Aircraft Brake Wear Control via Optical Sensing
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Solution Overview
Problem
Aircraft brake systems experience uneven wear of friction material due to differences in tolerances, exposure to elements, and varying coefficients of friction, leading to increased maintenance needs and costs, as well as potential aircraft downtime.
Innovation Solution
A brake controller system that monitors the available friction material on each brake and adjusts the braking force to ensure even wear across all brakes, by varying the force applied based on the wear data from sensors, allowing for consistent and controlled wear patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional wear pin indicators are used to measure brake wear, then wear detection is possible, but the inspection is imprecise and requires visual inspection
Solution Approach 1:
The patent replaces mechanical wear pin indicators with an optical measurement system. The optical sensor non-contactively measures the thickness of the friction material by emitting light and detecting the reflected or transmitted light, thereby eliminating the need for physical contact and visual inspection while providing more precise and automated measurements.
2Productivity
If brakes are operated without wear management, then braking function is maintained, but friction material wear becomes uneven leading to frequent maintenance
Solution Approach 1:
The system performs preliminary wear management by continuously monitoring friction material thickness and proactively adjusting brake force distribution before uneven wear becomes severe. The controller detects wear differences between brakes and preemptively modifies the braking force applied to each brake to equalize wear rates, preventing the need for frequent maintenance interventions.
Solution Approach 2:
The patent implements a closed-loop feedback system where the optical sensor continuously measures friction material thickness, the controller compares measurements between different brakes, and automatically adjusts brake force distribution based on the detected wear differences. This real-time feedback mechanism ensures even wear patterns and optimizes maintenance scheduling.
3Reliability
If wear sensors and control systems are added to manage brake wear, then even wear between brakes is achieved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical wear indication systems with an optical sensing system. The optical sensor non-contactively measures friction material thickness, eliminating the need for physical wear pins and their associated mechanical linkages. This substitution reduces mechanical complexity while providing more reliable and continuous wear data for the control system.
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 reduces the frequency of maintenance inspections, minimizes costs, and ensures that all brakes wear out at a similar rate, preventing aircraft downtime and optimizing maintenance schedules.
Implementation Method 1
an optical sensor that non-contactively measures a thickness of the friction material
Implementation Method 2
Each stator disk includes a friction material that engages the rotor disk as the brake disk stack is compressed, thereby converting kinetic energy into heat energy
Data Source
AI summary
A system, apparatus and method provide a means for managing wear of brake friction material such that even friction material wear is experienced between brakes. The available friction material of each brake is monitored to determine an amount of wear. Based on the amount of wear, a braking force applied by each brake may be varied to ensure even wear between brakes.