Hybrid Propulsion Torque Sensing for Aircraft Fault Isolation
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Solution Overview
Problem
Current hybrid electric powerplant systems for aircraft lack effective fault detection and mitigation capabilities, leading to potential permanent damage and system failures.
Innovation Solution
A hybrid electric propulsion system with torque sensors connected to a heat engine, electric motor, and combining gearbox, along with a controller that receives torque signals to control disconnect mechanisms and issue commands for torque compensation or maintenance alerts, enabling early detection and mitigation of faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fault detection methods are used in hybrid electric powerplant systems, then the system structure remains simple, but the ability to detect and mitigate faults early is insufficient
Solution Approach 1:
The patent implements preliminary fault detection by continuously monitoring torque signals from multiple sensors before actual failures occur. The controller compares expected torque values with actual measurements to detect anomalies early, enabling preventive action before permanent damage happens to the powerplant or its systems.
Solution Approach 2:
The system employs feedback mechanisms by using torque sensors on both the heat engine and electric motor shafts, along with a combining gearbox torque sensor, to continuously provide torque information back to the controller. This feedback loop enables real-time fault detection and allows the controller to adjust operations to mitigate detected issues.
2Measurement precision
If multiple torque sensors are installed on heat engine and electric motor shafts, then fault detection precision is improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by placing torque sensors at specific critical locations - on the heat engine shaft, electric motor shaft, and combining gearbox - rather than uniformly throughout the system. Each sensor monitors torque at its local position, providing precise measurement where needed most for fault detection while avoiding unnecessary sensors elsewhere.
Solution Approach 2:
The controller acts as an intermediary that receives torque signals from multiple sensors and processes them to detect faults. Rather than requiring direct complex interconnections between sensors, the controller mediates the information flow, comparing expected versus actual torque values to identify anomalies, thereby managing the complexity of multiple measurement points.
3Reliability
If disconnect mechanisms are added to isolate faulty components, then system safety is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent segments the hybrid powerplant system into distinct controllable modules - heat engine, electric motor, and combining gearbox - with disconnect mechanisms that can isolate faulty segments. This segmentation allows individual components to be disconnected and protected independently, improving safety by preventing fault propagation while maintaining a modular structure that facilitates manufacturing.
Solution Approach 2:
The disconnect mechanisms serve as beforehand cushioning by providing a pre-configured safety mechanism that can be activated when faults are detected. Rather than relying on reactive measures after failure, the system has predetermined disconnect paths ready to isolate faulty components, cushioning against potential damage and safety issues before they fully manifest.
Data Source
AI summary
A hybrid electric propulsion (HEP) system can include a heat engine torque sensor connected between a heat engine and a combining gear box to sense a heat motor input torque input to the combining gear box, an electric motor torque sensor connected between an electric motor and the combining gear box to sense an electric motor input torque input to the combining gear box, and a combining gear box torque sensor connected to an output of the combining gearbox. The system can include a HEP controller operatively connected to each of the heat engine torque sensor, the electric motor torque sensor, and the combining gear box torque sensor to receive one or more torque signals therefrom. The controller can be configured to output one or more output signals as a function of the signals from each of the heat engine torque sensor, the electric motor torque sensor, and the combining gear box torque sensor.