Flush-Mounted LED Lighting on Aircraft Control Surfaces
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Solution Overview
Problem
Traditional forward-facing aircraft floodlights face engineering challenges such as damage from airflow, aerodynamic drag, and mechanical stress, and are limited in placement due to their size and weight, particularly when used on landing gear or extendable lights.
Innovation Solution
An array of solid-state LEDs is mounted on the leading edge of the wing's slat control surface, utilizing thermally conductive materials for heat management and glass lenses for erosion resistance, allowing for adjustable light direction and intensity without significant mechanical system changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If traditional floodlights are mounted on landing gear or extendable lights, then illumination is provided, but the equipment is subject to damage from airflow, shock loads, vibration, and mechanical stress
Solution Approach 1:
The lighting system is segmented into multiple individual LED modules distributed across the control surface, rather than using a single large floodlight. This segmentation allows each module to be smaller, lighter, and more resistant to mechanical stress and vibration while collectively providing the required illumination intensity.
Solution Approach 2:
Instead of mounting lights on the landing gear (mobile structure), the invention inverts the mounting location to the control surface (fixed aerodynamic structure). This reversal protects the lighting system from the mechanical stresses and vibrations associated with landing gear operation while maintaining effective illumination.
2Illumination intensity
If extendable or gear-mounted lighting is placed in the airstream, then illumination is provided, but aerodynamic drag increases
Solution Approach 1:
The lighting system is divided into multiple small LED modules that can be integrated into the control surface geometry, allowing the light sources to be positioned within the aerodynamic flow path without creating significant drag, unlike large extendable light assemblies.
Solution Approach 2:
The lighting system is merged with the control surface structure itself, using the control surface as both the aerodynamic component and the mounting platform for the LEDs. This integration eliminates the need for separate extendable light assemblies that would protrude into the airstream and increase drag.
3Object-generated harmful factors
If an array of LEDs is mounted on the control surface, then illumination is provided with minimal drag, but thermal management becomes a challenge
Solution Approach 1:
The control surface's aerodynamic flow is utilized as a cooling mechanism for the LED modules. The high-velocity airflow over the control surface during flight provides convective cooling, dissipating heat from the LEDs without requiring active thermal management systems.
Solution Approach 2:
The system uses its own operational environment (the aerodynamic flow during flight) to provide thermal management for the LED modules. The flight conditions that generate aerodynamic drag also provide the cooling necessary to manage LED heat dissipation.
4Reliability
If glass lenses are used for erosion resistance, then durability is improved, but the density of glass makes the lens a significant portion of the light assembly's weight
Solution Approach 1:
Glass lenses are used only at the specific locations where erosion resistance is most critical (the forward-facing light sources), while other parts of the control surface can use lighter materials. This localized application of glass minimizes overall weight while providing necessary durability.
Solution Approach 2:
The light assembly uses composite construction, combining glass lenses for erosion-resistant light sources with lighter weight materials for the control surface structure and LED housings, optimizing the balance between durability and weight.
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 provides efficient and durable lighting with minimal aerodynamic drag and weight addition, enabling effective illumination during various flight phases while maintaining structural integrity and reducing drag-related issues.
Implementation Method 1
utilizing thermally conductive materials for heat management
Implementation Method 2
dissipate the heat into the air flowing over the wing
Implementation Method 3
Because of the erosion effects of high-speed airflow, forward-facing lenses are typically glass
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
A lighting assembly for movable control surfaces of a vehicle. The light assembly includes a lens (30), a plurality of light-emitting diodes (LEDs) (36) and a housing (24, 28) that receives the plurality of LEDs and the lens. The housing of the light assembly is received within the movable control surface, such that the lens is flush with a surface of the movable control surface. The light assembly includes a plurality of reflectors. The plurality of LEDs is rotatably mounted within the housing. The light assembly includes a controller that controls the position of the LEDs relative to the housing, based on a received control signal.