Electric Aircraft Propulsor Fault Detection and Torque Reallocation
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Solution Overview
Problem
Electric aircraft face challenges in maintaining safety during flights due to potential component malfunctions, particularly when a propulsor becomes inoperable, which can compromise the aircraft's integrity and pose risks to passengers and cargo.
Innovation Solution
A system and method for fault detection and control that includes a flight controller with sensors to detect propulsor malfunctions, an observer to generate prediction and residual data, and a mixer to adjust torque commands, allowing for safe operation even if one propulsor fails by redistributing torque among remaining propulsors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the aircraft operates with multiple propulsors, then the productivity and thrust capability are improved, but the reliability deteriorates when one propulsor fails
Solution Approach 1:
The system dynamically changes operational parameters by switching the mixer between first and second modes based on fault detection. When a propulsor failure is detected through residual analysis, the system reconfigures control parameters to redistribute torque among remaining functional propulsors, maintaining safe operation while adapting to the degraded state
Solution Approach 2:
The control system implements dynamic reconfiguration capability where the mixer can operate in different modes. The system transitions from normal multi-propulsor control to fault-tolerant control mode, dynamically adjusting torque distribution commands to ensure continued safe operation with reduced thrust capability
2Reliability
If fault detection systems are added to monitor propulsor status, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The system implements feedback-based fault detection using an observer that continuously monitors propulsor performance. Sensors provide feedback data on propulsor operation, and the observer generates residual signals by comparing actual sensor data with predicted values from a dynamic model. This feedback mechanism enables reliable fault detection without requiring complex additional hardware
Solution Approach 2:
The observer acts as an intermediary between the physical propulsor system and the control system. It processes sensor data and generates residual signals that indicate fault conditions, serving as a mediator that translates complex sensor information into interpretable fault indicators for the mixer and control system
3Reliability
If torque redistribution is implemented upon propulsor failure, then the safe operation is maintained, but the control complexity increases
Solution Approach 1:
The mixer implements dynamic control reconfiguration by switching between different operational modes. In normal operation, it controls all propulsors in first mode. Upon fault detection, it transitions to second mode to control only functional propulsors, dynamically adjusting torque distribution to maintain safe operation while managing control complexity through mode-based simplification
Data Source
AI summary
A system for fault detection and control in an electric aircraft including an inertial measurement unit, the inertial measurement unit including at least a sensor configured to detect a torque datum associated with at least a propulsor. The system includes an observer, the observer configured to generate a torque prediction datum associated with the at least a propulsor, compare the torque prediction datum with the torque datum, and generate a residual datum as a function of the comparison. The system includes a mixer, the mixer comprising circuitry configured to generate, as a function of the residual datum, a torque priority command datum and transmit, to the at least a propulsor, the torque priority command datum.