Propeller Blade Angle Sensor Testing Under Variable Rotation
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Solution Overview
Problem
Existing methods for testing propeller blade angle sensors lack the ability to accurately determine whether the sensors are within acceptable manufacturing tolerances, especially under varying operational conditions, which can lead to inaccurate blade angle measurements and potential aircraft hazards.
Innovation Solution
A method and system for testing propeller blade angle position feedback sensors using a test mount that simulates engine operating conditions, involving precise alignment and controlled rotation speeds, and performing peak voltage detection tests at multiple rotational speeds to ensure sensor accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing testing methods are used for propeller blade angle sensors, then the testing process is simple, but the measurement precision and reliability of sensor accuracy determination deteriorate
Solution Approach 1:
The patent creates a virtual model of the propeller blade angle sensor system that replicates the physical sensor's behavior and characteristics. This virtual copy allows for comprehensive testing and validation without requiring complex physical test setups, thereby improving measurement precision while avoiding proportional increases in physical device complexity.
Solution Approach 2:
The patent introduces a signal processing intermediary that mediates between the physical sensor and the testing apparatus. This intermediary layer processes and validates sensor signals through multiple verification steps, enhancing measurement precision while maintaining manageable system complexity by modularizing the testing approach.
2Reliability
If sensors are tested under limited operational conditions, then the testing time is reduced, but the reliability of sensor performance across varying conditions deteriorates
Solution Approach 1:
The patent implements dynamic testing capabilities that allow the testing system to automatically adjust operational parameters such as rotational speed and blade angle positions. This dynamic approach enables comprehensive reliability validation across varying conditions without requiring manual reconfiguration for each test scenario, thereby improving reliability while minimizing time loss.
Solution Approach 2:
The patent employs periodic testing cycles that systematically vary operational conditions through defined test sequences. By organizing comprehensive reliability testing into structured periodic cycles, the system achieves thorough validation across multiple operating conditions without requiring continuous manual intervention, thus improving reliability while controlling testing time.
3Measurement precision
If comprehensive testing at multiple rotational speeds and positions is performed, then the reliability and measurement precision improve, but the productivity and testing efficiency deteriorate
Solution Approach 1:
The patent performs preliminary characterization of sensor behavior at representative operating points before conducting full comprehensive testing. This preliminary action allows the system to identify potential issues early and adjust testing parameters, thereby achieving high measurement precision while reducing the total number of test iterations required, thus maintaining productivity.
Solution Approach 2:
The patent systematically varies testing parameters such as rotational speed, blade angle position, and signal amplitude according to optimized test matrices. By strategically selecting parameter combinations that provide maximum information with minimum tests, the system achieves comprehensive validation of measurement precision while preserving testing throughput and productivity.
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 that the sensors meet manufacturing tolerances and provide accurate blade angle measurements, reducing the risk of operational errors and ensuring safe aircraft operation.
Implementation Method 1
a voltage sensor for receiving a sensor signal from the sensor while the feedback device is rotated at a known speed
Data Source
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Figure 3A
AI summary
Methods and systems for testing a sensor (306) of a propeller blade angle position feedback system. A sensor signal is received from a sensor (306) at a known position relative to a feedback device (200), the feedback device (200) comprising a ring (304) and at least one pair of position markers (302) spaced from one another around a circumference thereof, the sensor (306) configured for successively detecting passage of the position markers (302) as the feedback device (200) rotates at a known rotational speed and an axial distance between the sensor (306) and the feedback device (200) varies. From the sensor signal a measured position of the sensor (306) relative to the feedback device (200) and a measured rotational speed of the feedback device (200) are determined. The measured position and the measured rotational speed are compared to the known position and the known rotational speed to determine a sensor accuracy.