Aircraft Engine Torque Sensor Calibration Using Expected Torque Lookup
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Solution Overview
Problem
Aircraft engine torque sensors require calibration and often become degraded, leading to unreliable measurements, which can compromise engine and aircraft operations, and existing calibration methods are prone to human error and cyber security risks.
Innovation Solution
A method and apparatus for calibrating aircraft engine torque sensors using a software-based approach that involves receiving engine and torque sensor parameters, determining conformance, measuring and calibrating raw torque, and applying non-torque parameters to a lookup structure to validate sensor health, without requiring additional hardware, thus preventing human error and cyber threats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manual calibration methods are used for torque sensors, then calibration can be performed, but human error and cyber security risks increase
Solution Approach 1:
The torque sensor calibration system performs self-validation by automatically comparing measured torque values against expected values derived from engine parameters and lookup structures. The system detects calibration errors and sensor degradation autonomously without requiring manual intervention, thereby eliminating human error and reducing cyber security vulnerabilities associated with manual calibration processes.
Solution Approach 2:
The system implements a feedback mechanism where the measured torque is compared against expected torque values calculated from engine parameters stored in lookup structures. This closed-loop feedback enables automatic detection of calibration drift and sensor degradation, allowing the system to identify and correct errors without human intervention, thus improving reliability while eliminating human error risks.
2Measurement precision
If additional hardware is added for calibration validation, then measurement accuracy improves, but device complexity and cost increase
Solution Approach 1:
The calibration system utilizes existing engine parameters and control units that serve multiple functions. The same control unit that manages engine operation also performs torque calibration and validation. Lookup structures containing engine parameters serve both operational control and calibration verification purposes, eliminating the need for dedicated calibration hardware and reducing overall system complexity.
Solution Approach 2:
Instead of adding physical calibration hardware, the system creates a virtual model of expected torque behavior using lookup structures containing engine parameters. This digital twin or copy of the expected torque characteristics is used to validate actual sensor measurements, achieving high measurement precision without additional physical components.
3Ease of operation
If manual calibration procedures are used, then flexibility is maintained, but productivity and consistency decrease
Solution Approach 1:
The system pre-populates lookup structures with engine parameters and expected torque characteristics during manufacturing or system setup. This preliminary action enables automatic calibration validation during operation without requiring manual procedures, significantly improving productivity and consistency while maintaining the flexibility to adapt to different engine configurations through programmable parameters.
Data Source
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AI summary
Input is received. A conformance is determined. When conformance is determined, a raw torque is measured from a torque sensor at an engine; the raw torque is calibrated using the torque sensor parameters to produce a calibrated torque value, non-torque parameters associated with the engine are measured and the non-torque parameters are applied to a lookup structure to obtain an expected torque value. A separation of the calibrated torque value and the expected torque value is determined and based upon the separation, an operation of the torque sensor is controlled.