Flight control surfaces guarantee a safe and precise control of the aircraft. As a result, hinge moments are generated. These moments need to be estimated in order to properly size the aircraft actuators. Control surfaces include the ailerons, rudder, elevator, flaps, slats, and spoilers, and they are moved by electric or hydraulic actuators. Actuator sizing is the key when comparing different flight control system architectures. This fact becomes even more important when developing more-electric aircraft. Hinge moments need to be estimated so that the actuators can be properly sized and their effects on the overall aircraft design are measured. Hinge moments are difficult to estimate on the early stages of the design process due to the large number of required input. Detailed information about the airfoil, wing surfaces, control surfaces, and actuators is needed but yet not known on early design phases. The objective of this paper is to propose a new methodology for flight control system sizing, including mass and power estimation. A surrogate model for the hinge moment estimation is also proposed and used. The main advantage of this new methodology is that all the components and actuators can be properly sized instead of just having overall system results. The whole system can now be sized more in detail during the preliminary design process, which allows to have a more reliable estimation and to perform systems installation analysis. Results show a reliable system mass estimation similar to the results obtained with other known methods and also providing the weight for each component individually.
