Electric drive systems for multifunctional trailing-edge control surfaces: Dynamic and thermal characterization under simulated flight loads

Reducing block fuel consumption remains a critical objective in the aircraft industry, driving the development of more aerodynamically efficient designs. High-aspect-ratio wings offer superior lift-to-drag ratios and are key enablers for next-generation fuel-efficient aircraft. However, their increased span leads to higher wing root bending moments and greater susceptibility to aeroelastic instabilities such as flutter. To mitigate these challenges, fast-acting moveables can be integrated into the wing trailing edge to enable active load alleviation and flutter suppression. This study investigates the mechanical and thermal performance limitations of electric servo actuators driving multifunctional trailing-edge panels and proposes a generalized characterization method for their use in aircraft primary control surfaces. The actuators were integrated into a representative wing section and subjected to representative aerodynamic loads. The actuator's operating envelope was assessed under various dynamic control scenarios, revealing that thermal limitations primarily constrain permissible operating times. Results indicate that while the actuator can exceed its rated operational envelope, it quickly reaches thermal limits during highly dynamic control scenarios, leading to actuator shutdown in under under these conditions. A Python-based zero-dimensional thermal model was developed that accurately replicates the actuator's thermal behavior compared to experimental data. The test rig provides a suitable environment for system characterization, actuator certification, and model validation. Based on these findings, design enhancements were implemented in the fairings of the Airbus eXtra Performance Wing demonstrator to reduce the risk of actuator overheating. Future work will employ a real-time, state-space aircraft model for hardware-in-the-loop simulations of full-flight missions, including gust load scenarios. • Simplified test rig represents wing section with electric actuator and MFTE panel. • Test rig replicates boundary conditions of complex flight maneuvers. • Thermal limits constrain actuator use under highly dynamic flight control scenarios. • 0D thermal model predicts actuator temperatures with less than 2 K mean deviation. • Fairing redesign enables airflow intake and extends maximum actuator operation time.