Digital Flight Control Surface Sensor Without Extra Monitoring Hardware

Solution Overview

Problem

Existing flight control systems with electro-mechanical actuators (EMAs) require additional sensors and circuitry for command-response and mechanical disconnect monitoring, leading to increased size, weight, and complexity, which is undesirable.

Innovation Solution

A digital surface position sensor with a position sensor, adaptable hardware input, and processing circuit that senses flight control surface position, processes signals to determine actuator position error, and generates fault signals when errors exceed thresholds, implementing command-response and mechanical disconnect monitoring without adding to the EMA's size or complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional sensors and circuitry are added for command-response and mechanical disconnect monitoring, then monitoring capability is improved, but device complexity increases

Engineering Contradiction:

Improvemonitoring capabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the command-response monitor and mechanical disconnect monitor functions into the existing surface position sensor assembly. The processing circuit in the sensor integrates multiple monitoring capabilities that were previously implemented as separate systems, thereby improving reliability without proportionally increasing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The surface position sensor is designed to perform multiple functions: it provides primary position feedback to the EMAC and simultaneously performs command-response monitoring and mechanical disconnect monitoring. This multi-functionality allows a single device to fulfill multiple safety and control roles, improving overall system reliability while avoiding the need for additional dedicated monitoring hardware.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If additional sensors and circuitry are added for command-response and mechanical disconnect monitoring, then monitoring capability is improved, but weight increases

Engineering Contradiction:

Improvemonitoring capabilityVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent merges the command-response monitor and mechanical disconnect monitor functions into the existing surface position sensor assembly. The processing circuit in the sensor integrates multiple monitoring capabilities that were previously implemented as separate systems, thereby improving reliability without proportionally increasing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The surface position sensor is designed to perform multiple functions: it provides primary position feedback to the EMAC and simultaneously performs command-response monitoring and mechanical disconnect monitoring. This multi-functionality allows a single device to fulfill multiple safety and control roles, improving overall system reliability while avoiding the need for additional dedicated monitoring hardware.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If additional sensors and circuitry are added for command-response and mechanical disconnect monitoring, then monitoring capability is improved, but size increases

Engineering Contradiction:

Improvemonitoring capabilityVSAvoidsize

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent combines the command-response monitor and mechanical disconnect monitor functions into the existing surface position sensor assembly. The processing circuit in the sensor integrates multiple monitoring capabilities that were previously implemented as separate systems, thereby improving reliability without proportionally increasing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The surface position sensor is designed to perform multiple functions: it provides primary position feedback to the EMAC and simultaneously performs command-response monitoring and mechanical disconnect monitoring. This multi-functionality allows a single device to fulfill multiple safety and control roles, improving overall system reliability while avoiding the need for additional dedicated monitoring hardware.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP4606700A1Flight control system digital surface position sensor with command-response monitor and mechanical disconnect monitor

Publication Date: 2025.08.27 HONEYWELL INTERNATIONAL INC

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AI summary

A digital surface position sensor includes a position sensor, an adaptable hardware input, and a processing circuit. The position sensor is adapted to be coupled to an aircraft flight control surface The adaptable hardware input provides an identification signal that identifies the aircraft flight control surface to which the position sensor is coupled. The processing circuit is configured to generate sensor actuator position data representative of flight control surface actuator position, determine flight control surface actuator position error, and generate a fault signal when the flight control surface actuator position error exceeds a predetermined threshold.