WO2003050002A1

WO2003050002A1 - Electronically controlled aircraft retractable landing light with manual refraction capability

Info

Publication number: WO2003050002A1
Application number: PCT/US2002/037472
Authority: WO
Inventors: Brian J. Barnhart; Saed M. Mubaslat; Scott E. Hamilton; Craig E. Giffen
Original assignee: Honeywell International Inc.
Priority date: 2001-12-12
Filing date: 2002-11-21
Publication date: 2003-06-19
Also published as: US20030107899A1; US7080928B2; CN1620385A; ES2280624T3; DE60217906T2; DE60217906D1; EP1453728A1; JP2005511400A; EP1453728B1; ATE352488T1

Abstract

An electronically controlled retractable landing light (100) for use with aircraft. A controller (106) compares the commanded position of a lighthead (108) by means of a contactless absolute position sensor (212).Operation of a brake (111), motor (110), and lamp (112) is controlled by a control unit (210). Electrical power to the brake (111), motor (110), and lamp (112) is slowly applied and removed to reduce electromagnetic emissions and extend the service life of a power stage (208), brake (111), motor (110), and lamp (112). The lighthead (108) may be manually stowed in the event of a fault.

Description

ELECTRONICALLY CONTROLLED AIRCRAFT RETRACTABLE LANDING LIGHT WITH

MANUAL REFRACTION CAPABILITY

CROSS REFERENCE [0001 ] This application is related to a copending application entitled

"Efficient Solid State Switching and Control System for Retractable

Aircraft Landing Lights," by inventors D. Melvin and S. Mubaslat (attorney docket number H0002974).

BACKGROUND OF THE INVENTION [0002] This application claims the benefit of U.S. Provisional

Application No. 60/339635 filed December 1 2, 2000 entitled "Electronically Controlled Retractable Landing Light. " Field of the invention. [0003] This invention relates to aircraft retractable landing lights. Specifically, the invention is directed to an aircraft retractable landing light having electronic position control and switching with manual lighthead retraction capability. Description of the related art. [0004] Landing lights are mounted to aircraft to illuminate the area forward of the aircraft during night operations on taxiways and runways. A "retractable landing light" is a remotely controlled, articulating light that can be stowed flush with the outside surface of the aircraft when not in use, reducing aerodynamic drag on the aircraft. The retractable landing light's lamp is housed in a lighthead. The lighthead is in turn hingedly affixed to a housing assembly, which is mounted to the airframe. The lighthead is extended for use and retracted to a stowed position by means of an unsealed torque-amplifying transmission mechanism driven by an electric motor. The lighthead is held in place by an electromechanical brake. When the flight crew actuates a remote control to an "Extend" position, the brake is released by applying electrical power to the brake's coil. Electrical power is simultaneously applied to the motor, causing the motor's output shaft to turn, driving the transmission. The lighthead then extends to a predetermined position, aiming the lamp to illuminate the area forward of the aircraft. Power is then removed from the motor and the brake, causing the lighthead to stop moving. The brake re-engages, preventing the motor's output shaft from turning. The holding force of the brake is amplified by the transmission mechanism, effectively holding the lighthead in position against the force of the windstream encountered by an aircraft in flight. The motor and brake are also simultaneously activated when the remote control is placed in a "Stow" position. However, power is applied to the motor so as to cause the motor's output shaft to rotate counter to the direction used to extend the lighthead. When the lighthead is flush with the surface of the aircraft, power is again removed simultaneously from the motor and brake, holding the lighthead in_. the stowed position. The lamp may be automatically switched on by means of a limit switch after the lighthead is extended and then switched off when the lighthead is retracted. Alternatively, the lamp may be manually controlled by a switch in the cockpit.

[0005] Prior retractable landing lights suffer from a number of shortcomings. In particular, prior retractable landing lights utilize electromechanical limit switches to detect the lighthead's position, and electromechanical relays for control of the motor, brake, and lamp. Electromechanical switches and relays have limited operational life due to mechanical wear. In addition, these switches and relays generate electromagnetic interference due to arcing at their electrical contacts. Electromechanical switches also hinder the ability to change the operational characteristics of the retractable landing light. It is desirable to change such operational characteristics as the extension angle of the lighthead and the switching sequence of the lamp, brake, and motor in order to meet the particular needs of various models of aircraft. [0006] Another drawback of electromechanical switches is that they do not lend themselves to precise position control due to the limited resolution of actuators. Precise position control is desirable to aim the lamp at the proper angle. If the lighthead is extended to a smaller angle than desired, the lamp will be aimed too close to the aircraft. Conversely, if the lighthead extension angle is too great, the lamp will be aimed too far ahead of the aircraft. Both conditions result in a reduction in visibility for the flight crew. Attempts to implement more precise mechanical position controls in prior retractable landing lights have resulted in more complex actuators, reducing the reliability of the retractable landing light. Mechanical wearing of the actuators, combined with changes in setting due to vibration, also contributes to shifting of the lamp extension angle over time, requiring regular maintenance to re-adjust the lighthead to the proper angle.

[0007] A further disadvantage of electromechanical switches and relays is that current flow through the motor, brake and lamp is limited only by the capacity of the aircraft's electrical system and wiring. This places significant stress on the relay contacts, motor, brake, and lamp, causing these components to suffer reduced service life. "Soft" starting of the motor, brake, and lamp is desirable to limit electromagnetic emissions and maximize the life of these components. [0008] A retractable landing light may be installed into more than one model of aircraft. However, design differences between models of aircraft usually necessitate a change in the extension angle setting of the lighthead so that the lamp is properly aimed for a particular aircraft. This involves a time-consuming manual adjustment of position-control limit switches and repeated cycling of the retractable landing light. Means for pre-setting selectable extension angles for different models of aircraft is desired in order to reduce the amount of maintenance work required to install the retractable landing light into two or more models of aircraft. [0009] Prior retractable landing lights utilize an open gearbox. Over time, exposure to the elements when the lighthead is extended causes a loss of gearbox lubrication. Low viscosity grease is used to counter this loss, but at the expense of gearbox efficiency, particularly at low temperature extremes. [0010] Retractable landing lights inherently have a failure mode whereby the lighthead cannot be retracted. The aircraft cannot be dispatched in this condition, requiring maintenance personnel to remove and replace the retractable landing light. This can cause significant delays in the dispatch of the aircraft, particularly if the failure occurs at a remote location with limited maintenance capability. Although prior retractable landing lights have included manual retraction capability, the release mechanisms are slow and cumbersome. [001 1] Some improvements in remotely articulating aircraft lights have been made, such as Hamilton et al. U.S. Patent No. 6,31 5,435 B1 . However, Hamilton et al. teaches the use of potentiometers having wiping elements in contact with a resistive element. Potentiometers are subject to wear-out, limiting the service life of the aircraft light. Further, Hamilton does not teach how to preconfigure the operating envelope of an articulating light for different aircraft models, since the preset positions disclosed in Hamilton define only the operating envelope limits for the lighthead. Changes in the operating envelope to accommodate different aircraft models must be made by trial-and-error upon installation of the light into the aircraft. Also, Hamilton does not disclose how to reduce electromagnetic emissions and extend the service life of the motor brake and motor. In Metz et al., U.S. Patent No. 5,355, 1 31 , an aircraft landing light utilizing contactless position sensing is taught. However, the position sensing disclosed in Metz does not accommodate reconfiguration of the operating envelope for different aircraft models, necessitating trial- and-error adjustment.

[0012] There is a need to limit inrush currents and eliminate the low- reliability relays and switches associated with retractable landing lights. There is also a need to provide a more reliable, precise, and easily reconfigurable means of controlling the position of the retractable landing light's lighthead. There is a further need to protect the gearbox from the elements. Finally, there is a need to provide capability for aircraft with failed retractable landing lights to delay repair and to dispatch with the failed light in place.

SUMMARY OF THE INVENTION

[0013] This invention is directed to an electronically controlled retractable landing light. The retractable landing light utilizes contactless absolute position sensing to detect the position of the lighthead . The retractable landing light also incorporates electronic control of the brake, motor, and lamp. An improved means of manually retracting the lighthead allows the aircraft to be dispatched in spite of a failure of the retractable landing light.

[0014] Specifically, the present invention includes filters to isolate electrical noise between the retractable landing light and the aircraft. A power supply is used to convert the power supplied by the aircraft to a level compatible with the retractable landing light. A power stage utilizes solid state switches with "soft-switching" capability to limit electrical stress on the solid-state switches when turning the brake, motor, and lamp on and off. This soft-switching capability reduces electromagnetic emissions from the brake, motor, and lamp, and extends the service life of these components. A control unit monitors mode and position command signals and lighthead position pre-sets. The control unit actuates the brake, motor, and lamp to move the lighthead to the commanded position, hold the lighthead in place, and turn the lamp on and off, depending on the mode selected. The control unit also provides proper, synchronized timing of the actuation of the brake, motor, and lamp to eliminate overlapping actuation of these devices for reduced electromagnetic emissions and to minimize the generation of switching transients on the aircraft electrical bus.

[001 5] The present invention comprises an electronically controlled retractable light, comprising: means for mounting the retractable light; an electrical motor connected with said mounting means, said motor including a brake; means for reducing speed and amplifying torque coupled to said motor, said speed reducing and torque amplifying means being environmentally sealed; a lighthead connected movably with said mounting means and connected with said speed reducing and torque amplifying means, said lighthead including at least one lamp; contactless means for monitoring absolute position of said lighthead; at least one solid state switch, wherein said solid state switch slowly activates and deactivates; and a control unit communicating with said position monitoring means to: monitor the position of said lighthead; provide timed actuation of said brake, motor, and lamp to prevent simultaneous actuation of said brake, motor and lamp; and to stow said lighthead or position said lighthead at a predetermined angle.

[0016] These and other features will become better understood with reference to the following description, appended claims, and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 shows the retractable landing light;

Figure 2 is an electrical block diagram of the retractable landing light; and

Figure 3 is a detail of the manual retraction means. DETAILED DESCRIPTION OF THE INVENTION

[0018] A retractable landing light 1 00 is shown in Figure 1 . A

baseplate or mounting means 102 is a chassis and also facilitates

mounting of the retractable landing light 1 00 into an aircraft. Power from

the aircraft is converted to a level compatible with a lamp 1 1 2 by a

transformer 1 04. A controller 106 monitors the position of a lighthead

1 08. The controller 106 also provides "soft start" solid-state power

switching of a motor 1 1 0, a brake 1 1 1 , and the lamp 1 1 2 to extend the

life of the motor 1 1 0, brake 1 1 1 , and lamp 1 1 2 and reduce

electromagnetic emissions. In addition, the controller 1 06 may provide protection from fault conditions such as excessive current or over-

temperature conditions, a stalled motor 1 1 0, and blockages to the

lighthead 1 08. Further, the controller 1 06 easily facilitates changes to

the setpoint of the lighthead 1 08 and the addition of new functions. The

controller 1 06 may optionally include means for regularly flashing the

lamp 1 1 2 on and off or from a higher voltage to a lower voltage to attract

the attention of other aircraft operating in the vicinity, reducing the risk of

runway incursions.

[0019] An environmentally sealed gearbox or other means for

reducing speed and amplifying torque 1 14 converts the high-speed, low-

torque output of the motor 1 1 0 to a low-speed, high-torque rotational

mechanical drive. The output of gearbox 1 1 4 is coupled to means for

driving and linking, such as a pair of drive arms 1 1 6 and connecting links

1 1 8, which provide leverage to move the lighthead 1 08 against the force

of the airstream encountered by an aircraft in flight.

[0020] Vibration-damping gasketing 1 20 is placed between the lamp

1 1 2 and a lamp retainer 1 22. The vibration-damping gasketing 1 20

equally distributes the retaining force applied to the lamp 1 1 2 by lamp

retainer 1 22, reducing the risk of failure of lamp 1 1 2 due to cracking of

the glass envelope of lamp 1 1 2. Further, the vibration-damping gasketing

1 20 reduces mechanical stress on the filament of lamp 1 1 2 due to

vibration, aiding to extend the service life of the lamp 1 1 2.

[0021 ] A block diagram of the electrical portion of the retractable

landing light 100 is shown in Figure 2. A set of filters 202 and 204 isolate electrical noise, such as electromagnetic interference, between the

aircraft and a power supply 206, a power stage 208, and a control unit

21 0. The power supply 206 converts electrical power from the aircraft to

a level compatible with the control unit 210 and the power stage 208.

The position of the lighthead 1 08 is sensed by an absolute position sensor

21 2. Means for controlling such as the control unit 21 0 provides control

functions, such as for example, turning the lamp 1 1 2 on and off,

actuation of power to brake 1 1 1 and motor 1 1 0, setting the direction of

rotation of the motor 1 10, and resolution of the position of the lighthead

1 08. The power stage 208 provides "soft start" electrical drive for the

brake 1 1 1 , motor 1 1 0, and the lamp 1 1 2 to reduce electrical stress on

brake 1 1 1 , motor 1 1 0, and lamp 1 1 2 and to reduce electromagnetic

emissions from the brake 1 1 1 , motor 1 1 0, and lamp 1 1 2. The control

unit 106 may also monitor for fault conditions, such as excessive current

or over-temperature conditions, a stalled motor 1 1 0, and blockages to the

lighthead 1 08. If a fault is detected, control unit 1 06 will disable power

stage 208 until the fault is cleared.

[0022] The extend angle setting switch 21 4 is set to the desired

position for a particular aircraft when the retractable landing light 1 00 is

installed into the aircraft. The extend angle setting switch 21 4 provides

selectable preset position commands to the control unit 21 0 for

positioning the lighthead 1 08 to one or more predetermined extension

angles, eliminating the time-consuming step of manually calibrating the

extension angle of lighthead 108 for a particular aircraft. Extend angle setting switch 21 4 may utilize one or more bits of digital logic, or may be

an analog voltage level, such as derived from a voltage divider network.

Means for monitoring the state of the extend angle setting switch 21 4,

such as control unit 210, is configured such that the state of extend

angle setting switch 214 represents a predetermined extension angle for

lighthead 1 08. Upon receiving an "Extend" command at terminal 21 8,

control unit 21 0 will position the lighthead 1 08 at the extension angle

represented by the state of extend angle setting switch 21 4.

[0023] Contactless means for monitoring absolute position 21 2,

such as a Hall-effect rotary position sensor, is coupled to the lighthead

108 and provides the control unit 21 0 with continuous information on the

angular extension position of the lighthead 1 08 so that the control unit

210 can control actuation of the brake 1 1 1 , actuation of the motor 1 1 0,

the direction of rotation of the motor 1 10, and illumination of the lamp

1 1 2 by appropriate synchronization of the on-off control of the power

stage 208. Incremental-type position encoders may alternatively be used,

but absolute-type position encoders are preferred because absolute-type

position encoders do not require periodic calibration to an index position.

[0024] The retractable landing light 100 is commanded to extend or

retract, and to switch the lamp 1 1 2 on and off, by means of control

signals supplied to the control unit 21 0. To command the lighthead 1 08

to a stowed position when the retractable light 1 00 is not in use, an

electrical control signal is applied to a "Retract" input terminal 21 6,

causing the lighthead 1 08 to move to a predetermined stow position, preferably out of the airstream to minimize aerodynamic drag on the

aircraft. To command the lighthead 1 08 to extend, an electrical control

signal is applied to an "Extend" input terminal 21 8. To turn on the lamp

1 1 2, an electrical control signal is applied to a "Lamp On" terminal 220.

The control unit 210 may optionally provide means for indicating to the

flight crew that the lighthead 1 08 is in an extended position, such as a

status output signal via a "Extended Indicator" terminal 224. The output

signal present at terminal 224 is wired to an appropriate indication means

in the cockpit, such as an indicator light or a caution and warning

computer. The voltage level present at the "Extended Indicator" terminal

224 may be fixed at a level compatible with the associated cockpit

indication means by connecting an appropriate voltage source to an

"Indicator Supply" input terminal 222.

[0025] If the lighthead 108 cannot be stowed due to a failure

condition, the aircraft may not be permitted to dispatch due to operating

limitations for the aircraft. The retractable landing light 1 00 may

optionally include means for disengaging the lighthead 1 08 to manually

stow the lighthead 1 08 as shown in Figure 3 to overcome this limitation.

The manual retraction means will allow the aircraft to dispatch under

conditions where the lighthead 1 08 must be stowed but operation of the

retractable landing light 1 00 is not required, such as daylight operations.

To manually stow the lighthead 1 08, one or more release bolts 302 are

removed. This disengages the drive arms 1 1 6 from the gearbox 1 1 4,

allowing the lighthead 1 08 to be pivoted to the stowed position by pushing the lighthead 1 08 until the lighthead 1 08 is flush with the

baseplate 1 02. The release bolts are then re-installed while holding the

lighthead 1 08 in place, securing the lighthead 1 08 in the stowed position.

The aircraft may then be dispatched.

[0026] In operation, the landing light 100 may be actuated by one of

manual and automatic means. For manual operation, the flight crew

commands the desired position for the retractable landing light 1 00 by

means of a control switch remotely mounted in the cockpit. Alternatively,

the command signal may be generated automatically, such as from an

"air-ground" switch that senses whether or not the aircraft is in flight.

When the controller 106 receives a command signal, the controller 106

compares the commanded position to the actual position of lighthead

1 08, using absolute position encoder 21 2. The controller 1 06 first

actuates the brake 1 1 1 and then the motor 1 10, which in turn drives a

speed reduction and torque amplification transmission means 1 1 4, such

as a gearbox. The gearbox 1 1 4, which is sealed from exposure to the

elements, converts the high-speed, low-torque output of the motor 1 10

into a low-speed, high-torque mechanical drive capable of extending the

lighthead 1 08 against the force of the windstream encountered by an

aircraft in flight. The gearbox 1 14 moves a drive arm 1 1 6, attached to

the lighthead 108 by a set of connecting links 1 1 8, causing the lighthead

1 08 to extend or retract as needed until the proper position for the

lighthead 1 08 is reached. The controller 106 controls power to the lamp

1 1 2, switching the lamp 1 1 2 on when the lighthead 1 08 is in an extended position and switching the lamp 1 1 2 off when the lighthead

1 08 is in a stowed position. The controller 1 06 provides a "soft start"

turn-on of the lamp 1 1 2 by limiting inrush current, thereby extending the

life of the lamp 1 1 2. The lighthead 108 further aids to increase the life of

lamp 1 1 2 through the use of vibration-damping gasketing 1 20 to reduce

mechanical stress on the lamp 1 1 2.

Claims

WHAT IS CLAIMED IS:

1. An electronically controlled retractable light (100), comprising: means for mounting (102) the retractable light; an electrical motor (110) connected with said mounting means (102), said motor including a brake (111); means for reducing speed and amplifying torque (114) coupled to said motor (110), said speed reducing and torque amplifying means (114) being environmentally sealed; a lighthead (108) connected movably with said mounting means (102) and connected with said speed reducing and torque amplifying means (114), said lighthead (108) including at least one lamp (112); contactless means (212) for monitoring absolute position of said lighthead (108); at least one solid state switch (210), wherein said solid state switch slowly activates and deactivates; and a control unit (106) communicating with said position monitoring means (212) to: monitor the position of said lighthead (108); provide timed actuation of said brake (111), motor (110), and lamp (112) to prevent simultaneous actuation of said brake (111), motor (110) and lamp (112); and to position said lighthead (108) at a predetermined angle.

2. The electronically controlled retractable light (100) of claim 1, further comprising an extend angle setting switch (214) to set at least one extension setpoint for said lighthead (108).

3. The electronically controlled retractable light (100) of claim 2, further comprising means (210) to monitor the state of said extend angle setting switch.

4. The electronically controlled retractable light (100) of claim 1, further comprising the means for reducing speed and amplifying torque (114) including means (116, 118) for driving and linking, and said retractable light (100) further comprising means (302) for disengaging said means for driving and linking (116, 118) from said means for reducing speed and amplifying torque to manually stow said lighthead (108).

5. The electronically controlled retractable light (100) of claim 1, wherein said lighthead (108) includes a lamp retainer (122) and vibration- damping gasketing (120) positioned between said lamp (112) and said lamp retainer (122).

6. The electronically controlled retractable light (100) of claim 1, wherein said control unit (210) provides means (224) for indicating to the crew when said lighthead (108) is not in a stowed position.

7. The electronically controlled retractable light (100) of claim 1, wherein said retractable light (112) is activated by one of manual and automatic means (106).

8. The electronically controlled retractable light (100) of claim 1, further including means to regularly flash said lamp (112) to attract attention.

9. The electronically controlled retractable light (100) of claim 1, wherein said control unit (210) additionally monitors for over-current faults, over-temperature faults, stall of said motor (112), and blockages of said lighthead (108) and wherein said control unit (210) disables said solid state switch (210) until said faults, motor stall, and blockages are no longer present.

10. A process for providing an electronically controlled, retractable light, comprising: providing means for mounting (102) the retractable light (100); placing at said mounting means (102) an electrical motor (110), said motor (110) including a brake (111); providing environmentally sealed means (114) for reducing the speed and amplifying the torque of said motor (110); movably connecting a lighthead (108) to said mounting means (102) and connecting said lighthead (108) with said means for speed reducing speed and torque amplifying (114), said lighthead (108) including at least one lamp (112); supplying electrical power to said brake (111), motor (110) and lamp (112) such that power to said brake (111), motor (110), and lamp (112) can be slowly activated and deactivated; applying torque to said lighthead (108) by way of said means for speed reducing and torque amplifying (114); providing contactless means for monitoring absolute position (212) of said lighthead(108); providing means for controlling (106) said lighthead in order to: monitor the position of said lighthead (108); provide timed actuation of said brake (111), motor (110), and lamp (112) to prevent simultaneous actuation of said brake (111), motor (110), and lamp (112); and stowing said lighthead (108) or positioning said lighthead (108) at a predetermined angle of extension.

11. The process of claim 10, further comprising the step of providing at least one extension setpoint for said lighthead (108).

12. The process of claim 11 , further comprising the step of monitoring said extension setpoint.

13. The process of claim 10, further comprising the steps of providing said means for speed reducing and torque amplifying (114) with means for driving and linking (116, 118), and providing means for disengaging (302) said means for driving and linking (116, 118) from said means for speed reducing and torque amplifying (114) to manually stow said lighthead (108).

14. The process of claim 10, further comprising the steps of adding a lamp retainer (122) to said lighthead (108) and placing vibration- damping gasketing (120) between said lamp (112) and said lamp retainer (122).

15. The process of claim 10, further comprising the step of providing means for indicating (224) to the crew when said lighthead (108) is not in a stowed position.

16. The process of claim 10, further comprising the step of regularly flashing said lamp (112) to attract attention.

17. The process of claim 10, further comprising the step of monitoring for over-current faults, over-temperature faults, stall of said motor (110), and blockages of said lighthead (108), and disabling said motor (110), brake (111), and lamp (112) until said faults, motor stall, and blockages are no longer present.