Aircraft Electric Brake Actuator Duty Cycle Management
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Solution Overview
Problem
Current aircraft electric brake systems lack a mechanism to limit brake force and prevent prolonged high-force applications, leading to oversized motors and controllers due to excessive duty cycles.
Innovation Solution
An electric brake control system that determines the aircraft's operational state and brake pedal force, commanding the actuator brakes to engage and de-energize the electric brake actuators when in a ground-idle state and exceeding a set force magnitude, thereby reducing the duty cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If electric brake actuators are used without a mechanism to limit brake force or prevent prolonged high-force applications, then the brakes can provide sufficient stopping power, but the motors and controllers become oversized due to excessive duty cycles
Solution Approach 1:
The brake actuation system is divided into two separate braking mechanisms: friction brakes for primary stopping power and actuator brakes for duty cycle management. This segmentation allows each component to be optimized for its specific function, enabling smaller motors and controllers while maintaining sufficient overall brake force.
Solution Approach 2:
The actuator brake serves as an intermediary mechanism that limits the force applied by the electric brake actuator during ground-idle operations. By introducing this intermediate force-limiting component, the system can use smaller motors and controllers without sacrificing the ability to provide sufficient stopping power when needed.
2Reliability
If electric brake actuators operate with high duty cycles during ground-idle operations, then the brakes can hold the aircraft against engine thrust, but the motors and controllers must be oversized to handle the prolonged operation
Solution Approach 1:
The braking function is segmented into friction brakes for primary stopping and actuator brakes for duty-cycle-limited holding. This allows the electric brake actuator to operate with reduced duty cycle while maintaining reliable brake holding capability through the combined system.
Solution Approach 2:
The system changes the operational parameters by introducing duty cycle limitations on the electric brake actuator during ground-idle operations. By controlling when and how long the actuator operates, the system maintains reliability without requiring oversized motors and controllers.
3Stability of the object's composition
If the electric brake actuator is continuously energized to maintain brake force, then the braking function is reliable, but the duty cycle increases and requires oversized components
Solution Approach 1:
Instead of continuous actuation, the system uses periodic action through the actuator brake mechanism that engages and disengages based on duty cycle requirements. This periodic operation maintains brake force consistency while reducing the duration the electric brake actuator remains energized.
Solution Approach 2:
The system maintains continuous useful braking action through the combination of friction brakes and actuator brakes, while the electric brake actuator itself operates intermittently. The useful braking function continues without interruption even though the actuator duty cycle is reduced.
Data Source
AI summary
A system and method of controlling aircraft brakes in an aircraft that includes a brake pedal and an electric brake actuator. An aircraft operational state is determined and an application force that is supplied to the brake pedal is determined. When the determined aircraft operational state is a ground-idle state and the determined application force is greater than a set force magnitude, an actuator brake is moved to engage the electric brake actuator and the electric brake actuator is de-energized.