Redundant Hydraulic Actuator Control for Shared Pre-Flight Testing
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Solution Overview
Problem
Conventional redundant vehicle control systems require multiple auxiliary pressure sources for pre-flight testing, which are not used during flight and increase weight and cost, while also posing safety risks due to dormant failures.
Innovation Solution
A redundant control system with primary and auxiliary hydraulic stages, where the auxiliary stage is used for ground-operation mode testing and the primary stages function independently during flight, reducing the number of auxiliary pressure sources needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple auxiliary pressure sources are added to each hydraulic stage for pre-flight testing, then testing capability is improved, but weight and device complexity increase
Solution Approach 1:
The auxiliary pressure source is designed to serve multiple hydraulic stages sequentially rather than being dedicated to a single stage. The system can switch between servicing different stages (e.g., flight control actuator, rotor brake, main rotor tilt actuator) using the same auxiliary pressure source, thereby eliminating the need for multiple separate auxiliary pressure sources and reducing overall system weight.
Solution Approach 2:
The patent combines the testing function for multiple hydraulic stages into a single integrated auxiliary pressure source. Instead of having separate auxiliary pressure sources for each stage, the system merges these functions into one shared resource that can be allocated to different stages as needed during pre-flight testing.
2Reliability
If multiple auxiliary pressure sources are added to each hydraulic stage for pre-flight testing, then testing capability is improved, but device complexity increases
Solution Approach 1:
The auxiliary pressure source is designed as a universal unit that can service multiple different hydraulic stages through a selection mechanism. This multi-functional design reduces the total number of components needed and simplifies the overall system architecture compared to having dedicated auxiliary pressure sources for each stage.
Solution Approach 2:
The system separates the testing function from the primary flight operation function. The auxiliary pressure source is specifically designed for ground-based testing operations and can be selectively engaged without interfering with flight operations. This segmentation allows the testing capability to be added without complicating the flight control system.
3Reliability
If auxiliary pressure sources are used during flight operations, then testing capability is maintained, but loss of substance occurs due to unnecessary operation
Solution Approach 1:
The system dynamically switches between different pressure sources based on operational mode. During flight operations, the primary pressure sources are activated while the auxiliary pressure source remains dormant. During pre-flight testing on the ground, the auxiliary pressure source is activated. This dynamic allocation ensures that hydraulic fluid is only consumed when actually needed for testing, avoiding unnecessary consumption during flight operations.
Solution Approach 2:
The auxiliary pressure source operates periodically only during pre-flight testing phases rather than continuously. The system alternates between using primary pressure sources during flight and auxiliary pressure sources during ground testing, creating a periodic usage pattern that minimizes overall hydraulic fluid consumption while maintaining testing capability.
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
This design reduces the number of auxiliary pressure sources required for testing, decreasing weight and cost while ensuring safety by enabling effective pre-flight testing without compromising flight operations.
Implementation Method 1
Each of the plurality of primary stages and the auxiliary stage include hydraulic stages including a pressure source
Data Source
AI summary
Embodiments of the disclosure include a redundant control system for a vehicle. The redundant control system includes first and second actuator pistons mechanically coupled to one another and disposed in respective first and second fluid chambers. The first and second actuator pistons are movable by first and second primary stages. One of the primary stages includes a bypass valve with a pilot valve actuatable in response to movement of the first actuator piston.