3D Sensor-Guided In-Flight Refueling Boom Control

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Solution Overview

Problem

Current aircraft refueling systems face challenges in maintaining precise station-keeping and refueling operations, especially in turbulent conditions and when atmospheric conditions distort visual images from cameras.

Innovation Solution

A system utilizing sensors to acquire scan data of the second vehicle, which is associated with a 3D model to provide monitored data. This system controls the refueling process, including the refueling boom, based on the monitored data, and can automatically adjust operations using an AI or machine learning system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If cameras are used to assist boom operator during connection process, then the operator can view images or video to guide the boom to fuel port, but atmospheric conditions such as rain, glare from sunlight can distort the acquired images or video and hinder the refueling operation

Engineering Contradiction:
Improveboom connection processVSAvoidimage quality
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The patent replaces the camera-based optical system with a sensor-based detection system that uses electromagnetic radiation (such as radar or LIDAR) to acquire spatial information about the second aircraft and boom position. This substitution eliminates the distortion problems caused by atmospheric conditions affecting visual images while providing reliable data for guiding the boom connection process.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If pilot manually operates control devices to maneuver trailing aircraft in relation to fuel tanker, then station-keeping can be maintained, but high level of skill, experience, and communication is required and difficulty arises during turbulence

Engineering Contradiction:
Improvestation-keepingVSAvoidmaneuvering stability
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The patent implements an automated control system where the sensor data is processed by a control unit that automatically adjusts the positioning of the first aircraft, second aircraft, and/or boom. This self-service capability reduces dependence on pilot skill and experience while maintaining station-keeping accuracy, and the automated system can respond more reliably to turbulent conditions than manual control.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The system continuously acquires spatial data from sensors about the relative positions of the aircraft and boom, processes this information, and uses it to make real-time adjustments to maintain proper alignment. This closed-loop feedback mechanism ensures reliable station-keeping and maneuvering by constantly monitoring and correcting position based on actual conditions.

Inventive Principle:
Principle #23Feedback

3Measurement precision

If sensors and 3D model registration system are used to acquire and process spatial data, then accuracy and safety of refueling is enhanced, but device complexity increases

Engineering Contradiction:
Improvespatial data accuracyVSAvoidcontrol system structure
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent employs sensors that serve multiple functions: they detect the position of the second aircraft, track the boom orientation, and provide spatial data for the 3D model registration system. This multi-functionality reduces the need for separate dedicated systems for each measurement task, thereby limiting the increase in device complexity while maintaining high measurement precision.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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

The system enhances the accuracy and safety of aircraft refueling by reducing the reliance on visual cues and enabling automatic control, thus improving station-keeping and refueling efficiency even in challenging conditions.

Implementation Method 1

The sensors can include one or more of light detection and ranging (LIDAR) sensors, lasers, infrared sensors, ultrasonic sensors, radio detection and ranging (RADAR) sensors

Methodology Applied
Scientific EffectLight detection and ranging (LIDAR): LIDAR

Implementation Method 2

The sensors can include one or more of light detection and ranging (LIDAR) sensors, lasers, infrared sensors, ultrasonic sensors, radio detection and ranging (RADAR) sensors

Methodology Applied
Scientific EffectRadio detection and ranging (RADAR): Radar

Data Source

PatentUS20250147515A1Systems and methods for controlling aircraft during in-flight refueling
Publication Date: 2025.05.08 THE BOEING CO
  • US20250147515A1 patent drawing
  • US20250147515A1 patent drawing
  • US20250147515A1 patent drawing

AI summary

A system and a method are configured for allowing a first vehicle to refuel a second vehicle. The system and the method include sensors configured to acquire scan data of the second vehicle. A control unit is in communication with the sensors. The control unit is configured to receive the scan data of the second vehicle from the sensors, associate the scan data with a three-dimensional (3D) model of the second vehicle, register the scan data with the 3D model to provide monitored data of the second vehicle, and control one or more of the first vehicle, the second vehicle, or a refueling boom of the first vehicle based on the monitored data.