Smart Boom Tip Assembly Load Alleviation
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Solution Overview
Problem
Existing aircraft refueling booms lack effective load attenuation, alleviation, and maintenance-friendly solutions, leading to potential failures due to mechanical stresses and reliance on unreliable contact detection systems.
Innovation Solution
A modular boom tip assembly with load sensing, digital signal conversion, and mechanical fuse for safe separation, integrated with ruddevators for load alleviation and digital communication to the central computer for automatic control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a passive contact loads attenuation mechanism based on a recoil shock absorber is used, then load attenuation is provided, but the mechanism is not properly integrated in the boom
Solution Approach 1:
The shock absorber is integrated into the boom tip assembly by merging it with the telescoping section and nozzle mounting structure. The shock absorber housing forms part of the boom tip assembly structure, and the telescoping section moves within the shock absorber housing, combining multiple functions into a single integrated unit rather than separate components.
2Difficulty of detecting and measuring
If coil signals are installed on the nozzle for contact detection, then contact detection is provided, but maintenance needs increase and potential for damage occurs
Solution Approach 1:
The system replaces fragile electrical coil signals with a robust mechanical fuse mechanism for contact detection. The mechanical fuse includes a fusible element that physically breaks under excessive load, providing a tangible, maintenance-free detection method that eliminates the need for electrical connections and signal processing at the nozzle tip.
3Force
If strain gauges are used for load alleviation, then load sensing is provided, but routing of analog signals and signal integrity become problematic
Solution Approach 1:
The system replaces electrical strain gauges with a mechanical fuse mechanism that directly senses and responds to load conditions through physical deformation and breaking of the fusible element. This mechanical approach eliminates the need for electrical signal routing, analog-to-digital conversion, and complex signal processing systems.
4Ease of operation
If the boom operator manually guides the boom to avoid boom deflections, then boom control is provided, but automatic load alleviation is not achieved
Solution Approach 1:
The mechanical fuse system provides automatic load alleviation by self-activating when excessive loads are detected. The fusible element automatically breaks under overload conditions, triggering the safe separation mechanism without requiring operator intervention or manual control inputs.
5Ease of operation
If the telescoping section is extended for nozzle engagement, then coupling is completed, but mechanical contact loads build up and stresses are placed on the boom
Solution Approach 1:
The shock absorber is pre-installed in the boom tip assembly to cushion against mechanical contact loads before they can cause damage. The shock absorber is positioned to absorb impacts during nozzle engagement and receptacle connection, protecting the boom structure from stress buildup.
Data Source
AI summary
A refueling apparatus for interconnecting a tanker aircraft (11) with a receiver aircraft in flight comprising a boom (21) joined to said tanker aircraft (11) by means of a mechanical articulation (41) having control means including a central computer station, an inner fuel conduit, a refueling nozzle (27) at its distal end and, and a smart tip assembly comprising a first module (83) having load sensing means, a second module (85) having load alleviation means and a third module (87), joined to the nozzle (27), having a mechanical fuse (99) for allowing the safe separation of tanker and receiver aircraft in the event of overloads. The invention also comprises a method of load alleviation for minimizing the loads on the boom (21).