Aircraft Fatigue Management via Load Signal Extraction
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Solution Overview
Problem
Current fatigue management systems for aircraft rely on conservative assumptions for fatigue damage accumulation, leading to unnecessary component replacements and increased costs, as they lack precise methods to determine individual component life based on actual usage patterns.
Innovation Solution
A fatigue management system that utilizes high-frequency load signal data from load classification flights, processed with heuristic models and statistical methods to accurately calculate fatigue damage, bypassing the need for full signal reconstruction and accounting for aircraft weight and position, thereby optimizing fatigue damage assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If load sensors are installed on all structural elements to accurately measure component loads, then measurement precision is improved, but device complexity and cost increase substantially
Solution Approach 1:
The patent creates a virtual copy of the physical load measurement system through finite element models and simulation data. Instead of installing physical sensors on every component, the system uses computational models that replicate the behavior of instrumented structures, allowing accurate load estimation without physical intrusion.
Solution Approach 2:
The patent replaces the mechanical sensor-based measurement system with an analytical approach using finite element analysis and operational data. The mechanical measurement chain (sensors, wiring, signal conditioning) is substituted with computational mechanics that calculate loads from operational parameters and structural models.
2Reliability
If a conservative Standard Mission Profile is assumed for all aircraft, then reliability is improved through safety margins, but productivity decreases due to unnecessary component replacements
Solution Approach 1:
The patent transitions from static, one-size-fits-all replacement schedules to dynamic, condition-based maintenance planning. The system continuously updates component life predictions based on actual operational data, allowing maintenance timing to adapt to real usage patterns rather than following fixed conservative intervals.
Solution Approach 2:
The patent changes the fundamental parameter from fixed replacement intervals to variable component life predictions. By incorporating actual operational parameters (flight hours, mission types, environmental conditions) into the assessment model, the system adjusts maintenance schedules based on real component degradation rates rather than conservative assumptions.
3Measurement precision
If full high-frequency load signal reconstruction is performed to calculate fatigue damage, then measurement precision is improved, but loss of time increases due to extensive data processing
Solution Approach 1:
The patent extracts only the essential information needed for fatigue damage calculation from the full load signal. Instead of reconstructing and processing complete high-frequency load time histories, the system identifies and uses only the critical load parameters (peak loads, cycle counts, stress ranges) that directly contribute to fatigue damage accumulation.
Solution Approach 2:
The patent applies partial action by calculating fatigue damage using a simplified subset of the full load signal information. Rather than performing complete signal reconstruction and analysis, the method uses strategically selected load parameters that provide sufficient accuracy for fatigue assessment while dramatically reducing computational effort.
Data Source
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AI summary
The invention relates to a fatigue management system for determining the individual life of components of at least one aircraft, particularly the individual life of at least one helicopter and/or components of said at least one helicopter. The invention relates as well to a method of operating said fatigue management system.