Force balance sensor and method for use therewith

Abstract

The present invention relates to a force balance sensor and a method for the same. A force balance sensor (100) includes a mechanical strain amplification system (130), the mechanical strain amplification system comprising: a sensor torsion member (110), the sensor torsion member having a first end (110a) and a second end (110b) spaced apart from each other along a longitudinal axis (110LA) of the sensor torsion member (110); at least one strain sensor (120), the at least one strain sensor coupled to the sensor torsion member (110) between the first end (110a) and the second end (110b); a first torsion reinforcement member (131) coupled to the first end (110a) of the sensor torsion member (110); and a second torsion reinforcement member (132) coupled to the second end (110b) of the sensor torsion member (110), wherein the first torsion reinforcement member (131) and the second torsion reinforcement member (132) are coupled to a torsion-resistant member (1002T).

Description

Technical Field

[0001] The exemplary embodiments relate generally to force balance sensors and, more particularly, to force balance sensors for flight control surfaces. Background Art

[0002] Typically, a flight control surface is operated by two actuators arranged on either side of the flight control surface. The actuators are driven by a controller and commanded by the controller to substantially the same position to adjust the positioning of the flight control surface. When calibrating and / or installing the actuators, small vibrations between the two actuators can result in a slight position difference between the two actuators, resulting in a possible flight control surface position error.

[0003] Additionally, even if the actuators are perfectly located in their positions, installation variations such as variations in the length of the horn radius between the two actuators can present a torque difference (also called force-fight) between the two flight control surface ends, and therefore a force difference on the actuators. This force difference on the actuators is difficult to account for by calibration. Typically, this force difference is supported by the torque placed on the flight control surface, which causes loads that can affect the useful life of the flight control surface.

[0004] The traditional solution to force disputes is based on the use of multiple pressure sensors that sense the pressure generated by the two actuators. The pressure sensors are placed to sense the pressure difference across the corresponding actuators. In some systems, in order to achieve triple redundant sensing (i.e., using three functionally equivalent units to provide redundancy), for example, 12 separate pressure transducers / sensors and associated signal processing electronics are used on the actuators to determine the force balance error between the actuators. In some cases, the use of multiple sensors may increase the force difference and produce counterproductive effects.

[0005] In another conventional solution, a torque sensor is placed in series between each horn and the torsion bar. Generally there is a torque sensor for each actuator, each generating a sensor signal for determining the force balance error between the actuators. Placing the torque sensor in series with the horn and the torsion bar (i.e., in the load path of the torsion bar) may detract from the stiffness of the torsion bar and effectively reduce the stiffness of the torsion bar to the stiffness of the torque sensor. Summary of the invention

[0006] Thus, apparatus and methods directed to addressing at least the concerns discussed above would find use.

[0007] The following is a non-exclusive list of embodiments according to the disclosed subject matter, which may or may not be claimed.

[0008] One embodiment according to the disclosed subject matter relates to a force balance sensor, the force balance sensor including a mechanical strain amplification system, the mechanical strain amplification system including: a sensor torsion member, the sensor torsion member having a first end and a second end spaced apart from each other along a longitudinal axis of the sensor torsion member; at least one strain sensor, the at least one strain sensor coupled to the sensor torsion member between the first end and the second end; a first torsion reinforcement member coupled to the first end of the sensor torsion member; and a second torsion reinforcement member coupled to the second end of the sensor torsion member, wherein the first torsion reinforcement member and the second torsion reinforcement member are coupled to a torsion-resistant member.

[0009] Another embodiment according to the disclosed subject matter is directed to an aircraft, the aircraft comprising: a fuselage; a control surface having a control surface frame, the control surface frame being pivotally coupled to the fuselage by a torsion member; a first actuator, the first actuator coupled to a first end and configured to pivot the control surface about a longitudinal axis; a second actuator, the second actuator coupled to a second end and configured to pivot the control surface about the longitudinal axis; a force balance sensor, the force balance sensor comprising a mechanical strain amplification system, the mechanical strain amplification system comprising: a sensor torsion member, the sensor torsion member having a first end and a second end spaced apart from each other along the longitudinal axis of the sensor torsion member; at least one strain sensor, the at least one strain sensor coupled to the sensor torsion member between the first end and the second end; a first torsion reinforcement member coupled to the first end of the sensor torsion member; and a second torsion reinforcement member coupled to the second end of the sensor torsion member, wherein the first torsion reinforcement member and the second torsion reinforcement member are coupled to the torsion member of the control surface.

[0010] Yet another embodiment in accordance with the disclosed subject matter relates to a method for controlling a control surface of an aircraft, the method comprising: actuating, by a controller, a first actuator and a second actuator to pivot the control surface relative to a fuselage about a longitudinal axis of a torsion member, wherein the torsion member pivotally couples a control surface frame of the control surface to the fuselage, and the first actuator and the second actuator are coupled to the torsion member at respective opposite ends of the torsion member to pivot the control surface; sensing strain on the torsion member by a force balance sensor disposed between opposite ends of the torsion member, the force balance sensor comprising a mechanical strain amplification system comprising a sensor torsion member, at least one strain sensor coupled to the sensor torsion member between a first end and a second end of the sensor torsion member, a first torsion stiffening member coupled to the first end of the sensor torsion member and the torsion member, and a second torsion stiffening member coupled to the second end of the sensor torsion member and the torsion member; and adjusting, by the controller, actuation of one or more of the first actuator and the second actuator based on the mechanically increased strain sensed by the at least one strain sensor. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Having thus generally described embodiments of the present disclosure, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, wherein like reference numerals refer to the same or similar parts throughout the several views, and wherein:

[0012] Figure 1 is a schematic illustration of an aircraft according to one or more aspects of the present disclosure;

[0013] Figure 2 is a top perspective view of a control surface and a control surface actuation system according to one or more aspects of the present disclosure;

[0014] Figure 3 is a top perspective view of a force balance sensor according to one or more aspects of the present disclosure;

[0015] Figure 4A According to one or more aspects of the present disclosure Figure 3 A side perspective view of a portion of a force balance sensor;

[0016] Figure 4B According to one or more aspects of the present disclosure Figure 3 A side perspective view of a portion of a force balance sensor;

[0017] Figure 4C According to one or more aspects of the present disclosure Figure 3 A side perspective view of a portion of a force balance sensor;

[0018] Figure 5 According to one or more aspects of the present disclosure, Figure 2 A method for controlling a control surface of an aircraft using a force balance sensor; and

[0019] Figure 6 It is a flow chart of the aircraft manufacturing and maintenance methods. DETAILED DESCRIPTION

[0020] Reference Figures 1 to 3 Aspects of the disclosure described herein provide a force balance sensor 100 that is integral with a flight control surface 1002 and that can measure differential torque (also referred to as force strife) induced in the control surface 1002 due to, for example, differences in forces applied at the various actuators 1010, 1020. The force balance sensor 100 is configured to increase the mechanical strain of the sensor torsion member 110 of the force balance sensor 100 relative to the torsion member 1002T of the flight control surface 1002 by increasing the magnitude of the torsional strain on the sensor torsion member 110 so that an electrical signal (of at least one strain sensor 120 of the force balance sensor 100) that is proportional to the torque imbalance of the actuator controller is above a lower noise threshold of the at least one strain sensor 120. The mechanical strain is a function of the surface stiffness and, for the aircraft 1000, is too low to be measured by the at least one strain sensor 120 due to electrical noise. Some aspects of the present disclosure increase the mechanical strain of the sensor torsion member 110 by mechanically increasing the magnitude of the torsional strain on the sensor torsion member 110 to cause the electrical signal of the at least one strain sensor 120 to be above the lower noise threshold.

[0021] As will be described herein, the force balance sensor 100 is configured to: isolate and mechanically increase shear stress, measure torque differences across the control surface 1002, such as between actuators 1010, 1020, reduce complexity compared to other conventional approaches (e.g., by employing fewer sensors and associated electronics), reduce the contribution of sensor errors while measuring torque differences between actuators 1010, 1020, and reduce the number of sensors compared to conventional sensor configurations. Exemplary, non-exclusive embodiments (which may or may not be claimed) in accordance with the disclosed subject matter are provided below.

[0022] Still refer to Figures 1 to 3In one aspect, the force balance sensor 100 described herein for sensing mechanical strain across at least one control surface 1002 of an aircraft 1000 includes a mechanical strain amplification system 130 having a sensor torsion member 110, at least one strain sensor 120, a first torsion stiffening member 131A, 131B, 131C (generally referred to as the first torsion stiffening member 131), a second torsion stiffening member 132A, 132B, 132C (generally referred to as the second torsion stiffening member 132), a first torsion rod end connection member 136, and a second torsion rod end connection member 137. Generally, the torsional stiffness of the control surface 1002 is generally such that any mechanical strain sensed by the at least one strain sensor 120 is likely to be within the signal noise (i.e., a low amplitude signal) generated by the at least one strain sensor 120. To make the signal generated by the at least one strain sensor 120 usable, the mechanical strain amplification system 130 is configured to mechanically increase the signal generated by the at least one strain sensor 120 such that the sensor signal is above a noise threshold of the at least one strain sensor 120 .

[0023] The force balance sensor 100 is configured such that the at least one strain sensor 120 senses torsional deformation of the sensor torsion member 110 of the mechanical strain amplification system 130 coupled to the torsion member 1002T of the control surface 1002. The mechanical strain amplification system 130 increases the signal sensed by the at least one strain sensor 120 to an accessible level above a noise threshold (i.e., above the level of noise generated by the at least one strain sensor 120 so that the signal can be obtained).

[0024] It should be noted that although the force balance sensor 100 is described herein with respect to torsional deformation of a control surface 1002 of an aircraft 1000 (e.g., a flap 1002F, a slat 1002S, an aileron 1002A, an elevator 1002E, a rudder 1002R, or any other suitable control surface), in other aspects, the force balance sensor 100 may be used in any suitable industry where it is desired to measure torsional deformation of a torsional member, such as marine, automotive, aerospace, etc. It should also be noted that although Figure 1 The aircraft 1000 shown in FIG. 1 is shown as a fixed-wing aircraft, but in other aspects the aircraft may be a rotary-wing aircraft or any other suitable aircraft.

[0025] like Figure 2As shown, a first actuator 1010 is coupled to a first end 1002E1 of a torsion member 1002T. The first actuator 1010 is further coupled to the fuselage 1001 in any suitable manner. A second actuator 1020 is coupled to a second end 1002E2 of the torsion member 1002T. The second actuator 1020 is also coupled to the fuselage 1001 in any suitable manner. Both the first actuator 1010 and the second actuator 1020 are configured to pivot the control surface 1002 about a longitudinal axis 1002LA of the torsion member 1002T (e.g., by extension and retraction of the actuator). The torsion member 1002T forms a primary load path or strain path between the two actuators 1010, 1020.

[0026] In one aspect, the torsion member 1002T is a hollow tube 1002HT ( Figure 3 ), wherein the mechanical strain amplification system 130 is arranged in the interior 1002IT of the hollow tube 1002HT. In other aspects, it can be compared with the Figure 4B and Figure 4C The mechanical strain amplification system 130 is coupled to the outer surface of the hollow tube 1002HT in a similar manner as described above. The hollow tube 1002HT can be coupled to the control surface 1002 in any suitable manner so that as the hollow tube 1002HT pivots about the longitudinal axis 1002LA, the control surface 1002 and the hollow tube 1002HT pivot as a single unit. In another aspect, the torsion member 1002T is a solid rod 1002SR having an outer portion 1002ET (i.e., no inner surface, Figure 4B ), wherein the mechanical strain amplification system 130 is arranged on the outer portion 1002ET of the solid rod 1002SR ( Figure 4B and Figure 4C ). In one aspect, the torsion member 1002T may be a combination of a solid rod and a hollow tube or any other suitable member having any suitable shape.

[0027] Still refer to Figures 2 to 4C As described above, the force balance sensor 100 generally includes a mechanical strain amplification system 130, which has a sensor torsion member 110, at least one strain sensor 120, a first torsion reinforcement member 131, and a second torsion reinforcement member 132. The mechanical strain amplification system 130 is arranged on or in the torsion member 1002T, and forms a secondary strain path between the first actuator 1010 and the second actuator 1020. The mechanical strain amplification system 130 generally has a lower stiffness than the torsion member 1002T that forms the primary strain path.

[0028] The mechanical strain amplification system 130 extends a distance D along the longitudinal axis 1002LA of the torsion member 1002T. In one aspect, the distance D can span the entire length of the torsion member 1002T or any suitable distance along the torsion member 1002T to increase the stiffness of the torsion member 1002T and increase the strain of the sensor torsion member 110, which will be further described herein. The distance D can also be generally related to the material used for one or more of the sensor torsion member 110, the first / second torsion reinforcement members 131, 132, and the control surface 1002.

[0029] In one aspect, the torsional stiffness of the torsion member 1002T is increased by the mechanical strain amplification system 130 so that kt=k1 TM +k2 MSA , where kt is the total stiffness, k1 TM is the stiffness of the torsion member, k2 MSA is the stiffness of the mechanical strain amplification system 130. In one aspect, the sensor torsion member 110 forms a torsion bar or tube disposed on or within a torsion member 1002T of the control surface 1002. The sensor torsion member 110 includes a first end 110E1 and a second end 110E2 spaced apart from each other along a mechanical strain amplification longitudinal axis 130LA of the mechanical strain amplification system 130, which may coincide with the longitudinal axis 1002LA of the torsion member 1002T. The first end 110E1 and the second end 110E2 are spaced apart from each other by a distance Y ( Figure 3 ). The distance Y may span any suitable length of the control surface 1002. In one aspect, the distance Y may be generally related to the material used for one or more of the torsion member 1002T, the first / second torsion stiffening members 131, 132, and the control surface 1002 (i.e., the material used may determine whether a larger or smaller sensor torsion member 110, and thus a larger or smaller distance Y, is needed to sense torsion on the torsion member 1002T).

[0030] In one aspect, the sensor torsion member 110 is a hollow tube 110HT ( Figure 4B and Figure 4C), wherein at least one strain sensor 120 is arranged on the outer portion 110ET of the hollow tube 110HT. The hollow tube 110HT can be coupled to the control surface 1002 in any suitable manner so that as the torsion member 1002T twists, the hollow tube 110HT twists relative to the control surface 1002. In other aspects, the sensor torsion member 110 can be a solid rod 110SR (i.e., without an inner surface) having an outer portion 110ET, wherein at least one strain sensor 120 is arranged on the outer portion 110ET of the solid rod 110SR. In one aspect, the sensor torsion member 110 can be a combination of a solid rod and a hollow tube or any other suitable member having any suitable shape. The sensor torsion member 110 is configured to have a material stiffness that is substantially lower than the torsion member 1002T, the first torsion reinforcement member 131, and the second torsion reinforcement member 132, which will be further described below.

[0031] Still refer to Figures 2 to 4C , the at least one strain sensor 120 is configured to sense strain applied to the sensor torsion member 110 (e.g., torsion of the sensor torsion member 110), for example, during pivotal movement of the control surface 1002 due to actuation of the first actuator 1010 and the second actuator 1020. In one aspect, the at least one strain sensor 120 is disposed within the torsion member 1002T such that the torsion member 1002T forms an electromagnetic shield for the at least one strain sensor 120 (i.e., the at least one strain sensor 120 is disposed within the torsion member 1002T such that the torsion member 1002T forms a Faraday cage around the at least one strain sensor 120 to guard or protect the at least one strain sensor 120 from electromagnetic interference). In one aspect, the at least one strain sensor 120 may be disposed within the sensor torsion member 110 to electromagnetically shield the at least one strain sensor 120, for example, when the sensor torsion member 110 is coupled to an exterior of the torsion member 1002T.

[0032] In one aspect, the first torsion reinforcement member 131 is coupled to the first end 110E1 of the sensor torsion member 110. The second torsion reinforcement member 132 is coupled to the second end 110E2 of the sensor torsion member 110. In one aspect, the first torsion reinforcement member 131 and the second torsion reinforcement member 132 each extend a respective predetermined longitudinal length 131L, 132L ( Figure 3). The first torsion reinforcement member 131 and the second torsion reinforcement member 132 are configured to increase the torsional stiffness of the torsion member 1002T over the length of the mechanical strain amplification system 130. The material stiffness of each of the first torsion reinforcement member 131 and the second torsion reinforcement member 132 is higher than the material stiffness of both the sensor torsion member 110 and the torsion member 1002T, while the sensor torsion member 110 has a lower material stiffness than the torsion member 1002T and the first torsion reinforcement member 131 and the second torsion reinforcement member 132.

[0033] Each of the first torsion reinforcing member 131 and the second torsion reinforcing member 132 having a higher material stiffness than the sensor torsion member 110 increases the torsional stiffness of the sensor torsion member 110 over the respective predetermined longitudinal lengths 131L, 132L. The increased torsional stiffness over the respective predetermined longitudinal lengths 131L, 132L results in an increase in the torsion of the sensor torsion member 110 coupled between the first torsion reinforcing member 131 and the second torsion reinforcing member 132 (i.e., the higher material stiffness of the first torsion reinforcing member 131 and the second torsion reinforcing member 132 reduces the torsion of the mechanical strain amplification system 130 over the respective predetermined longitudinal lengths 131L, 132L, so that any torsion that would occur over the respective predetermined longitudinal lengths 131L, 132L is transferred to the sensor torsion member 110 to mechanically increase the torsion in the sensor torsion member 110). The increase in the torsion of the sensor torsion member 110 thus mechanically increases the strain sensed by the at least one strain sensor 120 (i.e., increases the strain above the lower noise threshold of the at least one strain sensor 120).

[0034] Reference Figure 3 and Figure 4A , will be relative to Figure 4A The first torsion reinforcement member 131A shown depicts the first torsion reinforcement member 131 and the second torsion reinforcement member 132, but it should be understood that the second torsion reinforcement member is substantially similar and includes similar features. As described above, the first torsion reinforcement member 131A and the second torsion reinforcement member 132A are coupled to the sensor torsion member 110 disposed within the interior 1002IT of the torsion member 1002T. Each of the first torsion reinforcement member 131A and the second torsion reinforcement member 132A includes a respective first torsion bar 134A and a second torsion bar 135A. In one aspect, the first torsion bar 134A and the second torsion bar 135A are solid bars 134SR1, 135SR1 disposed within the torsion member 1002T (see Figure 3 ) or hollow tube 134HT1, 135HT1 (see Figure 4A). Each of the first torsion bar 134A and the second torsion bar 135A includes a first torsion bar end 134E1, 135E1 and a second torsion bar end 134E2, 135E2 separated from each other along the mechanical strain amplification longitudinal axis 130LA. Each of the first torsion bar 134A and the second torsion bar 135A is configured so that the first torsion reinforcement member 131 and the second torsion reinforcement member 132 have a higher material stiffness than the sensor torsion member 110 and the anti-torsion member 1002T. For example, each of the sensor torsion member 110 and the anti-torsion member 1002T can be formed of a material having a lower material stiffness than the first torsion bar 134A and the second torsion bar 135A.

[0035] In one aspect, first torsion bar end coupling members 136, 137 are disposed at first torsion bar ends 134E1, 135E1 of each torsion bar 134A, 135A. First torsion bar end coupling members 136, 137 are configured to fixedly couple first torsion bar ends 134E1, 135E1 to torsion member 1002T so that there is substantially no relative movement between torsion member 1002T and each of first torsion bar 134A and second torsion bar 135A.

[0036] On the other hand, if Figure 4B and Figure 4C As shown, the first torsion reinforcement member 131B, 131C and the second torsion reinforcement member 132B, 132C are substantially similar to the first and second torsion reinforcement members 131A, 132, but in this aspect, the first torsion reinforcement member 131B, 131C and the second torsion reinforcement member 132B, 132C are arranged on the outer portion 1002ET of the torsion member 1002T. The first torsion reinforcement member 131B, 131C and the second torsion reinforcement member 132B, 132C include one or more solid rods 134SR2, 135SR2 ( Figure 4C ) or hollow tube 134HT2, 135HT2 (see Figure 4B ) in the form of a corresponding first torsion bar 134B and a second torsion bar 135B.

[0037] In one aspect, the mechanical strain amplification system 130 may further include at least one vibration isolator 138, 139. The vibration isolators 138, 139 may be disposed at respective ends 110E1, 110E2 of the sensor torsion member 110. The at least one vibration isolator 138, 139 is configured to isolate the sensor torsion member 110 disposed on or within the torsion member 1002T from vibrations from the torsion member 1002T. The at least one vibration isolator 138, 139 absorbs and buffers vibrations generated by the torsion member 1002T to limit or reduce vibrations transmitted from the torsion member 1002T to the sensor torsion member 110.

[0038] Now refer to Figure 2 , Figure 3 and Figure 4B In one aspect, the force balance sensor 100 further includes at least one signal amplifier 150 coupled to the at least one strain sensor 120 and configured to electronically amplify a sensor signal generated by the at least one strain sensor 120. In one aspect, the force balance sensor 100 further includes a controller 170 coupled to the at least one strain sensor 120. The controller 170 includes a non-transitory computer program code configured to determine a torsional deformation (i.e., twist) between the first end 110E1 and the second end 110E2 of the sensor torsion member 110 based on the sensor signal received from the at least one strain sensor 120. The controller 170 is further configured to correct the torsional deformation to reduce the twist by actuation of the first actuator 1010 and the second actuator 1020.

[0039] In one aspect, the first torsion bar end coupling members 136, 137 of each of the first and second torsion bars 134A, 134B, 135A, 135B may include at least one aperture 145 (see Figure 4A ). The aperture 145 is configured to allow the wires 170W, 180W to pass through. For example, a power line 180W (such as for providing power 180 to at least one signal amplifier 150 and at least one strain sensor 120) can pass through one or more of the first torsion rod end coupling members 136, 137 and the second torsion rod end coupling members 138, 139. A signal line 170W (such as for providing sensor signals from at least one strain sensor 120 and at least one signal amplifier 150 to the controller 170) can also pass through the first torsion rod end coupling members 136, 137. In one aspect, the power line 180W and the signal line 170W can be arranged on opposite sides of at least the signal amplifier 150 to substantially prevent electromagnetic interference between the power line 180W and the signal line 170W. As an example, power 180 is provided by means of a power line 180W located at the side 1002SS2 of the control surface 1002, while the sensor signal is transmitted by means of a line 170W located at the side 1002SS1. In another aspect, power 180 to and sensor signals from at least one strain sensor 120 and at least one signal amplifier 150 can be provided in any suitable manner. For example, where the torsion member 1002T is solid, the wires 170W, 180W can lead to and from at least one signal amplifier 150 and at least one strain sensor 120 located outside the torsion member 1002T and the first and second torsion stiffening members 131B, 132B.

[0040] Now refer to Figure 5 , a method 400 for controlling a control surface 1002 of an aircraft 1000 using a force balance sensor 100 is shown. In one aspect, a first actuator 1010 and a second actuator 1020 are actuated by a controller 170 to pivot the control surface 1002 relative to the fuselage 1001 about a longitudinal axis 1002LA of a torsion member 1002T (see Figure 5 , box 401).

[0041] During and / or after pivoting of control surface 1002, force balance sensor 100 senses strain applied to sensor torsion member 110 via at least one strain sensor 120 coupled to sensor torsion member 110 between first end 110E1 and second end 110E2 (see FIG. 1 ). Figure 5 , block 402 ). In one aspect, the first torsion stiffening member 131 and the second torsion stiffening member 132 increase the torsional stiffness of the torsion member 1002T such that twisting of the sensor torsion member 110 mechanically increases the strain sensed by the at least one strain sensor 120 .

[0042] In one aspect, the sensor signal corresponding to the mechanically increased strain sensed by the at least one strain sensor 120 is further amplified by the at least one signal amplifier 150 and transmitted to the controller 170. Based on the mechanically increased strain sensed by the at least one strain sensor 120, the positions of the first actuator 1010 and the second actuator 1020 can be adjusted by the controller 170 (see Figure 5 , block 403). Adjusting the position of the first actuator 1010 and the second actuator 1020 reduces distortion of the sensor torsion member 110, and thereby the control surface 1002, to a level below a predetermined strain threshold.

[0043] The controller 170 is configured to receive signals from a number of sensors implemented in the sensor torsion member 110. For example, if more than one sensor 120A, 120B, 120C is provided, such as for triple redundancy (see Figure 4B ) and provide a signal to the controller 170, the controller 170 is configured to determine which sensor signal or combination of sensor signals to use to balance the forces between the two actuators 1010, 1020. The determination of which sensor signal or combination of sensor signals to use can be performed by the controller 170 in any suitable manner, such as by taking an average of the sensor signals, discarding one or more sensor signals if they differ from other sensor signals by a predetermined limit, etc. If one sensor signal differs from the other sensor signals by more than the predetermined limit, the controller 170 can be configured to notify the operator or other personnel of the aircraft 1000 that there is an abnormal sensor reading at the force balance sensor 100 for diagnosis and prognosis.

[0044] Once the selected signal is applied by the controller 170 to correct the torque difference between the two actuators 1010, 1020, the torque difference represented by the sensor signal is reduced, thereby maintaining all other disturbance constants in a closed-loop manner (e.g., the controller 170 can substantially continuously adjust the position of one or more of the actuators 1010, 1020 until the sensor signal received by the controller 170 from the at least one strain sensor 120 (or at least one signal amplifier 150) indicates that the torque difference between the two actuators 1010, 1020 is within a predetermined acceptable range). The selected sensor signal is configured to modify the position signal provided to each actuator 1010, 1020 to change the command position of one or more of the actuators 1010, 1020 to balance the forces between the two actuators 1010, 1020. In one embodiment, for maximum dynamic response, the signal will be halved and set with opposite signs to affect the two actuator position signals. To simplify integration, the entire signal amplitude should be used to modify the position command to only one actuator 1010, 1020. In both cases, the amplitude of the position command change may jump to prevent poor calibration, or to prevent some other problem from causing sufficient position authority to the force balance function to prevent certain failure modes from generating large surface position excursions beyond the nominal surface position required for flight control.

[0045] In one aspect, vibrations of the sensor torsion member 110 are damped by at least one vibration isolator 138 , 139 .

[0046] In one aspect, the torsion member 1002T shields the at least one strain sensor 120 from electromagnetic influences (see Figure 5 , box 404).

[0047] Available in Figure 6 Embodiments of the present disclosure are described in the context of an aircraft manufacturing and maintenance method 500 as shown. In other aspects, embodiments of the present disclosure may be applied in any suitable industry, such as, for example, automotive, marine, aerospace, etc. With respect to aircraft manufacturing, during pre-production, exemplary method 500 may include aircraft 1000 (see Figure 1 ) specifications and design (block 501) and material procurement (block 502). During production, component and subassembly manufacturing (block 503) and system integration (block 504) of aircraft 1000 may occur. Thereafter, aircraft 1000 may be certified and delivered (block 505) to enter service (block 506). While in service, aircraft 1000 may be scheduled for routine maintenance (block 507). Routine maintenance may include modification, reconfiguration, refurbishment, etc. of aircraft 1000, which may include one or more systems utilizing force balance sensors 100 as described herein.

[0048] The various processes of exemplary method 500 may be performed or executed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0049] The apparatus and methods shown or described herein may be employed in any one or more stages of the manufacturing and service method 500. For example, components or subassemblies corresponding to component and subassembly manufacturing (block 503) may be manufactured in a manner similar to the production of components or subassemblies in the commissioning of the aircraft 1000 (block 506). Moreover, one or more embodiments of the apparatus, method, or a combination of these embodiments may be utilized during the production stages 503 and 504, for example, to significantly speed up the assembly of the aircraft 1000 or reduce the cost of the aircraft 1000. Similarly, one or more embodiments of the apparatus or method, or a combination of these embodiments, may be utilized, for example, but not limited to, while the aircraft 1000 is in service (block 506) and / or during maintenance (block 507).

[0050] According to aspects of the present disclosure, the following is provided:

[0051] A1. A force balance sensor, the force balance sensor comprising:

[0052] A mechanical strain amplification system, the mechanical strain amplification system comprising:

[0053] a sensor torsion member having a first end and a second end spaced apart from each other along a longitudinal axis of the sensor torsion member;

[0054] at least one strain sensor coupled to the sensor torsion member between the first end and the second end;

[0055] a first torsion reinforcement member coupled to the first end of the sensor torsion member; and

[0056] a second torsion reinforcement member coupled to the second end of the sensor torsion member,

[0057] Wherein the first torsion reinforcement member and the second torsion reinforcement member are coupled to a torsion-resistant member.

[0058] A2. The paragraph described in A1, wherein torque is transmitted from the torsion member to the sensor torsion member by means of the first torsion reinforcement member and the second torsion reinforcement member to mechanically increase the strain sensed by the at least one strain sensor.

[0059] A3. A paragraph according to A1, wherein the first torsion reinforcement member and the second torsion reinforcement member increase the torsional stiffness of the torsion member over the length of the mechanical strain amplification system, wherein the distortion of the sensor torsion member arranged between the first torsion reinforcement member and the second torsion reinforcement member due to the differential torsional force applied to the opposite ends of the torsion member is increased relative to the distortion of the torsion member over the length of the mechanical strain amplification system to mechanically increase the strain sensed by the at least one strain sensor.

[0060] A4. The paragraph described in A1, wherein the torsion member comprises a hollow tube having an interior, wherein one or more of the at least one strain sensor, the first torsion reinforcing member, and the second torsion reinforcing member are arranged within the interior.

[0061] A5. The paragraph described in A1, wherein one or more of the at least one strain sensor, the first torsion stiffening member, and the second torsion stiffening member are arranged on the exterior of the torsion member.

[0062] A6. The paragraph according to A1, wherein each of the first torsion reinforcement member and the second torsion reinforcement member comprises:

[0063] a torsion bar having a first torsion bar end and a second torsion bar end spaced apart from each other along a longitudinal axis of the mechanical strain amplification system; and

[0064] a first torsion rod end coupling member disposed at the first torsion rod end and configured to fixedly couple the first torsion rod end to the torsion member;

[0065] Wherein the second torsion rod end is configured to be fixedly coupled to the sensor torsion member.

[0066] A7. The paragraph according to A1, wherein the material stiffness of each of the first torsion reinforcement member and the second torsion reinforcement member is higher than the material stiffness of both the sensor torsion member and the anti-torsion member.

[0067] A8. According to the paragraph described in A1, the force balance sensor further includes at least one signal amplifier connected to the at least one strain sensor.

[0068] A9. According to the paragraph described in A1, the force balance sensor further includes a controller connected to the at least one strain sensor, and the controller is configured to determine the torsional displacement between the first end and the second end of the sensor torsion member based on the sensor signal received from the at least one strain sensor.

[0069] A10. The paragraph according to A1, wherein the strain sensed by the at least one strain sensor is mechanically increased so that the strain sensed by the at least one strain sensor affects the signal from the at least one strain sensor to be above a noise threshold of the at least one strain sensor.

[0070] A11. The paragraph described in A1, wherein the at least one strain sensor is coupled to the sensor torsion member such that the torsion member forms an electromagnetic shield for the at least one strain sensor.

[0071] A12. The paragraph according to A1, wherein the torsional stiffness of the torsion member is increased by the mechanical strain amplification system so that kt=k1 TM +k2 MSA , where kt is the total stiffness, k1 TM is the stiffness of the torsion member, and k2 MSA is the stiffness of the mechanical strain amplification system.

[0072] B1. An aircraft, comprising:

[0073] body;

[0074] a control surface having a control surface frame pivotally coupled to the fuselage by a torsion member;

[0075] a first actuator coupled to the first end and configured to pivot the control surface about a longitudinal axis;

[0076] a second actuator coupled to the second end and configured to pivot the control surface about the longitudinal axis;

[0077] A force balance sensor, the force balance sensor comprising:

[0078] A mechanical strain amplification system, the mechanical strain amplification system comprising:

[0079] a sensor torsion member having a first end and a second end spaced apart from each other along a longitudinal axis of the sensor torsion member;

[0080] at least one strain sensor coupled to the sensor torsion member between the first end and the second end;

[0081] a first torsion reinforcement member coupled to the first end of the sensor torsion member; and

[0082] a second torsion reinforcement member coupled to the second end of the sensor torsion member,

[0083] Wherein the first torsion reinforcing member and the second torsion reinforcing member are coupled to the anti-torsion member of the control surface.

[0084] B2. The paragraph according to B1, wherein the torsion member comprises a hollow tube having an interior, wherein one or more of the at least one strain sensor, the first torsion stiffening member, and the second torsion stiffening member are arranged within the interior.

[0085] B3. The paragraph according to B1, wherein one or more of the at least one strain sensor, the first torsion stiffening member, and the second torsion stiffening member are arranged on the exterior of the torsion member.

[0086] B4. The paragraph according to B1, wherein each of the first torsion reinforcement member and the second torsion reinforcement member comprises:

[0087] a torsion bar having a first torsion bar end and a second torsion bar end spaced apart from each other along the longitudinal axis of the sensor torsion member; and

[0088] a first torsion rod end coupling member disposed at the first torsion rod end and configured to fixedly couple the first torsion rod end to the torsion member;

[0089] Wherein the second torsion rod end is configured to be fixedly coupled to the sensor torsion member.

[0090] B5. The paragraph according to B1, wherein the material stiffness of each of the first torsion reinforcement member and the second torsion reinforcement member is higher than the material stiffness of both the sensor torsion member and the anti-torsion member.

[0091] B6. According to paragraph B1, the aircraft further includes at least one signal amplifier connected to the at least one strain sensor.

[0092] B7. According to the paragraph described in B1, the aircraft further includes a controller coupled to the at least one strain sensor, the first actuator and the second actuator, the controller being configured to:

[0093] determining a torsional displacement between the first end and the second end of the sensor torsion member based on a sensor signal received from the at least one strain sensor; and

[0094] One or more of the first actuator and the second actuator are actuated such that twisting of the torsion member is reduced and the sensor signal received from the at least one strain sensor is below a predetermined strain threshold.

[0095] B8. The paragraph according to B1, wherein the strain sensed by the at least one strain sensor is mechanically increased so that the strain sensed by the at least one strain sensor affects the signal from the at least one strain sensor to be above a noise threshold of the at least one strain sensor.

[0096] B9. The paragraph according to B1, wherein the at least one strain sensor is coupled to the sensor torsion member such that the torsion member forms an electromagnetic shield for the at least one strain sensor.

[0097] B10. The paragraph according to B1, wherein the torsional stiffness of the torsion member is increased by the mechanical strain amplification system so that kt=k1 TM +k2 MSA , where kt is the total stiffness, k1 TM is the stiffness of the torsion member, and k2 MSA is the stiffness of the mechanical strain amplification system.

[0098] B11. According to the paragraph described in B1, the aircraft further comprises:

[0099] a controller coupled to the at least one strain sensor via a first coupling; and

[0100] A power source is coupled to the at least one strain sensor through a second coupler, wherein the first coupler extends through the first end of the torsion member and the second coupler extends through the second end of the torsion member to mitigate electromagnetic effects on a sensor signal generated by the at least one strain sensor.

[0101] C1. A method for controlling a control surface of an aircraft, the method comprising:

[0102] The first actuator and the second actuator are actuated by a controller to pivot the control surface relative to the fuselage about the longitudinal axis of the torsion member, wherein

[0103] The torsion member pivotally couples a control surface frame of the control surface to the fuselage, and

[0104] the first actuator and the second actuator being coupled to the torsion member at respective opposite ends of the torsion member to pivot the control surface;

[0105] sensing strain on the torsion member via a force balance sensor disposed between opposite ends of the torsion member, the force balance sensor comprising a mechanical strain amplification system including a sensor torsion member, at least one strain sensor coupled to the sensor torsion member between a first end and a second end of the sensor torsion member, a first torsion reinforcement member coupled to the first end of the sensor torsion member and the torsion member, and a second torsion reinforcement member coupled to the second end of the sensor torsion member and the torsion member; and

[0106] Actuation of one or more of the first actuator and the second actuator is adjusted by the controller based on the mechanically increased strain sensed by the at least one strain sensor.

[0107] C2. A paragraph according to C1, wherein the first torsion reinforcement member and the second torsion reinforcement member extend over a corresponding predetermined longitudinal length of the mechanical strain amplification system and increase the torsional stiffness of the torsion member over the corresponding predetermined length, so that the distortion of the sensor torsion member arranged between the first torsion reinforcement member and the second torsion reinforcement member due to the differential torsional force applied by the first actuator and the second actuator at the first end and the second end of the sensor torsion member is increased relative to the distortion of the torsion member over the length of the mechanical strain amplification system, so as to mechanically increase the strain sensed by the at least one strain sensor.

[0108] C3. The paragraph according to C1, wherein the material stiffness of each of the first torsion reinforcement member and the second torsion reinforcement member is higher than the material stiffness of both the sensor torsion member and the anti-torsion member.

[0109] C4. The paragraph according to C1, wherein the sensor signal corresponding to the mechanically increased strain sensed by the at least one sensor is amplified by at least one signal amplifier for transmission to the controller.

[0110] C5. The paragraph according to C1, wherein the strain sensed by the at least one strain sensor is mechanically increased so that the strain sensed by the at least one strain sensor affects the sensor signal from the at least one strain sensor so that its signal amplitude is higher than a noise threshold of the at least one strain sensor.

[0111] C6. According to the paragraph described in C1, the method further includes: shielding the at least one strain sensor from electromagnetic influences by the torsion-resistant member.

[0112] In the above-mentioned drawings, the solid lines (if any) connecting various elements and / or components can represent mechanical, electrical, fluid, optical, electromagnetic, wireless and other connections and / or their combinations. As used herein, "connection" means direct and indirect association. For example, component A can be directly associated with component B, or can be indirectly associated with component B, for example, by means of another component C. It should be understood that it is not necessary to represent all relationships among the various disclosed elements. Thus, there may also be connections other than those shown in the drawings. The dotted lines (if any) connecting the boxes representing various elements and / or components represent connections similar to those represented by the solid lines in function and purpose; however, the connections represented by the dotted lines may be selectively provided or may involve alternative embodiments of the present disclosure. Similarly, the elements and / or components (if any) represented by the dotted lines represent alternative embodiments of the present disclosure. One or more elements shown in the solid lines and / or dotted lines can be omitted from the specific embodiments without departing from the scope of the present disclosure. Environmental elements (if any) are represented by dotted lines. For clarity, virtual (imaginary) elements may also be displayed. Those skilled in the art will appreciate that some of the features shown in the drawings may be combined in various ways without necessarily including other features described in the drawings, other drawings, and / or the accompanying disclosure, even if the combination or combinations are not explicitly illustrated herein. Similarly, additional features not limited to the embodiments presented may be combined with some or all of the features shown and described herein.

[0113] In the above mentioned Figure 5 and Figure 6 In the disclosure, boxes may represent operations and / or portions thereof, and the lines connecting the various boxes do not imply any specific order or dependencies of the operations or portions thereof. Boxes represented by dashed lines represent alternative operations and / or portions thereof. The dashed lines connecting the various boxes, if any, represent alternative dependencies of operations or portions thereof. It should be understood that not all dependencies among the various disclosed operations need be represented. Figure 5 and Figure 6 The attached disclosure describing the operation of the method set forth herein should not be construed as necessarily determining the order in which the operations are to be performed. On the contrary, although an exemplary order is shown, it should be understood that the order of the operations can be modified when appropriate. Thus, certain operations can be performed in different orders or substantially simultaneously. In addition, those skilled in the art will understand that it is not necessary to perform all the operations described.

[0114] In the following description, numerical specific details are set forth to provide a thorough understanding of the disclosed concepts, while the disclosed concepts may be implemented without some or all of these specific details. In other cases, details of known devices and / or processes have been omitted to avoid unnecessarily obscuring the disclosure. Although some concepts will be described in conjunction with specific embodiments, it should be understood that these embodiments are not intended to be limiting.

[0115] Unless otherwise indicated, the terms "first", "second", etc. are used herein merely as labels and are not intended to impose order, position, or hierarchical requirements on the items to which these terms refer. In addition, for example, reference to a "second" item does not require or preclude the existence of, for example, a "first" or lower number item and / or, for example, a "third" or higher number item.

[0116] Reference to "one embodiment" herein means that one or more features, structures, or characteristics described in conjunction with the embodiment are included in at least one implementation. The phrase "one embodiment" in various places in the specification may or may not refer to the same embodiment.

[0117] As used herein, a system, device, structure, article, element, component or hardware that is "configured to" perform a specific function is actually able to perform the specific function without any changes, rather than just having the potential to perform the specific function after further modification. In other words, the system, device, structure, article, element, component or hardware that is "configured to" perform the specific function is specifically selected, generated, realized, utilized, programmed and / or designed for the purpose of performing the specific function. As used herein, "configured to" refers to the existing characteristics of a system, device, structure, article, element, component or hardware that enables the system, device, structure, article, element, component or hardware to perform the specific function without further modification. For the purposes of this disclosure, a system, device, structure, article, element, component or hardware that is described as "configured to" perform a specific function may be additionally or alternatively described as "suitable for" and / or "operable" to perform the function.

[0118] The different embodiments of the apparatus and methods disclosed herein include various components, features, and functionality. It should be understood that the various embodiments of the apparatus and methods disclosed herein may include any components, features, and functionality of any other embodiments of the apparatus and methods disclosed herein in any combination, and all of these possibilities are intended to fall within the scope of the present disclosure.

[0119] Many modifications of the embodiments set forth herein will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings.

[0120] Clause 1. A force balance sensor, the force balance sensor comprising:

[0121] A mechanical strain amplification system, the mechanical strain amplification system comprising:

[0122] a sensor torsion member having a first end and a second end spaced apart from each other along a longitudinal axis of the sensor torsion member;

[0123] at least one strain sensor coupled to the sensor torsion member between the first end and the second end;

[0124] a first torsion reinforcement member coupled to the first end of the sensor torsion member; and

[0125] a second torsion reinforcement member coupled to the second end of the sensor torsion member,

[0126] Wherein the first torsion reinforcement member and the second torsion reinforcement member are coupled to a torsion-resistant member.

[0127] Clause 2. A force balance sensor according to clause 1, wherein torque is transferred from the torsion member to the sensor torsion member by means of the first torsion reinforcement member and the second torsion reinforcement member to mechanically increase the strain sensed by the at least one strain sensor.

[0128] Item 3. A force balance sensor according to Item 1, wherein the first torsion reinforcement member and the second torsion reinforcement member increase the torsional stiffness of the torsion member over the length of the mechanical strain amplification system, wherein the distortion of the sensor torsion member arranged between the first torsion reinforcement member and the second torsion reinforcement member due to the differential torsional force applied to the opposite ends of the torsion member is increased relative to the distortion of the torsion member over the length of the mechanical strain amplification system to mechanically increase the strain sensed by the at least one strain sensor.

[0129] Clause 4. The force balance sensor of clause 1, wherein each of the first torsion stiffening member and the second torsion stiffening member comprises:

[0130] a torsion bar having a first torsion bar end and a second torsion bar end spaced apart from each other along a longitudinal axis of the mechanical strain amplification system; and

[0131] a first torsion rod end coupling member disposed at the first torsion rod end and configured to fixedly couple the first torsion rod end to the torsion member;

[0132] Wherein the second torsion rod end is configured to be fixedly coupled to the sensor torsion member.

[0133] Clause 5. The force balance sensor of Clause 1, wherein the material stiffness of each of the first torsion stiffening member and the second torsion stiffening member is higher than the material stiffness of both the sensor torsion member and the torsion-resistant member.

[0134] Clause 6. The force balance sensor of Clause 1, further comprising at least one signal amplifier coupled to the at least one strain sensor.

[0135] Clause 7. The force balance sensor of Clause 1, further comprising a controller coupled to the at least one strain sensor, the controller being configured to determine a torsional displacement between the first end and the second end of the sensor torsion member based on a sensor signal received from the at least one strain sensor.

[0136] Clause 8. A force balance sensor according to clause 1, wherein the strain sensed by the at least one strain sensor is mechanically increased so that the strain sensed by the at least one strain sensor affects the signal from the at least one strain sensor to be above a noise threshold of the at least one strain sensor.

[0137] Clause 9. The force balance sensor of Clause 1, wherein the at least one strain sensor is coupled to the sensor torsion member such that the torsion member forms an electromagnetic shield for the at least one strain sensor.

[0138] Clause 10. An aircraft, comprising:

[0139] body;

[0140] a control surface having a control surface frame pivotally coupled to the fuselage by a torsion member;

[0141] a first actuator coupled to the first end and configured to pivot the control surface about a longitudinal axis;

[0142] a second actuator coupled to the second end and configured to pivot the control surface about the longitudinal axis;

[0143] A force balance sensor, the force balance sensor comprising:

[0144] A mechanical strain amplification system, the mechanical strain amplification system comprising:

[0145] a sensor torsion member having a first end and a second end spaced apart from each other along a longitudinal axis of the sensor torsion member;

[0146] at least one strain sensor coupled to the sensor torsion member between the first end and the second end;

[0147] a first torsion reinforcement member coupled to the first end of the sensor torsion member; and

[0148] a second torsion reinforcement member coupled to the second end of the sensor torsion member,

[0149] Wherein the first torsion reinforcing member and the second torsion reinforcing member are coupled to the anti-torsion member of the control surface.

[0150] Clause 11. The aircraft of clause 10, wherein torque is transferred from the torsion member to the sensor torsion member via the first torsion stiffening member and the second torsion stiffening member to mechanically increase strain sensed by the at least one strain sensor.

[0151] Clause 12. An aircraft according to clause 10, wherein the first torsion reinforcement member and the second torsion reinforcement member increase the torsional stiffness of the torsion member over the length of the mechanical strain amplification system, wherein the distortion of the sensor torsion member arranged between the first torsion reinforcement member and the second torsion reinforcement member due to the differential torsional force applied to the opposite ends of the torsion member is increased relative to the distortion of the torsion member over the length of the mechanical strain amplification system to mechanically increase the strain sensed by the at least one strain sensor.

[0152] Clause 13. The aircraft of clause 10, wherein one or more of the sensor torsion member, the at least one strain sensor, the first torsion stiffening member, and the second torsion stiffening member are disposed within an interior portion or on an exterior portion of the torsion member.

[0153] Clause 14. The aircraft of clause 10, wherein each of the first torsion stiffening member and the second torsion stiffening member comprises:

[0154] a torsion bar having a first torsion bar end and a second torsion bar end spaced apart from each other along the longitudinal axis of the sensor torsion member; and

[0155] a first torsion rod end coupling member disposed at the first torsion rod end and configured to fixedly couple the first torsion rod end to the torsion member;

[0156] Wherein the second torsion rod end is configured to be fixedly coupled to the sensor torsion member.

[0157] Clause 15. The aircraft of clause 10, further comprising a controller coupled to the at least one strain sensor, the first actuator, and the second actuator, the controller being configured to:

[0158] determining a torsional displacement between the first end and the second end of the sensor torsion member based on a sensor signal received from the at least one strain sensor; and

[0159] One or more of the first actuator and the second actuator are actuated such that twisting of the torsion member is reduced and the sensor signal received from the at least one strain sensor is below a predetermined strain threshold.

[0160] Clause 16. The aircraft according to clause 10, wherein the torsional stiffness of the torsion member is increased by the mechanical strain amplification system so that kt=k1 TM +k2 MSA , where kt is the total stiffness, k1 TM is the stiffness of the torsion member, and k2 MSA is the stiffness of the mechanical strain amplification system.

[0161] Clause 17. The aircraft of clause 10, further comprising:

[0162] a controller coupled to the at least one strain sensor via a first coupling; and

[0163] A power source is coupled to the at least one strain sensor through a second coupler, wherein the first coupler extends through the first end of the torsion member and the second coupler extends through the second end of the torsion member to mitigate electromagnetic effects on a sensor signal generated by the at least one strain sensor.

[0164] Clause 18. A method for controlling a control surface of an aircraft, the method comprising:

[0165] The first actuator and the second actuator are actuated by a controller to pivot the control surface relative to the fuselage about the longitudinal axis of the torsion member, wherein

[0166] The torsion member pivotally couples a control surface frame of the control surface to the fuselage, and

[0167] the first actuator and the second actuator being coupled to the torsion member at respective opposite ends of the torsion member to pivot the control surface;

[0168] sensing strain on the torsion member via a force balance sensor disposed between opposite ends of the torsion member, the force balance sensor comprising a mechanical strain amplification system including a sensor torsion member, at least one strain sensor coupled to the sensor torsion member between a first end and a second end of the sensor torsion member, a first torsion reinforcement member coupled to the first end of the sensor torsion member and the torsion member, and a second torsion reinforcement member coupled to the second end of the sensor torsion member and the torsion member; and

[0169] Actuation of one or more of the first actuator and the second actuator is adjusted by the controller based on the mechanically increased strain sensed by the at least one strain sensor.

[0170] Clause 19. A method according to clause 18, wherein the first torsion reinforcement member and the second torsion reinforcement member extend over corresponding predetermined longitudinal lengths of the mechanical strain amplification system and increase the torsional stiffness of the torsion member over the corresponding predetermined lengths, so that the distortion of the sensor torsion member arranged between the first torsion reinforcement member and the second torsion reinforcement member due to the differential torsional force applied by the first actuator and the second actuator at the first end and the second end of the sensor torsion member is increased relative to the distortion of the torsion member over the length of the mechanical strain amplification system, so as to mechanically increase the strain sensed by the at least one strain sensor.

[0171] Clause 20. The method of Clause 18, wherein the sensor signal corresponding to the mechanically increased strain sensed by the at least one sensor is amplified by at least one signal amplifier for transmission to the controller.

[0172] Clause 21. The method of clause 18, wherein the strain sensed by the at least one strain sensor is mechanically increased so that the strain sensed by the at least one strain sensor affects a sensor signal from the at least one strain sensor such that its signal amplitude is above a noise threshold of the at least one strain sensor.

[0173] Clause 22. The method of clause 18, further comprising shielding the at least one strain sensor from electromagnetic influences by the torsion member.

[0174] It should therefore be understood that the present disclosure is not limited to the specific embodiments shown and modifications and other embodiments are intended to be included within the scope of the appended claims. In addition, although the foregoing description and related drawings describe embodiments of the present disclosure in the context of certain exemplary combinations of elements and / or functions, it should be understood that different combinations of elements and / or functions may be provided by alternative implementations without departing from the scope of the appended claims. Thus, the parenthesized reference numerals in the appended claims are provided for exemplary purposes only and are not intended to limit the scope of the protected subject matter to the specific embodiments provided by the present disclosure.

Claims

1. A force balance sensor (100), comprising: A mechanical strain amplification system (130), the mechanical strain amplification system comprising: a sensor torsion member (110) having a first end (110a) and a second end (110b) spaced apart from each other along a longitudinal axis (110LA) of the sensor torsion member (110); at least one strain sensor (120) coupled to the sensor torsion member (110) between the first end (110a) and the second end (110b); a first torsion reinforcement member (131) coupled to the first end (110a) of the sensor torsion member (110); and a second torsion reinforcement member (132) coupled to the second end (110b) of the sensor torsion member (110), wherein the first torsion reinforcement member (131) and the second torsion reinforcement member (132) are connected to the torsion-resistant member (1002T), wherein the first torsion reinforcement member (131) and the second torsion reinforcement member (132) increase the torsional stiffness of the torsion member (1002T) over the length of the mechanical strain amplification system (130), wherein the distortion of the sensor torsion member (110) arranged between the first torsion reinforcement member (131) and the second torsion reinforcement member (132) due to the differential torsional force applied to opposite ends (1002E1 / 1002E2) of the torsion member (1002T) is increased relative to the distortion of the torsion member (1002T) over the length of the mechanical strain amplification system (130) to mechanically increase the strain sensed by the at least one strain sensor (120), The material stiffness of the first torsion reinforcement member (131) and the second torsion reinforcement member (132) is higher than the material stiffness of both the sensor torsion member (110) and the anti-torsion member (1002T), while the sensor torsion member (110) has a lower material stiffness than the anti-torsion member (1002T) and the first torsion reinforcement member (131) and the second torsion reinforcement member (132).

2. The force balance sensor (100) according to claim 1, wherein torque is transmitted from the torsion member (1002T) to the sensor torsion member (110) by means of the first torsion reinforcement member (131) and the second torsion reinforcement member (132) to mechanically increase the strain sensed by the at least one strain sensor (120).

3. The force balance sensor (100) according to claim 1, wherein each of the first torsion reinforcement member (131) and the second torsion reinforcement member (132) comprises: a torsion bar (134) having a first torsion bar end (134E1) and a second torsion bar end (134E2) separated from each other along a longitudinal axis (110LA) of the mechanical strain amplification system (130); and a first torsion rod end connecting member (136), the first torsion rod end connecting member being arranged at the first torsion rod end (134E1) and being configured to fixedly connect the first torsion rod end (134E1) to the torsion member (1002T); The second torsion rod end (134E2) is configured to be fixedly coupled to the sensor torsion member (110).

4. The force balance sensor (100) of claim 1, further comprising at least one signal amplifier (150) coupled to the at least one strain sensor (120).

5. The force balance sensor (100) of claim 1, further comprising a controller (170) coupled to the at least one strain sensor (120), the controller (170) being configured to determine a torsional displacement between the first end (110a) and the second end (110b) of the sensor torsion member (110) based on a sensor signal received from the at least one strain sensor (120).

6. The force balance sensor (100) of claim 1, wherein the strain sensed by the at least one strain sensor (120) is mechanically increased so that the strain sensed by the at least one strain sensor (120) affects a signal from the at least one strain sensor (120) above a noise threshold of the at least one strain sensor (120).

7. A method for controlling a control surface (1002) of an aircraft (1000), the method comprising: The first actuator (1010) and the second actuator (1020) are actuated by a controller (170) to pivot the control surface (1002) relative to the fuselage (1001) about the longitudinal axis (110LA) of the torsion member (1002T), wherein The torsion member (1002T) pivotally couples the control surface frame of the control surface (1002) to the fuselage (1001), and The first actuator (1010) and the second actuator (1020) are coupled to the torsion member (1002T) at respective opposite ends of the torsion member (1002T) to pivot the control surface (1002); sensing strain on the torsion member (1002T) by a force balance sensor (100) arranged between opposite ends of the torsion member (1002T), the force balance sensor (100) comprising a mechanical strain amplification system (130), the mechanical strain amplification system comprising a sensor torsion member (110), at least one strain sensor (120) coupled to the sensor torsion member (110) between a first end (110a) and a second end (110b) of the sensor torsion member (110), a first torsion reinforcement member (131) coupled to the first end (110a) of the sensor torsion member (110) and the torsion member (1002T), and a second torsion reinforcement member (132) coupled to the second end (110b) of the sensor torsion member (110) and the torsion member (1002T); and adjusting, via the controller (170), actuation of one or more of the first actuator (1010) and the second actuator (1020) based on the mechanically increased strain sensed by the at least one strain sensor (120), wherein the first torsion reinforcing member (131) and the second torsion reinforcing member (132) extend over respective predetermined longitudinal lengths of the mechanical strain amplification system (130) and increase the torsional stiffness of the torsion member (1002T) over the respective predetermined longitudinal lengths, so that the distortion of the sensor torsion member (110) arranged between the first torsion reinforcing member (131) and the second torsion reinforcing member (132) due to the differential torsional force applied by the first actuator (1010) and the second actuator (1020) at the first end (110a) and the second end (110b) of the sensor torsion member (110) is increased relative to the distortion of the torsion member (1002T) over the length of the mechanical strain amplification system (130), so as to mechanically increase the strain sensed by the at least one strain sensor (120), The material stiffness of the first torsion reinforcement member (131) and the second torsion reinforcement member (132) is higher than the material stiffness of both the sensor torsion member (110) and the anti-torsion member (1002T), while the sensor torsion member (110) has a lower material stiffness than the anti-torsion member (1002T) and the first torsion reinforcement member (131) and the second torsion reinforcement member (132).

8. The method of claim 7, wherein the strain sensed by the at least one strain sensor (120) is mechanically increased so that the strain sensed by the at least one strain sensor (120) affects a sensor signal from the at least one strain sensor (120) such that its signal amplitude is above a noise threshold of the at least one strain sensor (120).

Images