Aircraft Wiper Fault Diagnostics via Smart Motor Drive
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Solution Overview
Problem
Aircraft windshield wiper systems rely on visual inspections, which are limited and can lead to intermittent failures causing flight cancellations and unscheduled maintenance, as internal failures are difficult to detect without invasive methods.
Innovation Solution
Integration of a smart motor drive with sensors and a failure diagnostic system that uses current and torque readings to determine failure conditions, enabling real-time fault detection and logging, and displaying information to operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection methods are used for WWS maintenance, then inspection simplicity is maintained, but detection precision of internal failures is insufficient
Solution Approach 1:
The patent replaces manual visual inspection with an automated diagnostic system that uses electrical measurements (current, voltage, resistance) to detect wiper system failures. The system substitutes mechanical/manual inspection methods with electronic sensing and automated analysis, enabling precise detection of internal failures without requiring physical disassembly or invasive examination.
Solution Approach 2:
The patent introduces intermediate sensing elements (current sensors, voltage sensors, resistance measurement circuits) that mediate between the wiper motor operation and the diagnostic system. These intermediaries convert physical motor parameters into measurable electrical signals, allowing the system to detect failures indirectly through electrical characteristics rather than direct mechanical inspection.
2Reliability
If interval inspection is performed to meet maintenance goals, then maintenance scheduling is simplified, but aircraft downtime increases due to unscheduled maintenance
Solution Approach 1:
The patent performs preliminary diagnostic actions by continuously monitoring wiper system electrical parameters during normal operation. The system detects potential failures before they manifest as actual malfunctions, allowing maintenance to be scheduled proactively rather than reactively. This preliminary detection prevents unscheduled maintenance and associated aircraft downtime.
Solution Approach 2:
The patent implements a feedback mechanism where the diagnostic system continuously monitors wiper motor electrical characteristics and provides real-time status information to the flight operations system. This feedback loop enables dynamic maintenance scheduling based on actual system condition rather than fixed intervals, optimizing aircraft availability while ensuring safety.
3Reliability
If wiper arms and blades are treated as consumable items with frequent replacement, then safety is maintained, but inventory costs and complexity increase
Solution Approach 1:
The patent enables the wiper system to perform self-diagnostics and self-reporting of its condition through integrated sensors and communication systems. The system monitors its own electrical parameters and identifies degradation trends, allowing maintenance to be based on actual condition rather than predetermined replacement schedules. This reduces unnecessary replacements and associated inventory requirements.
Solution Approach 2:
The patent shifts the maintenance criterion from time-based or usage-based replacement to condition-based replacement using electrical parameter monitoring. By tracking changes in current, voltage, and resistance parameters, the system determines actual component health status, allowing extended service life for components that remain functional and reducing inventory needs for premature replacements.
Data Source
AI summary
A windshield wiper system (WWS) is provided. The WWS includes a brushless direct current (BLDC) motor, a wiper arm and blade, a gearbox/converter operably interposed between the BLDC motor and the wiper arm and blade and a smart motor drive configured to determine a WWS failure condition and to operate the BLDC motor according to the determination.