Aircraft Actuator Redundant Position Sensing

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Existing servo-controlled electric actuators for aircraft flight control lack sufficient reliability, particularly in accurately measuring and maintaining the position of aerodynamic surfaces, which can lead to mechanical failures and position hysteresis issues.

Innovation Solution

A servo-controlled actuator with a rotary electric motor, screw, and nut mechanism, equipped with redundant position sensors and a servo-control circuit that compares data from two position sensors to detect faults and maintain accurate position control, ensuring the actuator stops at a reliable position in case of discrepancies, with the second sensor providing at least equivalent or higher resolution than the first.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single position sensor is used in existing actuators, then the device complexity is reduced, but the reliability and measurement precision deteriorate due to lack of redundancy and fault detection capabilities

Engineering Contradiction:
ImprovereliabilityVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies local quality by implementing redundancy specifically in the position sensing subsystem rather than throughout the entire actuator system. Two independent position sensors (first and second sensors) are installed to monitor the mechanical member position, with each sensor providing backup capability for the other. This localized redundancy enhances reliability of position measurement without unnecessarily complicating other parts of the actuator system.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent implements feedback through a control circuit that continuously receives position signals from both sensors, compares their outputs, and uses this feedback to detect faults. When the control circuit detects a discrepancy between the two sensor readings beyond a predetermined threshold, it generates a fault signal. This feedback mechanism enables real-time monitoring and fault detection, improving reliability while maintaining manageable system complexity.

Inventive Principle:
Principle #23Feedback

2Measurement precision

If higher resolution position sensors are used, then the measurement precision is improved, but the device complexity and cost increase

Engineering Contradiction:
ImproveresolutionVSAvoiddevice complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent applies partial or excessive action by using two position sensors with resolution equal to or greater than what would be required if only one sensor were used. This provides excessive measurement capability that enables both high precision position control and fault detection through comparison of the two sensor readings. The redundant sensing capacity ensures measurement precision is maintained even when one sensor degrades or fails.

Inventive Principle:
Principle #16Partial or excessive action

Solution Approach 2:

The patent implements beforehand cushioning by pre-installing redundant position sensors that can compensate for potential failures before they occur. The dual-sensor configuration provides a safety buffer against measurement errors, ensuring that if one sensor fails or drifts, the other can maintain accurate position measurement. This preemptive redundancy cushions against future reliability issues without requiring complex real-time correction mechanisms.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

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

Enhances the reliability and accuracy of the actuator by providing redundant position calculation and surveillance modules, reducing the likelihood of mechanical failures and position hysteresis, thereby improving the overall performance and safety of aircraft flight control systems.

Implementation Method 1

a rotary electric motor

Methodology Applied
Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Implementation Method 2

a screw arranged to be driven in rotation by rotation of the motor; a mechanical member (sometimes known as a 'nut') arranged to be driven in translation by rotation of the screw

Methodology Applied
Scientific EffectScrew mechanism: Screw

Data Source

PatentUS7764035B2Electric actuator for aircraft flight control
Publication Date: 2010.07.27 EUROCOPTER FRANCE SA
  • US7764035B2 patent drawing
  • US7764035B2 patent drawing
  • US7764035B2 patent drawing

AI summary

The invention relates to an actuator (9) comprising a rotary electric motor (12) a screw Old) driven in rotation by the motor, a mechanical member (15) driven in translation by the screw, a first position sensor (40) sensitive to a position of the electric motor and/or of the screw, a second position sensor (41) sensitive to a position of the mechanical member, and a servo-control circuit (11) connected to both of the position sensors and to the motor, this circuit delivering a power supply signal to the motor that varies as a function of a position setpoint signal (23) and as a function of signals delivered by the two position sensors; the second position sensor presents a resolution that is at least equivalent to the resolution of the first position sensor, and the servo-control circuit includes redundant modules (19, 22) for calculating the position of the mechanical member as a function of the signals/data delivered by the two sensors, together with at least two modules (17, 18) for mutual surveillance of the results delivered by the calculation modules.