Flight Control Cable Sensor with Magnetic Disengagement
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Solution Overview
Problem
Conventional flight control cable sensors can negatively affect the operation of flight control cables if they become disabled, leading to potential failures in detecting actuation and maintaining the position of flight control surfaces in aircraft.
Innovation Solution
A flight control cable sensor system utilizing a draw wire encoder with an extendable-retractable wire, a first connector co-movably fixed to the wire, and a second connector co-movably fixed to the flight control cable, which removably engages up to a predetermined pull-off force, allowing the cable to continue actuating even if the wire binds, using magnetic or mechanical engagement mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a draw wire encoder is used to detect flight control cable actuation, then measurement capability is improved, but the risk of binding and sensor failure increases
Solution Approach 1:
The sensor system is divided into independent functional segments: the draw wire encoder for measurement, the spring-loaded reel for force application, and the flight control cable for actuation. This segmentation allows the measurement function to be separated from the actuation function, enabling the sensor to detect cable movement without being part of the load-bearing path, thus reducing binding risk while maintaining measurement precision
Solution Approach 2:
The spring-loaded reel acts as an intermediary element between the draw wire encoder and the flight control cable. It provides a controlled mechanical interaction that allows the encoder to follow cable movement without direct binding, using spring force to maintain engagement while accommodating cable motion, thereby resolving the contradiction between measurement capability and reliability
2Measurement precision
If the sensor is rigidly connected to the flight control cable, then measurement accuracy is improved, but the cable operation is impeded when the sensor binds
Solution Approach 1:
The connection between the sensor and flight control cable is made dynamic rather than rigid. The spring-loaded reel allows the draw wire encoder to dynamically adjust its position and engagement force based on cable movement, maintaining measurement accuracy while accommodating variations in cable tension and movement, thus preventing binding and ensuring smooth cable operation
Solution Approach 2:
The spring constant and pre-load force of the spring-loaded reel are carefully selected to optimize the interaction between the sensor and cable. By adjusting these parameters, the system maintains sufficient engagement for accurate measurement while allowing enough compliance to prevent binding during cable actuation, resolving the contradiction between measurement precision and ease of operation
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
Ensures continued proper actuation of flight control cables and surfaces by disengaging when the pull-off force exceeds the predetermined limit, preventing binding issues and maintaining operational integrity even if the draw wire encoder malfunctions.
Implementation Method 1
one of the first connector or the second connector comprises a magnet; an other of the first connector or the second connector is made of a ferromagnetic material magnetically attracted to the magnet
Data Source
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AI summary
Disclosed herein is a flight control cable sensor for detecting actuation of a flight control cable of an aircraft. The flight control cable sensor comprises a draw wire encoder, comprising an extendable-retractable wire. The flight control cable sensor further comprises a first connector, co-movably fixed to the extendable-retractable wire, and a second connector, co-movably fixable to the flight control cable and configured to removably co-movably engage the first connector up to a predetermined pull-off force.