Aircraft Brake Controller PWM Current Regulation
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Solution Overview
Problem
Aircraft systems face inefficiencies due to varying voltage ranges (18V to 33V) affecting the current across brake coils, leading to excess power dissipation, which existing controllers fail to accurately manage.
Innovation Solution
A control system comprising a control processor, FPGA controller, high-side and low-side driver circuits, and sensors that receive threshold current values, compare sensed currents, and provide adjustment signals to maintain current within defined ranges, using pulse width modulation and fixed voltage signals to optimize brake coil energization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If voltage supply varies within the range of 18V to 33V to accommodate different operating conditions, then the brake system remains operational across different voltage conditions, but the current across the brake coil becomes excessive leading to increased power dissipation
Solution Approach 1:
The controller continuously monitors the actual voltage supply and adjusts the PWM duty cycle accordingly. When voltage increases, the controller reduces duty cycle to maintain constant current; when voltage decreases, it increases duty cycle. This closed-loop feedback mechanism ensures optimal power efficiency across the 18V-33V operating range while preventing excessive power dissipation.
Solution Approach 2:
The system dynamically adjusts the PWM duty cycle in real-time based on the detected voltage conditions. Rather than using a fixed duty cycle, the controller adapts its output characteristics to match the instantaneous voltage supply, enabling the brake coil to receive appropriate current levels regardless of whether the supply is 18V, 28V, or 33V.
2Device complexity
If a simple voltage switching system is used without current control, then the device complexity is reduced, but the current control precision deteriorates resulting in excess power dissipation
Solution Approach 1:
The patent replaces complex mechanical current regulation mechanisms with an electronic PWM control system. Instead of using variable resistors or mechanical switches to control current, the system uses digital PWM signals processed by an FPGA controller, achieving precise current control through software-based algorithms while maintaining relatively simple hardware architecture.
Solution Approach 2:
The controller dynamically changes the PWM duty cycle parameter based on detected voltage conditions and desired current targets. By adjusting this single parameter, the system achieves precise control over brake coil current without requiring complex hardware modifications, thereby maintaining simplicity while improving control accuracy.
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
The system ensures precise control of brake coil currents, enhancing operating efficiency and reducing power dissipation in aircraft electrical interfaces by maintaining currents within specified thresholds.
Implementation Method 1
an electromagnetic brake is energized through a coil in order to release the load shaft
Implementation Method 2
A controller than can accurately control current to a brake coil that adds operating efficiency to both a circuit and an aircraft electrical interface would be well received in the art
Data Source
AI summary
A system and method for controlling a brake coil in a motor having a control processor and a controller in communication with the control processor, the controller comprising a processor and memory with instructions stored thereon when executed by the processor cause the controller to receive signals indicative of threshold current values for the brake coil; provide enabling signals to each of a high-side and low-side driver circuit; receive signals indicative of a sensed current in the brake coil; compare the sensed current with the threshold current values; and provide an adjustment signal if the sensed current is outside a known range of values for the threshold current values.