Actuator Controller Voting Architecture for Lightweight Fault Integrity
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Solution Overview
Problem
Current aircraft actuation systems with electromechanical actuators (EMAs) face challenges in achieving high integrity while being cost-effective, lightweight, and less complex due to the need for redundant systems and complex hardware/software mitigation against common mode failures, which increases weight and cost.
Innovation Solution
A high-integrity electromechanical actuator control system with a command voting scheme and redundant control channels, including primary and backup channels with duty cycle computation circuits and shut-off circuits, to verify actuator control command integrity and generate PWM commutation control signals, ensuring system reliability without the need for fully redundant inverters or complex motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant control systems and complex hardware/software mitigation are implemented, then system reliability is improved, but system weight and cost increase
Solution Approach 1:
The control system is segmented into independent functional channels (first control channel, second control channel) with separate controllers (first controller, second controller) that can operate autonomously. This segmentation allows redundancy without requiring complete system duplication, reducing overall weight while maintaining reliability through independent fault isolation.
Solution Approach 2:
Instead of implementing full hardware redundancy with complete duplicate systems, the patent uses a simplified copying approach where the backup controller mirrors essential control functions through software and logic circuits. The second controller can assume control when the first controller fails, providing redundancy without the weight penalty of fully duplicated hardware systems.
2Reliability
If redundant control systems and complex hardware/software mitigation are implemented, then system reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges the redundancy management functions into a unified architecture where both controllers share common power management circuits, motor driver interfaces, and control algorithms. The first and second controllers are integrated through shared hardware resources and coordinated control logic, reducing the complexity that would arise from completely separate redundant systems.
Solution Approach 2:
The controllers are designed with universal functionality where each controller can perform both primary and backup roles. The control system implements multi-functional circuits that can operate in different modes (normal operation, failover, fault isolation), reducing the need for dedicated redundant hardware and simplifying the overall system architecture.
3Measurement precision
If command voting scheme and redundant control channels are implemented, then actuator control integrity is improved, but control system complexity increases
Solution Approach 1:
The control system implements dynamic failover capability where the active controller can switch between the first and second controllers based on real-time fault detection. The system dynamically adjusts control signal routing and controller activation states, allowing integrity verification through active monitoring without requiring complex static redundant architectures.
Data Source
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AI summary
A high-integrity electromechanical actuator control system includes a system function controller, a plurality of actuator controllers, and at least one electromechanical actuator. Each actuator controller includes a primary channel having a first controller, a second controller, and a duty cycle computation circuit, and includes a backup channel having a backup controller. The first controller receives digital actuator control commands from two functional control channels and supplies first digital duty cycle commands. The second controller receives digital actuator control commands from two functional control channels and supplies second digital duty cycle commands. The duty cycle computation circuit computes an average of the first and second duty cycle commands and generates pulse width modulated (PWM) commutation control signals based on the computed average. The backup controller receives digital actuator control commands from two different functional control channels and generates and supplies backup PWM commutation control signals.