Actuator Force Equalization Controller for Aircraft
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Solution Overview
Problem
Aircraft flight control systems face challenges in ensuring that multiple actuators are positioned equally to avoid force transients that can lead to metal fatigue damage, which is exacerbated by actuator mis-positioning and reactive forces.
Innovation Solution
A force equalization controller (FEC) system that senses forces across each actuator, computes differences in actuator forces, and generates corrective position commands to equalize forces, using rate feedback and delta pressure signals to stabilize the system and reduce fatigue risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple actuators are used to control flight control surfaces, then the control authority and redundancy are improved, but actuator mis-positioning occurs which causes large forces and metal fatigue damage
Solution Approach 1:
The patent implements a feedback control system that continuously monitors actuator positions and forces. Position sensors provide feedback signals proportional to actuator rate, and force sensors provide delta pressure signals. The controller computes differences in actuator rates and forces, then generates corrective commands to equalize forces among actuators, preventing fatigue damage while maintaining redundancy
Solution Approach 2:
The patent replaces traditional mechanical rigging and force balancing mechanisms with an electronic control system. Instead of mechanically pre-positioning actuators to share loads equally, the system uses electronic sensors and controllers to actively monitor and adjust actuator positions in real-time, substituting mechanical precision requirements with electronic measurement and control
2Strength
If actuator positioning precision is increased to avoid force fight, then metal fatigue damage is reduced, but device complexity and manufacturing precision requirements increase
Solution Approach 1:
The control system uses continuous feedback from position sensors and force sensors to detect and correct actuator mis-positioning. The feedback loop computes force differences and generates corrective commands, maintaining actuator synchronization without requiring extremely tight manufacturing tolerances or complex mechanical positioning mechanisms
Solution Approach 2:
The actuation system performs self-adjustment through the control system that automatically detects force imbalances and generates corrective positioning commands. The system monitors its own state through sensors and self-corrects without external intervention, reducing the need for complex external rigging and adjustment mechanisms
3Strength
If actuator positioning precision is increased to avoid force fight, then metal fatigue damage is reduced, but manufacturing cost increases due to heavy materials and complicated rigging
Solution Approach 1:
The patent replaces heavy mechanical rigging systems and force-balancing mechanisms with lightweight electronic sensors and controllers. Instead of using heavy materials and complicated mechanical adjustments to pre-position actuators, the system uses electronic measurement and active control to achieve force equalization, reducing both weight and manufacturing complexity
Solution Approach 2:
The system automatically equalizes actuator forces through electronic control without requiring manual rigging adjustments or heavy compensating mechanisms. The control system self-adjusts actuator positions based on sensor feedback, eliminating the need for complicated pre-installation rigging processes and heavy structural reinforcements
Data Source
AI summary
An actuation system including a plurality of actuators; a plurality of position sensors coupled to the actuators, the plurality of position sensors providing rate feedback signals proportional to an actuator rate; a plurality of force sensors coupled to the actuators, the plurality of force sensors providing delta pressure signals; and a feedback control loop configured to receive the rate feedback signals and delta pressure signals and compute a difference in actual actuator rates and sum the difference with a computed difference in actuator forces to generate actuator positioning commands that equalize the actuator forces on a control surface.