DE102022130957A1 - Smart redundant lightweight actuator - Google Patents

Abstract

An actuator (12) for a vehicle (2) with at least two redundant electrical on-board networks (4a,b) for electrical work output (Aa,b) and powerline communication (PLCa,b) contains an electric drive (16) with supply inputs (24a,b) for the work output (Aa,b) and redundant supply units (26a,b) which have a supply output (28a,b) for the work output (Aa,b) and a mains connection (14a, b) for the on-board networks (4a,b) for receiving the work output (Aa,b) and for powerline communication (PLCa,b) with the on-board network (4a,b).
A vehicle (2) with the on-board networks (4a,b) contains the actuator (12), which is redundantly connected to the on-board networks (4a,b) by means of its network connections (14a,b) in order to enable a redundant supply of working power (Aa,b) and a redundant powerline communication (PLCa,b).

Description

The invention relates to an actuator intended for use in a vehicle with redundancy requirements, in particular an aircraft.

Redundancy is necessary for actuators that are to be used in safety-critical applications, for example in an aircraft.

It is known from practice that in safety-critical applications two separate actuators are used to perform a single actuator task. In other words, a second actuator is installed that can completely take over the task of the first actuator should the first actuator fail.

The object of the invention is to propose improvements with regard to the use of actuators in safety-critical applications in vehicles.

The object is achieved by an actuator according to patent claim 1. Preferred or advantageous embodiments of the invention and other categories of invention emerge from the further claims, the following description and the attached figures.

The actuator is used or is designed for a vehicle, i.e. for use in a vehicle. The invention is based on a vehicle that has at least two redundant electrical on-board networks. Each of the on-board networks is designed to provide electrical power for consumers connected to the on-board network and to provide powerline communication on or via the on-board network, by means of which connected consumers can communicate with other powerline communication counterparts. Such a counterpart is, for example, an aircraft's avionics connected via a powerline communication counterpart.

The actuator contains an electric drive. The electric drive contains at least one, in particular exactly one, supply input. The supply input serves or is designed to supply the drive with an electrical work output, which is made available to the drive - from outside the drive - at the supply input.

• Die jeweilige Versorgungseinheit enthält wenigstens einen, insbesondere genau einen, Versorgungsausgang. Jeder der Versorgungsausgänge ist mit wenigstens einem, insbesondere genau einem der Versorgungseingänge verbunden und dient zur Versorgung dieses oder dieser Versorgungseingänge und damit des Antriebs mit der Arbeitsleistung. Mit anderen Worten wird der elektrische Antrieb über Versorgungsausgang und Versorgungseingang mit seiner elektrischen Arbeitsleistung, die er zur Ausführung seiner Aufgaben benötigt, versorgt. Insbesondere ist jeweils genau einer der Versorgungsausgänge mit genau einem der Versorgungseingänge verbunden. Deren Anzahl ist also gleich.

The actuator contains at least two supply units that are designed to be redundant. Each of the supply units has the following properties:

• The respective supply unit contains at least one, in particular exactly one, supply output. Each of the supply outputs is connected to at least one, in particular exactly one of the supply inputs and serves to supply this or these supply inputs and thus the drive with the working power. In other words, the electric drive is supplied with the electrical working power it needs to carry out its tasks via the supply output and supply input. In particular, exactly one of the supply outputs is connected to exactly one of the supply inputs. The number of these is therefore the same.

Each of the supply units contains at least one, in particular exactly one, in particular two-pole, mains connection. The mains connection serves or is set up to connect the respective supply unit to at least one, in particular exactly one of the on-board networks. Each of the mains connections is set up at least to receive the work output from the on-board network that is connected as intended. The mains connection is also set up for powerline communication with this or via this on-board network. The mains connection therefore fulfills a dual function: on the one hand to supply the actuator with the work output, and on the other hand to enable/provide powerline communication between the actuator and a powerline communication counterpart that is also located on the on-board network.

In particular, the supply output is a communication-free output, i.e. electrical power is available via it, but no processing or implementation of communication is possible via the supply output. This also applies in particular to the supply input. In other words, all processing and implementation of any communication with the on-board network or a counterpart takes place in the supply unit, but not on or in the drive.

• • erhebliche Einsparung im Gesamtsystem-Gewicht, da keine zwei diskreten Aktuatoren inklusive der mechanischen Anlenkung benötigt werden, z.B. um mehr als 40%.
• • Erhebliche Reduzierung der Gesamtsystem-Komplexität.
• • Es werden wenigstens zwei redundante Leistungsversorgungen (Power Rails) unterstützt.
• • Die Kommunikation und Kommandierung über die Stromversorgung (Bordnetz / Netzanschluss) reduziert den Verkabelungsaufwand im Fahrzeug erheblich (keine separaten Datenleitungen zu den Aktuatoren nötig).
• • Es können eine Vielzahl von Aktuatoren über eine Stromversorgung adressiert / angesteuert werden, zum Beispiel bis zu 255.
• • Insbesondere eine Standard-Powerline-Kommunikationsschnittstelle ist verfügbar, um mit der zentralen Avionik (avionics backbone) zu kommunizieren.
• • Ein Familienkonzept für Aktuatoren wird ermöglicht, d.h. Aktuatoren verschiedener Ausführungsformen usw. können zur Verfügung gestellt werden, um an ein und demselben Bordnetz angeschlossen zu werden. So können verschiedene Drehmoment-, Geschwindigkeits- usw. -anforderungen erfüllt werden.
• • Das Konzept ist sehr wartungsfreundlich; einzelne Aktuatoren können einfach, z.B. in Minuten, ausgetauscht (installiert, entfernt) werden, ggf. auch einfach durch alternative Aktuatoren ersetzt werden.

According to the invention, it is possible to expand or optimize powerline communication in a vehicle with regard to actuators in the safety-critical area. According to the invention, a redundant control unit in the form of the supply unit is integrated in the actuator with a single drive. This communicates via the power supply, i.e. the on-board network, with a counterpart, in particular with the central aircraft control system (avionics) in an aircraft. The actuator therefore requires in particular only two redundant supply connections in Form of network connections as an interface to the vehicle or aircraft. This results in the following advantages:

• • Significant savings in the overall system weight, e.g. by more than 40%, since two discrete actuators including the mechanical linkage are not required.
• • Significant reduction in overall system complexity.
• • At least two redundant power supplies (power rails) are supported.
• • Communication and commanding via the power supply (on-board network / mains connection) significantly reduces the wiring effort in the vehicle (no separate data lines to the actuators required).
• • A large number of actuators can be addressed/controlled via one power supply, for example up to 255.
• • In particular, a standard powerline communication interface is available to communicate with the central avionics backbone.
• • A family concept for actuators is enabled, ie actuators of different designs etc. can be made available to be connected to one and the same on-board network. This allows different torque, speed etc. requirements to be met.
• • The concept is very maintenance-friendly; individual actuators can be easily exchanged (installed, removed) in minutes, for example, and if necessary, simply replaced by alternative actuators.

The communication of the redundant integrated electronics in the form of the supply unit via the power supply (on-board network) enables a very efficient system design and very easy expandability. According to the invention, a "Smart Redundant Lightweight Actuator (SRLA)" is created. This results in a smart redundant lightweight actuator. This is implemented in an integrated manner including the necessary redundant electronics (supply unit), in particular within an actuator housing. The actuator is controlled using data/signal transmission via the supply line, i.e. powerline communication.

Applications for actuators include flap and rudder control, door operation, pump control, rotor head control. Communication in the vehicle can be standardized. Maintenance is simplified. The solution is not dependent on a specific avionics system, so it can work with different avionics generations (general vehicle control). The solution can be used in the retrofit area.

In a preferred embodiment, the drive has - as already indicated above - exactly one supply input per supply unit. This creates redundancy in the actuator from the mains connection to the respective supply input of the drive, so that only a failure of the drive itself leads to failure of the actuator. All other supply of / control of / communication with the drive in the actuator is then implemented redundantly.

In a preferred embodiment, the drive itself is also constructed at least partially redundantly with regard to the supply units. The redundancy of the supply units can thus also be expanded or extended "into the drive". Even a partial failure or partial defect in the redundant part of the drive itself does not then have to lead to failure of the actuator.

In a preferred variant of this embodiment, the drive contains at least one, in particular exactly one, movable output part. This is, for example, a rotor of a rotary motor or a carriage of a linear motor, etc. The drive then contains at least two stator parts. Each of the stator parts is designed or configured to act on the same drive part or parts. Each stator part together with the drive part(s) assigned in this way is designed to work independently as at least part of the drive, in particular as a complete drive, i.e. to fully fulfill the drive functionality, i.e. to independently fulfill the full drive functionality. In other words, the drive works completely as intended as long as the output parts and one of the stator parts work together as intended. This creates a particularly high level of redundancy in the drive as well.

In a preferred variant of this embodiment, each of the stator parts has exactly one of the supply inputs. This creates a particularly simple actuator that is, however, completely redundant for each stator part.

In a preferred variant of this embodiment, the drive contains, in particular is, an electric motor and each of the stator parts contains its own stator winding of the motor. This means that the stator winding is self-contained and independent of other stator windings or is designed separately. The corresponding stator winding together with the output part therefore fulfills the entire drive functionality. The drive part is in particular a rotor or a linear slide with a permanent magnet or (rotor) winding.

In a preferred embodiment, at least one of the supply units is designed as follows: It contains a power module connected to the mains connection and supplied with the working power during operation by this. This is set up to receive the working power from the on-board network. However, it does not have the ability for powerline communication, but does have the supply output. In other words, the power module is only set up to supply the drive with power from the on-board network, but not for powerline communication with the on-board network. The supply unit also contains a communication module connected to the mains connection. This is set up for powerline communication with the on-board network, but not for receiving the working power from the on-board network. In other words, the communication module only fulfills a communication task, but is not used to pass the working power from the on-board network to the drive. Each module can therefore be designed to be optimized for its task. Sensor information, for example, can also be supplied externally via the communication module, see below.

In a preferred variant of this embodiment, at least one of the supply units that contain a power module also contains a control module. The control module is designed to control the drive in terms of its operation by controlling the power module based on the powerline communication. In other words, the control module controls the actual drive functionality of the drive, for example switching it on or off depending on which commands/signals/values are delivered via the powerline communication. In addition, sensor information, for example, is processed in the control module, see below.

In a preferred embodiment, at least one of the supply units contains at least one sensor module. This serves or is set up to determine sensor information on the actuator. “On the actuator” includes information inside and/or outside the actuator, e.g. in its surroundings. For example, a motor position of a rotor/linear slide or an ambient temperature outside the actuator can be determined and processed inside the actuator or communicated outside the actuator. Other sensor modules can, for example, record temperatures, vibrations, wear, mechanical load, etc. Sensor information can thus be used internally in the actuator, for example for speed control/regulation of the drive, etc. Here, too, the control module can be designed to be optimized for its task. The actuator is then set up for internal processing and/or forwarding of the sensor information to the powerline communication.

In a preferred embodiment, the actuator has only one single plug connector per mains connection as electrical connections. In particular, the actuator has no other wired or wireless electrical interfaces, including communication and power interfaces. The only electrical power supply and communication therefore takes place via the plug connector. The plug connector is in particular a single plug contact/plug/socket. Alternatively, the plug connector can also be designed as a plug/socket group.

The object is also achieved by a vehicle according to claim 11. The vehicle has the above-mentioned at least two redundant electrical on-board networks. The vehicle contains at least one actuator according to the invention. This is connected to at least two of the on-board networks by means of at least two of its network connections in such a way that a redundant supply of working power and redundant powerline communication is possible via the at least two of the network connections from the at least two of the on-board networks. In other words, the actuator is connected to the at least two on-board networks in a completely redundant manner, with an independent supply of working power and independent powerline communication being possible via each of the two on-board networks. In particular, several actuators are connected to the on-board network. In particular, each of the actuators is uniquely addressed with regard to its powerline communication, so that each actuator can communicate individually and can therefore also be operated, controlled, etc. individually.

The vehicle and at least some of its possible embodiments as well as the respective advantages have already been explained in connection with the actuator according to the invention.

In a preferred embodiment, the vehicle is an aircraft. The above-mentioned advantages of the invention have a particularly significant impact on aircraft.

• 1 ein Fahrzeug mit zwei Bordnetzen und Aktuatoren in einem Blockdiagramm,
• 2 einen der Aktuatoren aus 1 in einem Blockdiagramm.

Further features, effects and advantages of the invention will become apparent from the following description of a preferred embodiment of the invention and the accompanying figures. In each case, a schematic diagram shows:

• 1 a vehicle with two on-board networks and actuators in a block diagram,
• 2 one of the actuators 1 in a block diagram.

1 shows a section of a vehicle 2, here an aircraft in the form of a passenger plane. The vehicle 2 has two redundant on-board networks 4a,b, each of which is designed with two wires. Each of the on-board networks 4a,b is supplied with electrical power from a respective power supply 6a,b, here an electrical on-board generator. A powerline communication unit 8a,b is connected to each on-board network 4a,b, which in turn is communicatively connected to an avionics unit 10a,b of the aircraft. Thus, on each of the on-board networks 4a,b, an electrical work output Aa,b from the power supply 6a,b and a powerline communication PLCa,b with or to the powerline communication unit 8a,b or avionics 10a,b are redundantly available for any consumers that may be connected. Both are symbolically indicated by arrows in the figure.

In the example, a total of 255 actuators 12 are connected to the on-board networks 4a,b, of which 1 only three are shown as examples. Each of the actuators 12 is redundantly connected to both on-board networks 4a,b using a respective network connection 14a,b. The respective network connections 14a are connected to the on-board network 4a, the respective network connections 14b to the on-board network 4b. The relevant actuator 12 is thus supplied with power Aa via a network connection 14a and enables powerline communication PLCa with the on-board network 4a. Each of the connections 14b enables a corresponding power Ab to be drawn from the on-board network 4b and enables communication PLCb with the on-board network 4b.

2 shows an example of one of the actuators 12 from 1 Each of the actuators 12 contains a drive 16, here a motor 30 in the form of an electric rotary motor. This contains an output part 20 in the form of a rotor that can rotate about an axis of rotation 18, as well as two redundant stator parts 22a,b, as will be explained in more detail below. The electric drive 16 has two redundant supply inputs 24a,b. The supply inputs 24a,b are each used to redundantly or solely supply the drive 16 with the drive power Aa or Ab. In the example, a gear 17 (not explained in more detail) is connected downstream of the drive 16. The rotation about the axis of rotation 18 during operation is indicated by arrows.

The actuator 12 also contains two supply units 26a,b which are also designed to be redundant with one another. Each of the supply units 26a,b has a supply output 28a,b. These are connected 1:1 to supply the supply inputs 24a,b. In addition, the supply units 26a,b have the respective network connections 14a,b explained above. The network connections 14a,b are therefore each set up to receive power Aa,b from the on-board networks 4a,b and for powerline communication PLCa,b with the on-board networks 4a,b. The drive 16 therefore has exactly one supply input 24a,b per supply unit 26a,b.

The drive 16 itself is also constructed at least partially redundantly with regard to the supply units 26a,b. This is achieved by the drive 16 having a single non-redundant movable drive part 20, but two redundant stator parts 22a,b. Each of the stator parts 2a,b together with the output part 20 is designed to fulfill the full drive functionality of the drive 16. In other words, a single stator part 22a or 22b together with the output part 20 is sufficient to develop the full drive power of the drive 16, here the motor. This means that even if the start part 22a or the start part 22b fails, the drive 16 can fully fulfill its drive functionality (drive the rotary axis 18) as intended. Each of the stator parts 22a,b has exactly one of the supply inputs 24a,b. The drive 16 here is the motor 30, the output part 20 is a rotor 32 and each of the stator parts 22a,b contains a stator winding 34a,b.

Each of the supply units 26a,b contains a power module 36a,b that is supplied by the respective mains connection 14a,b or is connected to it. This is set up to receive the respective power Aa,b from the on-board network 4a,b, but has no capability for powerline communication PLCa,b and has the respective supply output 28a,b.

Each of the supply units 26a,b also contains a communication module 38a,b that is communicatively connected to the network connection 14a,b. This is set up for powerline communication PLCa,b with the respective on-board network 4a,b, but not for receiving/transmitting the respective work output Aa,b. Each of the supply units 26a,b also contains a control module 40a,b. This is connected to the power modules 36a,b and communication modules 38a,b and set up to control the drive 16 by controlling the respective power module 36a,b with regard to its operation on the basis of the power line communication PLCa,b. The supply units 26a,b also each contain a sensor module 42a,b, here a respective redundant motor position sensor, which is coupled to the rotation axis 18 or shaft of the rotor 32. Each of the sensor modules 42a,b is also connected to the control module 40a,b and is used to determine a respective sensor information on the actuator 12. Here, a current angle of rotation of the rotation axis 18 is determined. The sensor modules 42a,b are also used to forward the relevant sensor information to the powerline communication PLCa,b, here by connecting to the control modules 40a,b. In the control modules 40a,b, the motor position can be used internally to operate the drive 16, for example to regulate the speed or to determine a specific current rotation position. However, the sensor information can also be transmitted to the respective avionics 10a,b for powerline communication PLCa,b via the on-board networks 4a,b, so that it is also available outside the actuator 12.

The power connections 14a,b are each designed as single plug contacts 44a,b. The plug contacts 44a,b represent the only electrical connections of the actuator 12. The actuator 12 therefore has no other wired or wireless electrical interfaces.

List of reference symbols

2

vehicle

4a,b

On-board network

6a,b

Power supply

8a,b

Powerline communication unit

10a,b

Avionics

12

Actuator

14a,b

Mains connection

16

drive

17

transmission

18

Rotation axis

20

Output section

22a,b

Stator part

24a,b

Supply input

26a,b

Supply unit

28a,b

Supply output

30

engine

32

rotor

34a,b

Stator winding

36a,b

Power module

38a,b

Communication module

40a,b

Control module

42a,b

Sensor module

44a,b

Plug contact

Aa,b

Work performance

PLCa,b

Powerline communication

Claims (12)

Actuator (12) for a vehicle (2) with at least two redundant electrical on-board networks (4a,b), each of the on-board networks (4a,b) being designed to provide an electrical working power (Aa,b) and a powerline communication (PLCa,b), - with an electric drive (16) with at least one supply input (24a,b) for supplying the drive (16) with an electrical working power (Aa,b), - with at least two redundant supply units (26a,b), each of the supply units (26a,b): - a supply output (28a,b) connected to at least one of the supply inputs (24a,b) for supplying at least one of the supply inputs (24a,b) with the working power (Aa,b), and - a mains connection (14a,b) for connecting the supply unit (26a,b) to at least one of the on-board networks (4a,b), - with the mains connection (14a,b) at least for receiving the Work power (Aa,b) from the on-board network (4a,b) and for powerline communication (PLCa,b) with the on-board network (4a, b). Actuator (12) after Claim 1 , characterized in that the drive (16) has exactly one supply input (24a,b) per supply unit (26a,b). Actuator (12) according to one of the preceding claims, characterized in that the drive (16) is constructed at least partially redundantly with regard to the supply units (24a, b). Actuator (12) after Claim 3 , characterized in that the drive (16) contains at least one movable output part (20) and at least two redundant stator parts (22a,b) for acting on the same output part (20), wherein each stator part (22a,b) with the associated output parts (20) is designed to independently fulfill the full drive functionality of the drive (16). Actuator (12) after Claim 4 , characterized in that each of the stator parts (22a,b) has exactly one of the supply inputs (24a,b). Actuator (12) according to one of the Claims 4 until 5 , characterized in that the drive (16) contains a motor (30) and each of the stator parts (22a,b) contains its own stator winding (34a,b) of the motor. Actuator (12) according to one of the preceding claims, characterized in that at least one of the supply units (26a,b): - contains a power module (36a,b) supplied by the mains connection (14a,b), which is set up to receive the working power (Aa,b) from the on-board network (4a,b), but has no capability for powerline communication (PLCa,b) and has the supply output (28a,b), and - contains a communication module (38a,b) connected to the mains connection (14a,b), which is set up for powerline communication (PLCa,b) with the on-board network (4a,b), but not for receiving the working power (Aa,b) from the on-board network (4a,b). Actuator (12) after Claim 7 , characterized in that at least one of the supply units (26a,b) with the power module (36a,b) contains a control module (40a,b) which is designed to control the drive (16) by controlling the power module (36a,b) with regard to its operation on the basis of the powerline communication (PLCa,b). Actuator (12) according to one of the preceding claims, characterized in that at least one of the supply units (26a,b) contains at least one sensor module (42a,b) which is configured to determine sensor information on the actuator (12). Actuator (12) according to one of the preceding claims, characterized in that the actuator (12) has as electrical connections exclusively a single plug contact (44a,b) per mains connection (14a,b). Vehicle (2) with at least two redundant electrical on-board networks (4a,b), each of the on-board networks (4a,b) being designed to provide an electrical working power (Aa,b) and a powerline communication (PLCa,b), with at least one actuator (12) according to one of the preceding claims, which is connected to at least two of the on-board networks (4a,b) by means of at least two of its network connections (14a,b) in such a way that a redundant supply of working power (Aa,b) from and a redundant powerline communication (PLCa,b) with the at least two of the on-board networks (4a,b) is possible via the at least two of the network connections (14a,b). Vehicle (2) to Claim 11 , characterized in that the vehicle (2) is an aircraft.

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