Digital Test System for Rocket Stage Electromechanical Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automated test systems for electromechanical components in liquid rocket stage assemblies rely on analog control circuitry, requiring intermediate interface circuitry and lacking direct digital data transfer, which complicates accurate motor velocity and positioning control.
Innovation Solution
A fully digital system with direct digital data transfer between a test computer and electromechanical device drivers, utilizing analog interfacing circuits, digital processing hardware, and purpose-designed software algorithms to calculate and control motor velocity and positioning in real-time, with parameters monitored through a computer backplane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If analog control circuitry is used, then the system can interface with electromechanical components, but the system complexity increases due to intermediate interface circuitry requirements
Solution Approach 1:
The patent replaces analog control circuitry with a fully digital control system. The digital signal processor directly generates control signals for electromechanical components without requiring intermediate analog interface circuitry. This substitution of digital for analog electronics eliminates the complex analog-to-digital and digital-to-analog conversion stages, thereby reducing overall system complexity while maintaining manufacturing ease.
Solution Approach 2:
The patent extracts and removes the intermediate analog interface circuitry from the system architecture. By implementing direct digital control, the unnecessary analog buffer stages and interface converters are eliminated, simplifying the system while preserving the ability to interface with electromechanical components through purely digital communication pathways.
2Measurement precision
If analog control circuitry is used, then the system can control motor velocity and positioning, but the measurement precision of motor parameters decreases
Solution Approach 1:
The patent substitutes digital signal processing for analog control to achieve superior measurement precision. Digital signal processors can accurately measure motor current, velocity, and position parameters with higher resolution and without the noise and drift issues inherent in analog systems. The direct digital control architecture enables precise parameter monitoring while keeping the control system relatively simple through integrated digital processing.
3Manufacturing precision
If direct digital data transfer is implemented, then the control accuracy improves, but the device complexity increases
Solution Approach 1:
The patent implements a digital signal processor that performs multiple functions within a single integrated device. The DSP both controls motor velocity and positioning while simultaneously measuring motor parameters and communicating with the host system through digital interfaces. This multi-functionality achieves high positioning accuracy through direct digital control without proportionally increasing system complexity, as one component handles multiple critical tasks.
Solution Approach 2:
The patent merges the control and measurement functions into a unified digital control system. The digital signal processor integrates both the control algorithm execution and the parameter measurement capabilities in one device, eliminating the need for separate analog control circuits and measurement instrumentation. This consolidation achieves high positioning accuracy while actually reducing overall system complexity compared to traditional separated analog systems.
Data Source
AI summary
Method and system that produce requisite drive signals to fully exercise and test electromechanical elements of a liquid rocket stage including solenoid valve drives, DC motor drives and actuator drive signals. The electrical driver tester includes a signal processor, power driver circuits, and A/D and D/A circuits to monitor and control the drive circuitry. Drive current is monitored and a signal proportional to the current is produced for the purpose of analyzing current profiles as part of the test regimen for the device under test. Actuator speed and positioning are controlled in real time with a tailored lead lag control algorithm implemented with digital signal processor hardware.