor Control and
Protection Unit and are used to
stop the EMP in the event of
any fault condition being detected.

The FSOV is fitted with size 32


hydraulic ports and is designed
for a nominal flow of 350 l/min
under a pressure of 220 psi.
The unit integrates a high precision electrical motor which is
powered under 28Vdc. The
motor has been specially optimized for very low electrical
consumption, allowing a significant weight reduction of the aircraft cabling.

EATON CORPORATION AEROSPACE C5-37A June 2006

Monitoring and Control


Protection Units (MCPU)
The A380 has two Eaton
Vickers brand MCPUs per aircraft. The system integrates particular protection functions to
ensure total safety during operation of the unit as well as a
control system managing the
starting sequence of the unit.

Slat Drive System

Oil Filler

Eatons Vickers brand Slat Drive


System integrates a bi-directional
variable displacement hydraulic
motor and sensors to provide
closed loop motor control, and a
brake release mechanism with
an associated control valve.

Eatons Oil Filler provides a high security oil fill cap for the auxiliary power
unit on the A380.

Chip Detector
Eatons Tedeco brand chip
detectors are provided for the
Trent 900 jet engine. The Chip
Detectors detect and collect ferrous wear particles in the engine
lubrication system.

The A380 aircraft is the first


commercial aerospace platform
using variable displacement
hydraulic motors to drive the
secondary flight controls.

Oil Fill Valve

Sight Gauge

When the A380s oil level in the auxiliary power unit reaches valve seat,
Eatons Oil Fill Valve closes to hold
the oil level at the preset point.

Eatons Tedeco brand sight gauge is


mounted to the exterior of a tank or
housing to provide visual indication of
a liquid over a wide range.

Quantitative Debris Monitor


System & Lubriclone
Eatons QDM Sensors are provided for the GP7200 engine used on
the A380 aircraft. Tedeco brand
QDMs generate an electrical pulse
proportional to the mass of ferrous
wear particles to signal an early
warning of potential failure of lubricated engine gears and bearings.
The sensor is mounted in a
Lubriclonecyclonic separator that
removes entrained air from the
scavenged oil while providing a quiescent area for the sensor to capture the debris with high efficiency.

Power Contactor
The A380 is supplied with three
pole single throw 115VAC 400Hz
AC contactors. Four Power
Contactors are integrated in each
Motor Switching Unit to control
the starting sequence of the AC
Hydraulic Pump Motors.

EATON CORPORATION AEROSPACE C5-37A June 2006

Flexible Hose Assemblies

Rynglok Fittings

Check Valves

Eatons Aeroquip brand assemblies are utilized extensively


throughout the A380 aircraft.
The standard wire braided technology is being used for the low
and medium pressure hose
assemblies and the Kevlar
braise technology is being used
for the high pressure hose
assemblies.

Eatons Aeroquip brand


Rynglok type fittings are all permanent high pressure connections for the A380 hydraulic system, which are also qualified as
a repair method for the operators.

A new generation of Eatons


Aeroquip brand Check Valves
have been designed and qualified for the A380. These check
valves are optimized for very low
pressure drops in a reduced
envelope and weight, while
maintaining extra long life.

High Pressure Maintenance


Free Accumulator (HPMFA)
These accumulators are precharged with Helium and are
operating with either 5000 psi
or 6000 psig of hydraulic fluid.
Located in various areas of the
A380, the accumulators are part
of the hydraulic generation of
the A/C. In addition to dampening the pulsations of the pumps
and absorbing the pressure
spikes which are inerrant to any
hydraulic circuit, they also
respond to the instantaneous
flow demands that the system
is not able to supply.
The accumulators are also primarily used to maintain the
brakes of the aircraft during
parking mode and are used as a
backup solution for the emergency braking of the Body
Landing Gear and the Wings
Landing Gears. As well, they
are used on the Steering Local
Electro-Hydraulic Generation
System (LEGHS) of the aircraft.

Rudder Electric Back-up


Hydrostatic Actuator Reservoir
Eaton supplies four maintenance
free reservoirs per A380. These
are part of the Rudder Electric
Back-up Hydrostatic Actuator
(EBHA).

Centurion Mechanical Seals

Electro-Hydraulic Reservoir

Steering Reservoir

Eaton provides Centurion


Mechanical Seals for the
GP7200 engine. These are stationary, face type seals
designed for managing high
speed, large axial movement
and high pressure applications.

Eaton supplies maintenance free


reservoirs for the A380. These
are part of the Aileron and the
Elevator Electro-Hydraulic
Actuators (EHA).

Eaton supplies one steering


reservoir per A380. It is part of
the Steering Local ElectroHydraulic Generation System
(LEGHS). This reservoir uses a
metal bellow to separate the
gas from the fluid. It is Helium
pre-charged and sealed at
Eaton for the life of the aircraft.
The reservoir is equipped with
a dual electrical and visual level
volume indicator. The electrical
information is transmitted to
the Electric Control Unit (ECU )
that will automatically control
the fluid refilling of the reservoir
when a low level is reached.

These are metal bellow reservoirs that are pre-charged with


33 cu.in of helium and are working at 350 psig max. They are
design to operate 5000 psig of
hydraulic pressure.

EATON CORPORATION AEROSPACE C5-37A June 2006

These are metal bellows reservoirs. They are pre-charged with


helium and are working at 870
psig max. They are design to
opeate at 5000 psig of hydraulic
pressure.

Electrically Driven Fuel Pumps


Eaton supplies a total of 21 electrically driven fuel pumps and
associated canisters for each A380 aircraft. The pumps are used to
transfer fuel from the various tanks to the aircraft's engines, and
between tanks during flight. There are three main different pump
types - Transfer, Engine Feed and Trim - operating from a variable
frequency power supply which has required the development of new

fuel pump technology. The pumps use brushless dc motors, with


power conditioning and control electronics incorporated in the
pumps, and use the fuel itself as a cooling medium. The pumps are
fitted in tank mounted canisters which allow them to be removed
without the need to drain the fuel tank.

Engine Feed Fuel Pump

Wing Transfer Fuel Pump

Trim Transfer Fuel Pump

APU Fuel Pump

Eight engine feed pumps are


used to supply fuel to the
engines.

Ten wing transfer pumps are


fitted in the wings of the A380
to transfer fuel between the
different fuel tanks.

Two trim transfer pumps are


mounted in the horizontal tail
plane to move fuel between
the centre tank and the tail
tank to help trim the aircraft.

One fixed frequency APU


pump is fitted to supply fuel to
the Auxiliary Power Unit.

Jet Pumps

Hydraulic Sliding Unions

Eaton supplies four jet pumps


per aircraft for some inter-tank
fuel transfers. This type of
pump is not as efficient as an
electrical pump but having no
moving parts offers high reliability.

The A380 Sliding Unions are


installed in the rear spar area
of the wings and in the inner
pylons. Their function is to
cater for expansion and contraction of pipe length due to
thermal changes, and movements due to significant wing
deflection. They are part of the
Hydraulic Power Distribution
System, which delivers the
hydraulic pressure to the different consumers such as
ailerons, elevators, rudder,
landing gear etc.

Collector Cell Pressure


Holding Valve

Horizontal Tail Plane (HTP)


Ducting

The valve prevents flow from


the collector cell back into the
feed tank following a pump
shut off. It will also act as a
non-return valve to prevent recirculation of flow through the
feed pump that is not
operating.

Horizontal Tail Plane Refuel,


Transfer & Vent System
Ducting.

EATON CORPORATION AEROSPACE C5-37A June 2006

Trent 900 Engine Build-Up


(EBU)
Eaton is a key supplier in the
development and manufacture
of the EBU for the Trent 900
Engine. The EBU has nine sub
systems; ECS (Cabin Air),
Starter Air, Thermal Anti-ice,
Hydraulics, Variable frequency
generator (VFG) Cables, VFG
Cooler Pipes, Drains and Fireextinguishing. The nine EBU
sub systems contain more
than 85 Eaton designed
components.

High Pressure Air Ground


Connector with Non-Return
Valve
Used for high pressure air supply for engine starting from an
external compressor three
inch connector for a standard
pneumatic connection, (3 per aircraft).

10

Composite Struts

Composite Shafts

Water Drain Valve

Eatons very lightweight and


strong structural struts perform
two primary functions, they
stiffen the floor by reducing the
free bending length of the
beams, and working as
cantilever pivots, they help
prevent fuselage distortion. The
upper deck longitudinal struts
form part of the connection
between the fuselage and the
structural ceiling, performing a
similar job to the main deck
struts. They also triangulate the
joint between the beam and
the ribs stiffening and
strengthening the structure.
Eaton supplies a total of 95
struts for the main deck floor
and 74 for the upper deck per
aircraft in a varying sizes

Eatons very lightweight carbon


reinforced plastic tubes, made
using a filament winding
process, provide the
transmission shafts for taking
power from rotary actuators to
operate flaps and slats in the
aircraft wings. There are 41 flap
shafts and 62 slat shafts of
varying sizes per aircraft.

The water train valve is a


lightweight composite
component designed to drain
waste water in a continuous
cycle via the outlet connection.
The unit acts as an air stop
device to prevent loss of cabin
pressure through the normally
open sink, and a backflow
prevention device is
incorporated within the
assembly.

Supplemental Cooling System


Reservoir

Trim Tank Check Valve

There are two Bellows reservoirs for the supplemental cooling system of the A380. The
reservoirs are used to compensate for the thermal expansion
of the closed circuit and to provide a minimum pressure to the
pumps that will circulate the
Galden fluid all over the aircraft
in the galleys and the electronic
compartments of the aircraft.
These reservoirs are equipped
with a monitoring device that
permanently controls the
remaining fluid volume.

EATON CORPORATION AEROSPACE C5-37A June 2006

The Trim Tank Check Valve is a


non-return valve mounted
within the Horizontal Tail Plane
(HTP), between the Trim Tank
and the Trim Vent Tank of all
A380 variants. Its main
function is to allow the
drainage of the Vent Tank to the
Trim Tank.

Eaton Corporation
Aerospace Operations
3 Park Plaza Suite 1200
Irvine, California 92614
Phone: (949) 253-2117
Fax:
(949) 253-2111
http://www.aerospace.eaton.com

Eaton Corporation
Actuation Systems
4690 Colorado Blvd.
Los Angeles, California 90039
Phone: (818) 409-0200
Fax:
(818) 241-3772

Eaton Corporation
Actuation Systems
P.O. Box 872
3675 Patterson Avenue
Grand Rapids, Michigan 49588-0872
Phone: (616) 949-1090
Fax:
(616) 949-2744

Eaton Corporation
Fluid Conveyance
Route 2 Box 361
Meadowbrook Road
Eastanollee, Georgia 30538
Phone: (706) 779-3351
Fax:
(706) 779-2638

Eaton Corporation
Fluid Conveyance
2500 W. Argyle St.
P.O. Box 1845
Jackson, MI 49202-1845
Phone: (517) 787-8121
Fax:
(517) 789-4716

Eaton Corporation
Fluid Conveyance
300 South East Avenue
Jackson, Michigan 49203-1972
Phone: (517) 787-8121
Fax:
(517) 787-5758

Eaton Corporation
Fluid Conveyance
11642 Old Baltimore Pike
Beltsville, Maryland 20705
Phone: (301) 937-4010

Eaton Corporation
Fluid Conveyance
Fluid Conveyance
15 Pioneer Ave.
Warwick, Rhode Island 02888
Phone: (401) 781-4700

Eaton GmbH
Fluid Conveyance
Posttach 1026
Carl -Benz-Strasse 9
D-82205 Gilching
Germany
Phone: (49) 810-575-0
Fax:
(49) 810-575-27

Eaton S.A.
Fluid Conveyance
Chemin De Pau
64121 Serres-Castet
France
Phone: (33) 559-333-864
Fax:
(33) 559-333-865

Eaton Aviation SAS


Fluid Conveyance
30 bix, rue du Vieil Abreuvoir
78100 Germain-en-laye
France
Phone: +33 (130) 87 04 04
Fax: +33 (130) 87 03 84

Eaton S.A.
Fluid Conveyance
2 Rue Lavoistier BP 54 78310
Coignieres, France
Phone: +33 1-30-69-3000

Eaton Limited
Fluid Conveyance
Broad Ground Road
Lakeside
Redditch
Worcs B98 8YS
England
Phone: (44) 152-751-7555
Fax:
(44) 152-751-7556

Eaton Corporation
Fluid Power
5353 Highland Drive
Jackson, Mississippi 39206-3449
Phone: (601) 981-2811
Fax:
(601) 987-5255

Eaton Limited
Fluid Power
Larchwood Avenue
Bedhampton
Havant Hampshire P09 3QL
Phone: (44) 2392-487260
Fax:
(44) 2392-492400.

Eaton Aerospace Limited


Fuel Power
Abbey Park
Titchfield, Fareham
Hampshire
PO14 4QA
United Kingdom
Phone: +44 (0) 1329 853000
Fax: +44 (0) 1329 853797

Eaton Corporation
Sensing & Controls
24 E. Glenolden Avenue
Glenolden, Pennsylvania 19036
Phone: (610) 522-4000
Fax: (610) 522-4900

Eaton Corporation
Sensing & Controls
15 Durant Avenue
Bethel, Connecticut 06801
Phone: (800) 736-1557
Fax:
(203) 796-6313

Eaton Corporation
Sensing & Controls
3184 Pullman
Costa Mesa, California 92626
Phone:
(800) 300-9320
Phone:
(949) 642-2427
Fax:
(949) 722-4475

Eaton Corporation
Sensing & Controls
2250 Whitfield Avenue
Sarasota, Florida 34243
Phone: (800) 955-7354
Fax:
(941) 751-7173

2006 Eaton Corporation


All Rights Reserved
Printed in USA
Copying or Editing is Forbidden
Form No. C5-37A
June 2006

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