Backup Thrust Reverser Power Control for Fail-Safe Deployment

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Solution Overview

Problem

Thrust reverser actuation systems in aircraft are vulnerable to failure due to high loads after deployment, which can result in catastrophic consequences during landing.

Innovation Solution

A backup thrust reverser actuation system control architecture that includes an AC power supply, a power supply and motor control for an electric motor, and a backup power supply to ensure continued operation in case of primary power failure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a primary power supply system is used for the thrust reverser actuation system, then the system can operate normally during flight, but the system becomes vulnerable to catastrophic failure if the power supply fails during landing

Engineering Contradiction:

Improvesystem reliabilityVSAvoidpower supply system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The backup power supply is pre-configured and connected to the thrust reverser actuation system before any failure occurs. The system includes pre-established electrical connections between the backup power supply, rectifier, and motor control components, ensuring that power can be immediately transferred without requiring complex real-time decision-making or system reconfiguration during a failure event.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The backup power supply acts as a protective cushion against power failure during critical landing operations. By having a redundant power source already in place and integrated into the system architecture, the design cushions against the harmful effect of primary power supply failure, preventing catastrophic loss of thrust reverser functionality.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Strength

If the thrust reverser actuation system is designed with high load capacity for deployment, then the system can handle deployment forces, but the system becomes vulnerable to damage from loads after deployment

Engineering Contradiction:

Improvedeployment load capacityVSAvoidpost-deployment reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The motor control system dynamically adjusts its operation based on the deployment state. During deployment, the system handles high loads with full power capability. After deployment, the control system modifies operational parameters to prevent excessive loads that could damage the actuation system, thereby maintaining reliability while preserving the strength needed for initial deployment.

Inventive Principle:

Principle #15Dynamics

3Reliability

If a backup power supply is added to the system, then system reliability improves during power failure, but the system complexity and component count increase

Engineering Contradiction:

Improvefail-safe operationVSAvoidsystem architecture complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The backup power supply is electrically merged with the primary power supply system through common connection points at the rectifier and motor control. This merging allows the system to switch between power sources without requiring completely separate control circuits or complex switching mechanisms, thereby improving reliability while limiting the increase in overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

4Strength

If the end stops are designed to withstand high impact forces, then they can protect against deployment impacts, but their size and weight increase

Engineering Contradiction:

Improveimpact resistanceVSAvoidend stop weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The controlled power down sequence performs a preliminary action by gradually reducing motor power before the thrust reverser reaches its final deployed position. This preliminary reduction in driving force lessens the impact velocity and force on the end stops, allowing them to be designed with reduced size and weight while still providing adequate protection against deployment impacts.

Inventive Principle:

Principle #10Preliminary action

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 backup system architecture provides a fail-safe mechanism for controlled power down of the thrust reverser actuation system, reducing the risk of catastrophic failure and allowing for reduced size and weight of end stops.

Implementation Method 1

The AC power supply is connected to a rectifier to convert the AC signal to a DC signal

Methodology Applied

Scientific EffectRectification:

Implementation Method 2

The rectifier may be connected to a DC link capacitor

Methodology Applied

Scientific EffectCapacitance: Capacitance

Implementation Method 3

The brake control switch is connected to a brake resistor

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentEP4177456B1Back-up thrust reverser actuation system control

Publication Date: 2025.01.15 GOODRICH ACTUATION SYST

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AI summary

A system architecture for a backup thrust reverser actuation system control is provided. The system architecture includes an AC power supply (101, 201) of an aircraft, a power supply (102, 202) and a motor control (103, 203) adapted to control an electric motor (M) of a thrust reverser actuation system. The system architecture further includes a backup power supply (105, 212) adapted to provide power to the electric motor in the event that the power supply fails