Aircraft Load Sensor Calibration Using Component-Level Pre-Assembly
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Solution Overview
Problem
Conventional aircraft load sensor calibration processes are complex and time-consuming, requiring ground-based measurements that prolong development time, especially in critical phases before flight trials.
Innovation Solution
A method and device for calibrating load sensors on aircraft using a calculation unit that evaluates a linear system of equations based on mechanical loading of aerofoils or control surfaces, allowing for quicker and more efficient calibration by calculating load coefficients from measurement signals provided by load sensors installed at the load cross-sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ground-based calibration measurements are performed on the entire assembled aircraft in the final assembly line, then calibration accuracy is achieved, but calibration time is significantly prolonged
Solution Approach 1:
The patent applies preliminary action by performing calibration measurements on individual aircraft components (wing boxes, control surfaces) separately before final assembly. Load sensors are calibrated on component-level substructures using simplified test setups, and these calibration results are then transferred to the fully assembled aircraft. This eliminates the need for time-consuming ground-based calibration of the complete aircraft while maintaining calibration accuracy through the use of identical load paths and sensor configurations.
2Reliability
If complex calibration processes are used to ensure accurate load measurements, then measurement reliability is improved, but process complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the calibration process into independent component-level calibrations rather than requiring a single complex calibration of the entire assembled aircraft. Each component (wing box, control surface) is calibrated separately using simplified test rigs that replicate the actual load paths. This segmentation reduces overall process complexity while maintaining measurement reliability through systematic verification at each component level.
Solution Approach 2:
The patent uses copying by creating simplified replica test setups that replicate the critical load paths and sensor configurations of the actual aircraft components. These copy models allow calibration to be performed on individual components before assembly, with the calibration characteristics being transferred to the final assembled structure. This approach simplifies the calibration process while ensuring accurate load measurements through faithful reproduction of the measurement conditions.
3Manufacturing precision
If load sensors are calibrated on the fully assembled aircraft, then comprehensive system calibration is achieved, but development time is extended in critical phases
Solution Approach 1:
The patent performs calibration measurements on individual aircraft components and subassemblies before final assembly, allowing calibration to be completed earlier in the manufacturing process. Load sensors are calibrated on component-level test rigs, and these calibration results are transferred to the assembled aircraft, eliminating the need to wait until final assembly for calibration completion and thereby accelerating the development schedule.
Solution Approach 2:
The calibration process is segmented into independent component-level calibrations that can be performed in parallel on different aircraft parts. This segmentation allows multiple calibration operations to occur simultaneously rather than sequentially on the complete aircraft, significantly reducing total calibration time while maintaining comprehensive system calibration through the integration of individually calibrated components.
Data Source
AI summary
A device and a method for calibrating load sensors which are provided at least one load cross-section of an aerofoil or control surface of an aircraft, the load sensors being calibrated on the basis of load coefficients (αi) of the load sensors, which load coefficients a calculation unit calculates by evaluating a linear system of equations formed by means of mechanical loading of the aerofoil or control surface.