Actuator Interface Controller for Aircraft Wiring Weight Reduction
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Solution Overview
Problem
Conventional aircraft and unmanned drones have limited operational capabilities due to weight constraints from conventional wiring systems used for power supply and control, which restricts endurance, maneuverability, and sustainable altitude.
Innovation Solution
The implementation of an actuator interface controller that steps down high voltage from a high voltage power bus to a low voltage power bus, using lighter high gage wiring for long-distance high voltage transmission and heavier low gage wiring for short-distance low voltage delivery, reducing overall wiring weight and incorporating fiber optic cabling for signal communication, thereby enhancing power supply and control efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional low voltage wiring is used for long-distance power transmission, then the remote device can be powered, but the wiring weight increases significantly
Solution Approach 1:
The power transmission system is segmented into two parts: high voltage transmission for long distances using lightweight wiring, and low voltage distribution for short distances near the remote device. This segmentation allows each segment to use optimized wiring gauge, reducing overall weight while maintaining reliability.
Solution Approach 2:
The voltage parameter is changed along the transmission path - starting at high voltage for long-distance transmission to minimize current and wiring weight, then stepped down to low voltage near the destination to enable safe device operation. This parameter change resolves the contradiction between transmission efficiency and device compatibility.
2Weight of moving object
If high voltage is transmitted over long distances using lightweight high gage wire, then wiring weight is reduced, but voltage must be stepped down for remote device operation
Solution Approach 1:
An interface controller acts as an intermediary device that performs voltage conversion from high voltage to low voltage. This intermediary component absorbs the complexity of voltage transformation, allowing the wiring system to remain simple while enabling high voltage transmission over long distances.
Solution Approach 2:
The interface controller located near the remote device performs the voltage stepping down function locally, making the power supply system self-sufficient. The controller automatically manages the voltage conversion without requiring complex external control systems, reducing overall system complexity.
3Ease of manufacture
If conventional wiring systems are used throughout the aircraft, then power supply is simple, but electromagnetic interference affects operational capability
Solution Approach 1:
Traditional electrical wiring for signal transmission is replaced with fiber optic cabling that uses light instead of electricity. This substitution eliminates electromagnetic interference entirely while maintaining communication functionality, resolving the contradiction between manufacturing simplicity and electromagnetic compatibility.
4Reliability
If heavy low gage wiring is used for short-distance low voltage delivery, then remote device operation is reliable, but overall wiring weight increases
Solution Approach 1:
The wiring system is segmented by function and distance: lightweight high gage wire for long-distance high voltage transmission, and heavy low gage wire only for short-distance low voltage delivery near the device. This segmentation ensures reliability where needed while minimizing overall weight.
Solution Approach 2:
Different wiring qualities are applied locally based on specific requirements: lightweight wiring for transmission segments where weight matters, and heavy wiring for distribution segments where reliability is critical. This local optimization resolves the contradiction between weight and reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces wiring weight, enhances modularity, reliability, and operational capabilities by minimizing electromagnetic interference, facilitating easier component replacement, and enabling longer distance data transmission, ultimately improving the aircraft's endurance and maneuverability.
Implementation Method 1
The power supply may be configured to step down the high voltage received to a low voltage that is lower than the high voltage on the high voltage power bus and place the low voltage onto the low gage wire that may act as a low voltage power bus
Implementation Method 2
incorporating fiber optic cabling for signal communication
Data Source
AI summary
An actuator controller with a power supply that steps down a high voltage for use by remote auxiliary loads in an aircraft is provided. A high voltage power bus running through the aircraft may use high gage or smaller diameter wiring, resulting in weight savings in the power bus. A control network running through the aircraft may use fiber optic cabling, providing further weight reductions. An actuator controller may receive the high voltage from the power bus and provide a lower voltage to a remote device. The actuator controller may facilitate communication between the control network and the remote device. The integration of control and power supply may enhance endurance, reliability, and enable localized calibration of the remote device. Modular wing components may include interface controllers, high and low power busswork, and remote devices. The modular wing components may include power and control interconnections.