Distributed Electromechanical Brake System for Aircraft Wire Weight Reduction
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Solution Overview
Problem
Aircraft electromechanical braking systems face inefficiencies due to heavy wire weight and significant electromagnetic interference (EMI) from long-distance high-voltage drive signals, along with design challenges from extreme temperature variations and large-sized electromechanical actuator controllers (EMACs).
Innovation Solution
A distributed electromechanical brake system with local functionality at each wheel, where electromechanical brake actuators (EBAs) receive power and control signals directly from a brake control unit (BCU) via a remote data concentrator (RDC), reducing wire weight and EMI by minimizing signal modulation distance and integrating control electronics within the EBAs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage drive signals are transmitted over long distances from EMACs to EBAs, then braking control is achieved, but wire weight increases significantly
Solution Approach 1:
The system segments the control architecture by distributing intelligence to remote data concentrators (RDCs) at each wheel station, which independently generate drive signals for local EBAs. This eliminates the need for long-distance high-voltage signal transmission from a centralized EMAC, thereby reducing wire weight while maintaining braking control functionality.
Solution Approach 2:
The patent transitions from a centralized control architecture to a distributed architecture, fundamentally changing the system's organizational dimension. By placing control functionality at the wheel level rather than at a centralized location, the system reorganizes the control flow spatially, eliminating long transmission paths and associated wiring.
2Reliability
If high-voltage drive signals are transmitted over long distances, then braking control is achieved, but electromagnetic interference (EMI) increases significantly
Solution Approach 1:
The patent extracts the signal modulation function from centralized EMACs and relocates it to distributed RDCs at each wheel station. By generating drive signals locally rather than transmitting them over long distances, the system eliminates the primary source of EMI associated with long-distance high-voltage signal transmission.
Solution Approach 2:
The RDC acts as an intermediary device that receives low-voltage control signals from the BCU via aircraft wiring, then locally converts them to high-voltage drive signals for the EBA. This intermediary function eliminates the need for long-distance high-voltage transmission, thereby reducing EMI while maintaining braking control.
3Weight of stationary object
If EMACs are moved to the landing gear to reduce wire weight, then wire weight decreases, but EMI and electrical noise issues persist
Solution Approach 1:
Instead of consolidating control functions in a single EMAC location (either centralized or at landing gear), the patent segments control functionality into distributed RDCs at each wheel station. This segmentation ensures that high-voltage signal generation occurs locally at each wheel, eliminating long transmission paths and associated EMI regardless of the RDC's physical location.
Solution Approach 2:
Each wheel station's RDC independently generates its own high-voltage drive signals locally, without relying on long-distance transmission from other locations. This self-service approach to signal generation eliminates the EMI problems associated with long-distance high-voltage transmission while achieving wire weight reduction.
4Reliability
If redundant brake system controllers and EMACs are implemented, then braking reliability is improved, but device complexity increases
Solution Approach 1:
The RDC is designed as a multi-functional device that consolidates multiple responsibilities: it acts as a data concentrator for sensor information, a control signal generator, a power management unit, and a communication node. By combining these functions into a single distributed unit at each wheel, the system achieves redundancy and reliability without proportionally increasing overall system complexity.
Solution Approach 2:
The patent segments the brake control system into independent, identical RDC units at each wheel station. This modular segmentation allows for redundancy (multiple identical units) while keeping each unit's complexity manageable and standardized, facilitating easier manufacturing, testing, and maintenance compared to a single complex centralized controller.
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
The solution reduces wire weight and EMI, enhances system reliability, and optimizes performance in extreme temperatures, while maintaining redundancy and flexibility in aircraft braking systems.
Implementation Method 1
Each EBA includes a power device for effectuating braking of an associated wheel
Data Source
AI summary
A brake system of a vehicle includes a plurality of electromechanical brake actuators (EBAs) proximate the wheels of the vehicle. Each EBA includes a power device for effectuating braking of an associated wheel, and electronics to generate a drive signal for the power device. The brake system may further include at least one brake control unit (BCU) for converting a brake command signal into a control signal for each EBA. The electronics for each EBA may be configured to convert the corresponding control signal into the drive signal that is applied to the power device to cause movement of the power device and effectuate braking of the vehicle.