Propeller Fatigue Life Monitoring via Physics-Based Algorithms
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Solution Overview
Problem
Current methods for monitoring propeller health rely on assumptions based on flight hours, flight cycles, and calendar days, which can lead to inaccurate fatigue life consumption estimates, potentially resulting in premature or delayed maintenance.
Innovation Solution
A system comprising a processing unit with programmed algorithms that apply aircraft parameter data, such as air speed, altitude, and engine data, to determine the fatigue life consumption of critical propeller components, providing real-time alerts for maintenance when thresholds are reached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flight hours, flight cycles, and calendar days are used to monitor propeller health, then maintenance scheduling is simplified, but fatigue life consumption estimation accuracy deteriorates
Solution Approach 1:
The patent transforms the monitoring parameters from simple operational metrics (flight hours, cycles, calendar days) to physics-based parameters that directly reflect actual stress and loading conditions on propeller components. By changing the parameter basis from time-based to stress-based measurements, the system achieves both accurate fatigue life estimation and maintains operational simplicity through automated processing.
2Measurement precision
If physics based algorithms with multiple aircraft parameters are used, then fatigue life consumption accuracy is improved, but system complexity increases
Solution Approach 1:
The patent employs a multi-functional processing unit that integrates multiple aircraft parameter inputs (air speed, altitude, engine data, load factor) and processes them through unified physics-based algorithms. This single system performs data collection, processing, fatigue life calculation, and maintenance alert generation, thereby managing complexity through consolidation rather than proliferation of separate systems.
Solution Approach 2:
The processing unit acts as an intermediary between raw aircraft operational data and fatigue life consumption results. It mediates the complex relationship between multiple input parameters and the final accuracy outcome by applying standardized physics-based algorithms, thereby managing system complexity through a centralized computational layer.
3Device complexity
If traditional monitoring methods are used, then system simplicity is maintained, but safety deteriorates due to potential fatigue failure
Solution Approach 1:
The system performs preliminary assessment of fatigue life consumption by continuously processing aircraft parameter data through physics-based algorithms. By calculating fatigue life consumption in advance and providing maintenance alerts before critical thresholds are reached, the system proactively prevents fatigue failures while maintaining relative system simplicity through automated computational processing.
Solution Approach 2:
The system establishes a feedback loop where aircraft operational data continuously feeds into fatigue life consumption calculations, which then generate maintenance alerts that inform subsequent operational decisions. This closed-loop feedback mechanism enhances safety by continuously monitoring and responding to changing propeller health conditions without requiring complex manual intervention systems.
Data Source
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AI summary
A system for monitoring propeller (102) health comprising: a processing unit having a processor (300) which is programmed to apply a plurality of algorithms to inputted aircraft parameter data (10); a plurality of data inputs for inputting aircraft parameter data (10) into the algorithms, wherein the processor (300) is configured to apply the physics based algorithms to the aircraft parameter data (10) to determine at least the fatigue life consumption (18) of one or more critical components of a propeller (102); and an output device 400, 500 which is able to output an indication of the determined fatigue life consumption (18) to an observer