Aircraft Fuel Tank Sensor Fault Detection Using Gradient Consistency
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Solution Overview
Problem
Existing methods for identifying sensor malfunctions in aircraft fuel tanks are time-consuming and expensive, requiring tanks to be emptied and filled completely, and cannot be performed during flight.
Innovation Solution
A method involving an electronic control device that verifies sensor functionality during flight by monitoring fuel level signals, calculating gradients, and comparing consistency among sensors to detect malfunctions, regardless of fuel levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual control procedures are performed on the ground with tanks placed in completely empty and completely full conditions, then sensor malfunction identification is achieved, but the process becomes time-consuming and expensive
Solution Approach 1:
The patent applies preliminary action by performing sensor verification during normal flight operations before actual fuel consumption occurs. The system continuously monitors fuel quantity measurements and compares them with expected consumption based on engine parameters, detecting sensor malfunctions in advance rather than waiting for ground-based testing after flight.
Solution Approach 2:
The system enables self-service by using the aircraft's own operational data (engine fuel consumption, flight parameters) to verify sensor accuracy during normal flight. The comparison between measured fuel quantity and calculated consumption allows the system to self-diagnose sensor malfunctions without external intervention or special testing conditions.
2Measurement precision
If manual control procedures require tanks to be completely empty and completely full, then sensor measurement range verification is achieved, but the complexity and cost increase
Solution Approach 1:
The patent applies partial action by verifying sensor functionality during normal operational fuel levels rather than requiring extreme conditions of completely empty or full tanks. The system continuously monitors fuel quantity throughout the flight, providing ongoing verification without needing to push the system to its absolute boundaries.
Solution Approach 2:
The system achieves universality by using the same sensor and measurement system for both normal fuel quantity indication and malfunction detection. The dual-purpose approach eliminates the need for separate testing equipment or procedures, as the operational fuel measurement system itself performs the verification function.
3Reliability
If ground-based sensor control procedures are used, then sensor functionality is verified, but the aircraft cannot be serviced during flight and maintenance time increases
Solution Approach 1:
The system performs preliminary verification of sensor functionality during flight operations before the aircraft returns to ground. By continuously monitoring and comparing fuel measurements with expected consumption, the system identifies malfunctions in advance, allowing maintenance to be scheduled proactively rather than reactively after flight.
Solution Approach 2:
The aircraft performs self-verification of sensor functionality during normal flight operations using its own operational data. The system compares measured fuel quantity with calculated consumption based on engine parameters, enabling the aircraft to self-diagnose sensor issues without requiring ground-based equipment or procedures.
Data Source
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AI summary
Method for identifying malfunction conditions of the sensors that measure the amount of fuel in the tanks of an aircraft (1) provided with at least one first tank (2/6) arranged on a first side of the aircraft and at least one second tank (4/8) arranged on a second side, each first and second tank (2/6; 4/8) is provided with a plurality m of sensors (11) detecting the level of fuel within the respective tank (2/6 and 4/8). The method performs a symmetry control wherein the level gradients (11) associated with the first tank (2/6) and the second tank (4/8) are compared to each other; and if the values of the compared gradients are close, a consistency condition is detected. As an alternative to the symmetry control, a discontinuity control is carried out wherein the step of comparing the consumption gradient associated with each sensor (11) with a reference gradient comprising an average consumption gradient of the other sensors and/or with the total consumption gradient is carried out.