Dynamic Aircraft Refuelling Flow Control via Electronic Valves
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Solution Overview
Problem
Conventional aircraft refuelling systems are inefficient due to fuel flow restrictors sized for maximum pressure, leading to extended refuelling times, as they do not adapt to the specific needs of individual fuel tanks, resulting in suboptimal refuelling optimization.
Innovation Solution
The implementation of flow control valves and an electronic control unit that dynamically regulates fuel flow rates in real-time, taking into account fuel level and pressure data, allows for optimized distribution and minimizes the influence of temperature fluctuations, enabling efficient refuelling of wing tanks with a balanced fuel repartition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If fuel flow restrictors are sized according to maximum fuel pressure (55 psig), then the refuelling pipework can handle maximum pressure, but refuelling times are extended due to unnecessarily restricted flow rates
Solution Approach 1:
The patent applies dynamics by replacing static fuel flow restrictors with dynamic flow control valves that can adjust their opening degree in real-time. The electronic control unit continuously monitors fuel pressure, flow rate, and tank level data, then dynamically modulates the valve openings to optimize refuelling speed while maintaining safe pressure limits. This transforms the system from a fixed restriction design to an adaptive control system that maximizes flow rate within safety constraints.
Solution Approach 2:
The patent changes the operating parameters of the fuel flow control system by using flow control valves with variable opening degrees instead of fixed restrictors. The electronic control unit adjusts valve parameters (opening degree, flow coefficient) based on real-time feedback from pressure sensors, flow meters, and tank level indicators, thereby optimizing the refuelling process under varying conditions.
2Stress or pressure
If a general regulation is performed by a fuel pressure regulator, then the maximum pressure in the refuelling pipework is defined, but the system cannot be optimized according to the concrete needs of individual fuel tanks
Solution Approach 1:
The patent segments the fuel refuelling system by providing individual flow control valves for each fuel tank instead of a single centralized pressure regulator. This allows independent control of fuel flow to each tank (wing tanks, center tank) based on their specific requirements, such as current fuel level, capacity, and refuelling priority. The electronic control unit manages each valve separately, enabling tailored refuelling strategies for different tanks simultaneously.
Solution Approach 2:
The patent implements local quality by enabling each fuel tank to receive customized refuelling control through its dedicated flow control valve. The electronic control unit adjusts the opening degree of each valve according to local conditions (tank level, pressure, flow rate), allowing optimal refuelling performance for each specific tank rather than applying a uniform pressure regulation to all tanks.
3Stress or pressure
If fuel flow restrictors are used to control flow rate, then pressure can be managed, but refuelling rates cannot be increased to reduce refuelling times
Solution Approach 1:
The patent replaces the passive mechanical fuel flow restrictors with active electronically-controlled flow control valves. Instead of relying on fixed mechanical restrictions, the system uses electronic actuators to precisely control valve openings, enabling dynamic adjustment of flow rates. This substitution allows the system to maximize refuelling rates while maintaining pressure control through electronic feedback loops rather than mechanical constraints.
Solution Approach 2:
The patent implements feedback control by using sensors to continuously monitor fuel pressure, flow rate, and tank level, then feeding this data back to the electronic control unit. The controller adjusts the flow control valves in real-time based on this feedback, optimizing refuelling rates while maintaining safe operating pressures. This closed-loop control enables higher refuelling rates compared to open-loop mechanical restrictors.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6B
AI summary
The aircraft refuelling equipment (20) of an aircraft comprises a pipework (22) in which a fuel supply line (13) is connected to a plurality of tank supply lines, fuel tanks connected to tank supply lines of the pipework, first valves (24, 25,26) allowing each fuel tank to be disconnected from the fuel supply line, and at least one captor (30) that provides a signal indicative of a pressure or a flow rate. For each of said first valves, a first valve flow parameter can be estimated, using said captor. The equipment further comprises: - at least one actuator associated with each of said first valves, the actuator allowing adjustment of the opening of the associated first valve; and an electronic control unit (ECU) connected to the respective actuator-first valve assemblies and adapted to regulate an opening of the first valves, using respective first valve flow parameter data.