Aircraft Engine Control Unit Diagnostic Device
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Solution Overview
Problem
Current diagnostic methods for aircraft engine control units are cumbersome, requiring disassembly and are prone to errors, leading to increased maintenance time and costs due to the complexity of connecting multiple connectors and the inability to identify faults accurately without dismantling equipment.
Innovation Solution
A portable, autonomous diagnostic device with a single connection cable for automatic continuity and electrical insulation tests, allowing for fault identification without simulating flight conditions, and a method to analyze the health status of connectors and control units directly on the aircraft, reducing the need for disassembly and minimizing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a test bench is used to carry out diagnosis, then the control unit can be thoroughly tested, but the test bench is heavy and not easily transportable
Solution Approach 1:
The invention divides the diagnostic system into two parts: a portable diagnostic device that can be easily transported and a test bench that remains in the workshop. The portable device performs preliminary diagnostics and fault identification, while the test bench handles comprehensive testing when the control unit is removed. This segmentation allows the diagnostic capability to be distributed between a mobile unit and a stationary unit, resolving the contradiction between portability and diagnostic completeness.
2Adaptability or versatility
If a diagnostic device with multiple connecting ports is used, then comprehensive tests can be performed, but the device becomes oversized and connectors may interfere with maintenance operations
Solution Approach 1:
The connecting capability is segmented between the portable diagnostic device and the control unit itself. The portable device has a single connecting port that interfaces with the control unit's existing multiple ports. The control unit's internal architecture provides the versatility for comprehensive testing, while the portable device maintains a compact form factor with minimal external connectors, thus resolving the contradiction between testing capability and device size.
Solution Approach 2:
The portable diagnostic device copies or replicates the functionality of the test bench's connecting capabilities through software and processing power, rather than physically replicating multiple heavy connectors. The device uses its single port to communicate with the control unit's existing connector system, leveraging the control unit's own architecture to provide comprehensive testing capability without adding physical bulk to the portable device.
3Adaptability or versatility
If multiple connectors are used to connect the diagnostic device, then comprehensive tests can be performed, but the connectors may become intertwined and interfere with maintenance operations
Solution Approach 1:
The connecting function is segmented so that the portable diagnostic device uses a single connector, while the control unit's existing connector system handles the complexity of multiple connections. This segmentation eliminates the problem of intertwined connectors during maintenance operations, as only one connector needs to be managed by the technician, while preserving comprehensive testing capability through the control unit's internal connector architecture.
4Loss of time
If faults are identified without dismantling equipment, then maintenance time is reduced, but the ability to identify the source of the fault is limited
Solution Approach 1:
The portable diagnostic device implements feedback mechanisms that allow it to identify faults and their sources without physical dismantling. The device communicates with the control unit's internal systems, receives feedback signals, and uses this information to trace faults back to their specific sources (such as specific sensors, actuators, or internal circuits). This feedback loop enables non-invasive fault source identification, resolving the contradiction between reduced maintenance time and accurate fault localization.
Data Source
AI summary
A method for diagnosing an engine control unit of an aircraft uses a device having an autonomous and mobile electronic diagnostic unit and connecting means for connecting the unit to an engine control unit of an aircraft. The connecting means advantageously includes a single connection cable.