Acceptance testing of actuators using predetermined thresholds

• US 20060036402A1
• Filed: 07/27/2005
• Published: 02/16/2006
• Est. Priority Date: 07/28/2004
• Status: Active Grant

• Current Assignee: HR Textron, Inc.
• Original Assignee: HR Textron, Inc.
• Inventors: Deller, Robert W., Lee, Joon H.
• Granted Patent: US 7,283,934 B2
• Time in Patent Office: Days
• US Class Current: 702/183
• CPC Class Codes: B64F 5/60 Testing or inspecting aircraft components or systems
• CPC Class Codes: F15B 19/005 Fault detection or monitoring
• CPC Class Codes: G01R 31/2829 Testing of circuits in sensor or actuator systems testing of apparatus for measuring electric or magnetic variables G01R35/00; testing of indicating or recording apparatus G01D; in airbag systems B60R21/0173; checking gas analysers G01N33/007; monitoring or fail-safe circuits for electromagnets H01F7/1844
• CPC Class Codes: G01R 31/343 in operation
• CPC Class Codes: G05B 19/4063 Monitoring general control system G05B19/4062 takes precedence
• CPC Class Codes: G05B 2219/42298 Measure backlash, time difference between point A to point B and from B to A, if too large
• CPC Class Codes: G05B 2219/45071 Aircraft, airplane, ship cleaning manipulator, paint stripping
• CPC Class Codes: G05B 23/0254 based on a quantitative model, e.g. mathematical relationships between inputs and outputs; functions: observer, Kalman filter, residual calculation, Neural Networks

Abstract

An improved technique of acceptance testing an actuator system involves measuring system parameters of the actuator system during operation of the actuator system, and storing the measured system parameters in computerized memory as a set of measured system parameters. The technique further involves obtaining a set of predetermined thresholds. Each predetermined threshold corresponds to a particular measured system parameter. The technique further involves electronically indicating whether the actuator system is in acceptable condition based on an electronic comparison of the set of measured system parameters stored in the computerized memory and the set of predetermined thresholds, e.g., providing a warning of a need for service or of imminent failure when one or more of the system parameters exceeds a corresponding threshold.

Claims

1. A test system to acceptance test an actuator system, the test system comprising:

a data acquisition circuit configured to interface with the actuator system;

a controller including a processing core and computerized memory; and

a communications medium which connects the data acquisition circuit to the controller, the processing core being configured to;

measure system parameters of the actuator system, through the data acquisition circuit, during operation of the actuator system and store the measured system parameters in the computerized memory as a set of measured system parameters,

obtain a set of predetermined thresholds, each predetermined threshold corresponding to a particular measured system parameter, and

electronically indicate whether the actuator system is in acceptable condition based on an electronic comparison of the set of measured system parameters stored in the computerized memory and the set of predetermined thresholds.

2. A test system as in claim 1 wherein the processing core, when obtaining the set of predetermined thresholds, is configured to:

define, as the set of predetermined thresholds, a set of threshold values based on a database of experience formed from periodically measured and saved system parameters of the actuator system which were accumulated during operation of the actuator system within an aircraft working environment.

3. A test system as in claim 2 wherein the processing core, when measuring the system parameters of the actuator system during operation of the actuator system, is configured to:

direct the data acquisition circuit to receive sensor signals from sensors of the actuator system, the sensor signals identifying operating conditions of the actuator system during operation; and

direct the data acquisition circuit to quantify the operating conditions identified by the sensor signals as at least a portion of the system parameters.

4. A test system as in claim 3 wherein the data acquisition circuit includes a set of counters;

and wherein the processing core, when directing the data acquisition circuit to quantify the operating conditions identified by the sensor signals, is configured to;

enable incrementing of the set of counters based on particular operating events identified by the sensor signals to count the particular operating events.

5. A test system as in claim 3 wherein the data acquisition circuit includes a set of integrators;

and wherein the processing core, when directing the data acquisition circuit to quantify the operating conditions identified by the sensor signals, is configured to;

enable collecting, within the set of integrators, cumulative sums of particular operating conditions defined by the sensor signals multiplied by times of exposure to the particular operating conditions to record total cumulative exposure times to the particular operating conditions.

6. A test system as in claim 3 wherein the data acquisition circuit includes a set of peak detectors;

and wherein the processing core, when directing the data acquisition circuit to quantify the operating conditions identified by the sensor signals, is configured to;

enable tracking, within the set of peak detectors, particular operating conditions identified by the sensor signals to determine greatest magnitudes of the particular operating conditions.

7. A test system as in claim 2 wherein the system parameters of the actuator system which were accumulated during operation of the actuator system within the aircraft working environment have system parameter types;

and wherein the processing core, when defining the set of threshold values, is configured to;

generate an average value for each system parameter type,

generate a peak value for each system parameter type, and

form the set of threshold values from the average value for each system parameter type and from the peak value for each system parameter type.

8. A test system as in claim 7 wherein the system parameter types are selected from the group consisting of Total Flight Time, Controller Temperature Profile, Motor Temperature Profile, Average Actuator Position, Position/Time Profile, Distance by Position Profile, Load by Position Profile, Work by Position Profile, Peak Load by Position Profile, Peak Work by Position Profile, Peak Hall State/Potentiometer by Position, Illegal Hall States, and Watchdog Events.

9. A method of acceptance testing an actuator system, the method comprising:

measuring system parameters of the actuator system during operation of the actuator system and storing the measured system parameters in computerized memory as a set of measured system parameters;

obtaining a set of predetermined thresholds, each predetermined threshold corresponding to a particular measured system parameter; and

electronically indicating whether the actuator system is in acceptable condition based on an electronic comparison of the set of measured system parameters stored in the computerized memory and the set of predetermined thresholds.

10. A method as in claim 9 wherein obtaining the set of predetermined thresholds includes:

defining, as the set of predetermined thresholds, a set of threshold values based on a database of experience formed from periodically measured and saved system parameters of the actuator system which were accumulated during operation of the actuator system within an aircraft working environment.

11. A method as in claim 10 wherein measuring the system parameters of the actuator system during operation of the actuator system includes:

receiving sensor signals within a data acquisition circuit from sensors of the actuator system, the sensor signals identifying operating conditions of the actuator system during operation; and

quantifying, within the data acquisition circuit, the operating conditions identified by the sensor signals as at least a portion of the system parameters.

12. A method as in claim 11 wherein the data acquisition circuit includes a set of counters;

and wherein quantifying the operating conditions identified by the sensor signals includes;

incrementing the set of counters based on particular operating events identified by the sensor signals to count the particular operating events.

13. A method as in claim 11 wherein the data acquisition circuit includes a set of integrators;

and wherein quantifying the operating conditions identified by the sensor signals includes;

collecting, within the set of integrators, cumulative sums of particular operating conditions defined by the sensor signals multiplied by times of exposure to the particular operating conditions to record total cumulative exposure times to the particular operating conditions.

14. A method as in claim 11 wherein the data acquisition circuit includes a set of peak detectors;

and wherein quantifying the operating conditions identified by the sensor signals includes;

tracking, within the set of peak detectors, particular operating conditions identified by the sensor signals to determine greatest magnitudes of the particular operating conditions.

15. A method as in claim 10 wherein the system parameters of the actuator system which were accumulated during operation of the actuator system within the aircraft working environment have system parameter types;

and wherein defining the set of threshold values includes;

generating an average value for each system parameter type,

generating a peak value for each system parameter type, and

forming the set of threshold values from the average value for each system parameter type and from the peak value for each system parameter type.

16. A method as in claim 15 wherein the system parameter types are selected from the group consisting of Total Flight Time, Controller Temperature Profile, Motor Temperature Profile, Average Actuator Position, Position/Time Profile, Distance by Position Profile, Load by Position Profile, Work by Position Profile, Peak Load by Position Profile, Peak Work by Position Profile, Peak Hall State/Potentiometer by Position, Illegal Hall States, and Watchdog Events.

17. A computer program product that includes a computer readable medium having instructions stored thereon for acceptance testing an actuator system such that the instructions, when executed by a computer, cause the computer to:

measure system parameters of the actuator system during operation of the actuator system and store the measured system parameters in computerized memory as a set of measured system parameters;

obtain a set of predetermined thresholds, each predetermined threshold corresponding to a particular measured system parameter; and

electronically indicate whether the actuator system is in acceptable condition based on an electronic comparison of the set of measured system parameters stored in the computerized memory and the set of predetermined thresholds.

18. A computer program product as in claim 17 wherein obtaining the set of predetermined thresholds includes:

defining, as the set of predetermined thresholds, a set of threshold values based on a database of experience formed from periodically measured and saved system parameters of the actuator system which were accumulated during operation of the actuator system within an aircraft working environment.

19. A computer program product as in claim 18 wherein measuring the system parameters of the actuator system during operation of the actuator system includes:

receiving sensor signals within a data acquisition circuit from sensors of the actuator system, the sensor signals identifying operating conditions of the actuator system during operation; and

quantifying, within the data acquisition circuit, the operating conditions identified by the sensor signals as at least a portion of the system parameters.

20. A computer program product as in claim 18 wherein the system parameters of the actuator system which were accumulated during operation of the actuator system within the aircraft working environment have system parameter types;

and wherein defining the set of threshold values includes;

generating an average value for each system parameter type,

generating a peak value for each system parameter type, and

forming the set of threshold values from the average value for each system parameter type and from the peak value for each system parameter type.