Electric Brake Actuator Segmentation for Clamping Force Accuracy
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Solution Overview
Problem
Current electric aircraft carbon brake systems fail to achieve the required accuracy in brake clamping force, leading to unequal distribution of brake energy during taxiing, which affects directional stability and causes damage from excessive temperatures.
Innovation Solution
A method and system that dedicate a portion of electric brake actuators to low brake clamping force commands and another portion to high brake clamping force commands, allowing for precise control of brake actuation to maintain accuracy and sensitivity, especially at low taxiing speeds, without affecting normal braking operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single set of electric brake actuators is used for all brake clamping force levels, then the device complexity is reduced, but the measurement precision of brake clamping force accuracy deteriorates
Solution Approach 1:
The brake actuator system is segmented into two distinct groups: a first group of actuators dedicated to low brake clamping force commands and a second group dedicated to high brake clamping force commands. This segmentation allows each group to be optimized for its specific force range, thereby improving measurement precision and control accuracy without requiring a single complex actuator system to handle all force levels.
2Stability of the object's composition
If brake clamping force accuracy is improved by dedicating separate actuators to low and high force ranges, then brake energy distribution becomes more equal, but the device complexity increases
Solution Approach 1:
The brake actuator system is divided into two functional segments: first actuators for low force commands and second actuators for high force commands. This segmentation enables precise control of brake energy distribution across different taxiing conditions, maintaining directional stability by preventing unequal energy distribution while keeping each segment's design relatively simple.
Solution Approach 2:
Different portions of the brake system are assigned different functional qualities: the first actuator group is optimized for low-force precision control during taxiing maneuvers, while the second actuator group is optimized for high-force applications during normal braking. This local quality differentiation resolves the contradiction by providing appropriate control characteristics for each operational context.
3Productivity
If the sensitivity to brake commands is increased at low clamping force levels, then the productivity of brake control is improved, but the device complexity increases
Solution Approach 1:
The actuator system is segmented into low-force and high-force groups, with the first group providing enhanced sensitivity and responsiveness for low clamping force commands during taxiing. This segmentation improves productivity by ensuring that low-force commands receive dedicated, optimized actuation without requiring the entire system to be redesigned for high sensitivity.
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
This approach enhances the accuracy and sensitivity of brake commands, reducing brake wear and preventing damage by ensuring precise control of brake energy distribution, meeting industry standards for the Boeing 787 and maintaining directional stability during taxiing.
Implementation Method 1
electrically actuated brakes are typically carbon brakes including a torque plate and a carbon heat sink stack containing the friction surfaces that are clamped together by four electric brake actuators with a clamping brake force to cause a wheel to decrease its speed of rotation
Implementation Method 2
it causes the friction surfaces of the carbon brakes to make contact, creating brake torque to slow down the rotational speed of the wheel
Data Source
AI summary
The method and system for increasing accuracy of clamping force of electric aircraft carbon brakes, once braking has been commenced, provides a first pair of electric brake actuators with a range of low brake clamping force responsive to low brake clamping force commands, and a second pair of electric brake actuators with a range of high brake clamping force responsive to high brake clamping force commands. The first pair of electric brake actuators is actuated to apply a minimum residual braking force once wheel braking is commenced, and the second pair of electric brake actuators is actuated only when the commanded braking force is in the high range of brake clamping force.