Torque Tube Strain Gauge Sensor with Self-Powered Wireless Transmission
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Solution Overview
Problem
Current aircraft trailing edge flap systems lack the ability to measure axial/torsional force applied to drive aircraft surfaces, leading to potential issues like actuator jams and malfunctions, which can result in increased or decreased torque in the shaft, and are not effectively addressed by existing speed and position measurement systems.
Innovation Solution
A torque tube sensor system that includes a sensor body with strain gauges and Wheatstone bridge configuration, using IR or RF frequency signals for communication, and a self-powered design with a permanent magnet stator to measure mechanical strain and detect excessive torque, allowing for wireless data transmission to a receiver for further processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If speed and position measurement systems are used to monitor torque tube operation, then the control system can detect over/under speeds and position errors, but the system cannot detect over torque scenarios or actuator jams
Solution Approach 1:
The patent replaces traditional mechanical torque measurement methods with a strain gauge-based electrical sensing system. Strain gauges bonded to the torque tube convert mechanical strain into electrical signals, enabling torque measurement without direct mechanical contact and allowing integration with electronic control systems for real-time monitoring and fault detection.
Solution Approach 2:
The patent introduces strain gauges as intermediary sensing elements that indirectly measure torque by detecting dimensional changes in the torque tube. These strain gauges act as mediators between the mechanical torque load and the electronic measurement system, converting physical stress into measurable electrical resistance changes through the Wheatstone bridge circuit.
2Loss of information
If traditional strain gauge systems are used without wireless communication, then the system structure remains simple, but the system cannot provide real-time torque data for remote monitoring and control
Solution Approach 1:
The torque tube sensor system is designed to perform multiple functions: it measures torque through strain gauges, processes signals through Wheatstone bridge circuitry, and transmits data wirelessly via RF or infrared communication. This multi-functional integration allows a single system to provide both measurement and communication capabilities, reducing the need for separate monitoring equipment.
Solution Approach 2:
The patent replaces physical wiring and mechanical data transmission with wireless electromagnetic communication. Instead of using cables to transmit torque data from the torque tube to the control system, the invention employs RF or infrared transmitters to send data wirelessly, eliminating the need for complex wiring harnesses and improving system reliability.
3Use of energy by moving object
If self-powered design with permanent magnet stator is implemented, then the system can operate autonomously without external power, but the device complexity increases due to additional components
Solution Approach 1:
The torque tube sensor system generates its own power through a permanent magnet stator that converts the rotational motion of the torque tube into electrical energy. This self-powered design eliminates the need for external power sources or batteries, allowing the sensor to operate autonomously and independently, extracting energy directly from the mechanical motion it is designed to measure.
Solution Approach 2:
The patent combines the power generation function with the torque measurement function by integrating the permanent magnet stator directly into the sensor assembly. The stator is positioned to interact with the rotating torque tube, simultaneously generating electrical power for the strain gauges and communication systems while the torque tube operates, merging two functions into a single integrated system.
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
Enables real-time monitoring of torque on the torque tube, preventing damage to flight surfaces by detecting over-torque scenarios and facilitating early detection of actuator malfunctions, thus enhancing the reliability and safety of aircraft control systems.
Implementation Method 1
an armature carried by the first body section that interacts with a permanent magnet stator, the armature being in electrical contact with the strain gauge circuitry and providing power to the strain gauge circuitry and the receiver
Implementation Method 2
one or more strain gauges including a first strain gauge disposed in the first body section... strain gauge circuitry connected to the first strain gauge and at least three other resistive elements in a Wheatstone bridge configuration
Data Source
AI summary
A torque tube sensor to measure torque on a torque tube or shaft includes: a sensor body including at least a first body section and a second body section; one or more strain gauges including a first strain gauge disposed in the first body section; at least one transmitter; and strain gauge circuitry connected to the first strain gauge and at least three other resistive elements in a Wheatstone bridge configuration including two arms, the transmitter being connected between the two arms. The sensor also includes at least one receiver configured to receive signals generated by the at least one transmitter; and an armature carried by the first body section that interacts with a permanent magnet stator, the armature being in electrical contact with the strain gauge circuitry and providing power to the strain gauge circuitry and the receiver. The sensor can be part of an assembly.