Integrated Position Sensor with Dual Outputs for Fewer EMA Wires

Solution Overview

Problem

The existing configuration of electro-mechanical actuators (EMAs) in aircraft requires multiple interconnecting wires between the EMA and the EMA controller, leading to increased weight and complexity due to redundant sensor interfaces.

Innovation Solution

An integrated position sensor with dual synchronized outputs is implemented, which reduces the number of interconnections by processing and combining motor position data and actuator position data into a single sensor data packet, transmitted via fewer communication buses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If each sensor is interfaced via its own separate interface to achieve robustness and redundancy, then reliability is improved, but device complexity and weight increase due to multiple interconnecting wires

Engineering Contradiction:

Improvesensor interface robustnessVSAvoidnumber of interconnecting wires

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple sensor interfaces are merged into a single integrated interface. The patent combines multiple sensor data streams (from redundant sensors) into one communication channel, eliminating the need for separate wires for each sensor while maintaining all redundancy and robustness features through software-based sensor management.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

A single sensor interface is designed to handle multiple sensor types and functions universally. The interface can accommodate various sensor protocols and data formats, allowing one wire to replace multiple dedicated wires while maintaining compatibility with different sensor configurations for robustness.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If each sensor is interfaced via its own separate interface to achieve robustness and redundancy, then reliability is improved, but weight increases due to connector size and internal wiring

Engineering Contradiction:

Improvesensor interface robustnessVSAvoidEMA and EMAC weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

Multiple sensor interfaces are merged into a single integrated interface. The patent combines multiple sensor data streams (from redundant sensors) into one communication channel, eliminating the need for separate wires for each sensor while maintaining all redundancy and robustness features through software-based sensor management.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If redundant sensors are interfaced via separate interfaces to achieve robustness, then reliability is improved, but the number of interconnecting wires increases adding weight to the cable bundle

Engineering Contradiction:

Improvesensor redundancyVSAvoidcable bundle weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

Multiple sensor interfaces are merged into a single integrated interface. The patent combines multiple sensor data streams (from redundant sensors) into one communication channel, eliminating the need for separate wires for each sensor while maintaining all redundancy and robustness features through software-based sensor management.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12319403B2Integrated position sensor with dual synchronized outputs

Publication Date: 2025.06.03 HONEYWELL INTERNATIONAL INC

AI summary

A system configuration significantly reduces the number of interconnections needed between an electromechanical actuator (EMA) and an EMA controller (EMAC) while maintaining redundancy and other safety aspects needed by the target application. This allows simplification of communication interfaces between multiple sensors in the EMA and EMAC and unification of the interface to multiple sensors inside the EMAC, leading to cost and weight reduction that can be significant for many aerospace products and applications, including unmanned vehicle (e.g., UAM/UAV) applications.