Description:FIELD OF THE INVENTION:

The invention relates to a technical field of airborne or aerospace system application comprising load simulator. In particular, the invention relates to an Aerodynamic Load Simulator for Testing Control and Actuation System. More particularly, the invention relates to an aerodynamic load simulator which is used for testing the control system performance of control actuation system (CAS) and to ensure control actuation system’s (CAS’s) motor static and dynamic load withstanding capability at lab level.

BACKGROUND OF THE INVENTION:

In a missile system, aerodynamic loads are introduced during flight at the missile fins as a function, for example, of air density or fin angle. The missile fin control system must respond to these loads to maintain flight control. In testing response of such systems, the dynamic response of a loading device must be significantly better than that of the test article that it loads so as to not unrealistically affect performance of the article. Since missile fin control systems are inherently high-performance servos, the performance requirements of the load simulator are demanding. It has been the prior art custom to load such systems with passive devices such as mechanical springs or torsion bars or by means of a pneumatic actuator with a large pressure chamber which is the equivalent of a pneumatic spring. There are disadvantages of these devices. For example, they are not adaptable to rapidly switching from an opposing to an aiding or overdrive load which reflect a realistic condition for many applications. They are also inflexible with respect to permitting rapid dynamic variations in loading.

Further, the flight actuation system plays an important role in the accurate guidance of the flight vehicles. The actuators driving the control surfaces are aerodynamically loaded during flight. The design, testing and selection process of the flight actuators play an important role to ensure the stable and safe flight. Since a reliable flight actuation system can ensure appropriate guidance, the importance of the qualification process cannot be neglected. Qualification of the actuators through field trials is a very costly and time-consuming process. The testing process using real flights takes more time and is costly. For ground testing, aerodynamic loading systems are used. The aerodynamic loading system is ground-based hardware in the loop (HWIL) simulator that can be used for exerting aerodynamic loads on actuation system of flight vehicles in real-time experiment. The actuation system under test is directly connected to the loading motor through a stiff shaft and the aerodynamics loading is applied in real time according to the flight trajectory generated by a flight computer.

The load simulator simulates the aerodynamic loads on actuators in flight in a laboratory. It is used to evaluate whether the performance of actuation system meets the aircraft requirements. The maneuverability and control precision of aircraft are attracting more and more attention with the development of aviation industry.

Korea Patent Publication No. KR100875998B1 discloses a load simulator for flight control actuation system having stiffness implemental device of airframe mounting structure which is provided to test the dynamic load characteristic test in the airframe mounting condition. The load simulator for flight control actuation system comprises the moment of inertia copying the rotating inertia load, the moment arm assembled in the shafting plane column shape, the load servo driver copying the aviation load generated in flying, the location servo driver performing the rotational fluctuation control of exercise of the operation object, the airframe structure supporting part rigidity realization equipment, assembling and supporting the location servo driver, the simulator frame supporting the moment arm, the driver neutrality road and the row information commercial gap phase.

However, the load simulator of the existing prior art cannot be used for testing the control system performance of control actuation system (CAS) by ensuring control actuation system’s (CAS’s) motor static and dynamic load withstanding capability at lab level. Also, the simulator of prior art may not be designed for lab level testing while simulating the aerodynamic loads on the fins while the missile is in flight and the performance in terms of input angle to motor and the response time taken by motor to rotate the given angle and current drawn by motor. Further, a safety locking feature which will not allow the free movement of the control actuation system (CAS) is not disclosed in existing load simulators.

In particular, the control actuation system (CAS) of missile is an electro-mechanical actuation module having independently actuated fins Aero-foil with actuation control unit for executing the command received from on-board computer. The control actuation system (CAS) provides in-flight maneuverability and control over the missile for the entire flight envelope. The control actuation system (CAS) has to cater to the requirement of aerodynamic loads experience during the flight of the missile and respond within the specific time-limits without delaying in the maneuver process.

Therefore, there is a need to design such an Aerodynamic Load Simulator which is to be used for testing the control system performance of control actuation system (CAS) and to ensure control actuation system’s (CAS’s) motor static and dynamic load withstanding capability at lab level.

The present invention provides an Aerodynamic Load Simulator for Testing Control and Actuation System. The load simulator of the present invention is used for testing the control system performance of control actuation system (CAS) and to ensure control actuation system’s (CAS’s) motor static and dynamic load withstanding capability.

OBJECT(S) OF THE INVENTION:

A primary object of the present invention is to provide an Aerodynamic Load Simulator for Testing Control and Actuation System.

Another object of the present invention is to develop an aerodynamic load simulator for testing the static load withstanding capability of motors used in control and actuation system at lab level.

Another object of the present invention is to develop an aerodynamic load simulator for testing the dynamic load withstanding capability of motors used in control and actuation system at lab level.

Another object of the present invention is to provide an aerodynamic load simulator for simulating load profile for entire flight envelope.

Another object of the present invention is to provide an aerodynamic load simulator which can be operated with minimum training.

Another object of the present invention is to provide an aerodynamic load simulator with a safety locking feature which will not allow the free movement of the control actuation system (CAS) and requires effort of the operator.

Yet another object of the present invention is to provide a method for testing Control and Actuation System (CAS) by measuring the performance of control actuation system (CAS) with the Aerodynamic Load Simulator.

SUMMARY OF THE INVENTION:

Accordingly, the present invention provides an Aerodynamic Load Simulator for Testing Control and Actuation System. In particular, the present invention provides an aerodynamic load simulator for testing the static and dynamic load withstanding capability of motors used in control and actuation system (CAS). More particularly, the Aerodynamic Load Simulator is used in the lab for measuring the performance of control actuation system (CAS). The control actuation system (CAS) is to be fixed in the test set-up with the adapters.

The present invention provides an aerodynamic load simulator for simulating load profile for entire flight envelope and can be operated with minimum training. The aerodynamic load simulator of the present invention is provided with a safety locking feature which will not allow the free movement of the control actuation system (CAS) and requires effort of the operator.

In one aspect of the present invention, the invention provides an Aerodynamic Load Simulator (100) for testing Control and Actuation System (CAS) (200) comprises:
- a base plate (1) for mounting a plurality of brackets (2);
- a plurality of springs (3) mounted on brackets (2) to simulate the load;
- a plurality of adapters (4) for mounting in control actuation system (CAS) (200) frame;
- a shaft (5) for supporting control actuation system (CAS) (200) frame;
- a cover (6) for locking the control actuation system (CAS) (200) in the setup; and
- a plurality of elongated slots (7) present in the surrounding of the cover (6);
wherein the aerodynamic load simulator (100) is the test setup designed for lab level testing of control actuation system’s (CAS’s) (200) motors and control system performance; and
wherein the control actuation system (CAS) (200) is to be fixed in the test set-up with the adapters (4).

The base plate (1) is octagonal in shape comprising a circular opening (8) at the centre portion of the base plate (1).

The shaft (5) is mounted in the middle portion of the circular opening (8) of the base plate (1) for supporting the control actuation system (CAS) (200) frame during testing of the motors of the control actuation system (CAS) (200).

The shaft (5) and the control actuation system (CAS) (200) with the cover (6) are fixed with each other by screwing a nut (9) in threaded portion (10) with a circular plate (11). The diameter of the circular plate (11) and the diameter of upper portion of the cylindrical cover (6) are same in dimensions.

The diameter of the circular opening (8) of the base plate (1) and the diameter of lower portion of the cylindrical cover (6) are same in dimensions for fixing the cover (6) in opening (8) of base plate (1).

The brackets (2) are mounted on alternate sides of octagonal base plate (1) with a plurality of screws (12) and the bracket (2) comprises the spring (3) mounted on a cylindrical portion with screws (13) to produce loads for simulating the aerodynamic loads.

The cylindrical portion for placing the spring (3) comprises the adapter (4) for mounting in control actuation system (CAS) (200) frame.

The cover (6) is cylindrical in shape comprising a plurality of elongated slots (7) to adapt the adapters (4) in it.

The adapters (4) are to be inserted in elongated slots (7) provided on the cover (6) to lock the control actuation system (CAS) (200) frame in a test set up of simulator (100).

In another aspect of the present invention, the invention provides a method for testing Control and Actuation System (CAS) (200) by measuring the performance of control actuation system (CAS) (200) with the Aerodynamic Load Simulator (100) as described above comprises the steps:
- fixing the control actuation system (CAS) (200) in the test set-up with the adapters (4);
- providing a command to motors for deflecting fins by a predetermined angle;
- transmitting the said deflection to an attached spring (3) which opposes the motion due to development of load in form of torsion; and
- monitoring response time by in-built encoders of the control actuation system (CAS) (200);
wherein the spring (3) is designed to produce loads to simulate aerodynamic loads; and
wherein the response time and current drawn by the motor for rotation of the provided angle creates the basis for acceptance of the control actuation system (CAS) (200).

The above description merely is an outline of the technical solution of the present disclosure. The summary is descriptive and exemplary only and is not intended to be in any way restricting. In order to know the technical means of the present disclosure more clearly so that implementation may be carried out according to contents of the specification, and in order to make the above and other objectives, characteristics and advantages of the present disclosure clear and easy to understand, specific embodiments of the present invention will be described in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS:

The drawings described herein are intended to provide a further understanding of the invention and are intended to be a part of the invention. However, the drawings as shown are representative for illustration and are non-limiting the scope of the invention. In the drawings:
Figure 1 shows the structural design of Load Simulator (100) without Control Actuation System (CAS) (200) connected to shaft (5).

Figure 1A shows the enlarged view of portion (A) of Load Simulator (100) as shown in Figure 1.

Figure 2 shows the structural design of Load Simulator (100) with Control Actuation System (CAS) (200) connected to shaft (5).

DETAILED DESCRIPTION OF THE INVENTION:

The present invention relates to an Aerodynamic Load Simulator for Testing Control and Actuation System.

The flight actuation system plays an important role in the accurate guidance of flight vehicles. The actuators driving the control surfaces are aerodynamically loaded during flight. The design, testing and selection process of the flight actuators play an important role to ensure the stable and safe flight. Since a reliable flight actuation system can ensure appropriate guidance, the importance of the qualification process cannot be neglected. Qualification of the actuators through field trials is a very costly and time-consuming process. The testing process using real flights takes more time and is costly. The load simulator simulates the aerodynamic loads on actuators in flight in a laboratory. It is used to evaluate whether the performance of actuation system meets the aircraft requirements. The maneuverability and control precision of aircraft are attracting more and more attention with the development of aviation industry.

The control actuation system (CAS) of missile is an electro-mechanical actuation module having independently actuated fins Aero-foil with actuation control unit for executing the command received from on-board computer. The control actuation system (CAS) provides in-flight maneuverability and control over the missile for the entire flight envelope. The control actuation system (CAS) has to cater to the requirement of aerodynamic loads experience during the flight of the missile and respond within the specific time-limits without delaying in the maneuver process.

Accordingly, the present invention provides an aerodynamic load simulator for testing the static and dynamic load withstanding capability of motors used in control and actuation system (CAS). In particular, the aerodynamic load simulator of the present invention is the test set up designed for testing of performance of motors used in control actuation system (CAS). The control actuation system (CAS) is to be fixed in the test set-up with the adapters.

The present invention provides an aerodynamic load simulator for simulating load profile for entire flight envelope and can be operated with minimum training. The aerodynamic load simulator of the present invention is provided with a safety locking feature which will not allow the free movement of the control actuation system (CAS) and requires effort of the operator.

In one aspect of the present invention, the invention provides an aerodynamic load simulator for testing control and actuation system. Figure 1 shows the structural design of Load Simulator (100) without Control Actuation System (CAS) (200) connected to shaft (5).

Referring to figure 1, the aerodynamic load simulator (100) of the present invention comprises of a base plate (1) for mounting a plurality of brackets (2), specially designed plurality of springs (3) to simulate the load, a plurality of adapters (4) for mounting in control actuation system (CAS) (200) frame, a shaft (5) for supporting control actuation system (CAS) (200) frame and a cover (6) for locking the control actuation system (CAS) (200) in the test setup. The aerodynamic load simulator (100) is the test setup designed for lab level testing of control actuation system’s (CAS’s) motors and control system performance.

Figure 1A shows the enlarged view of portion (A) of Load Simulator (100) as shown in Figure 1. Some of the above components of Load Simulator (100) such as a bracket (2), a specially designed spring (3) and an adapter (4) are shown in enlarged view as one assembly. In one embodiment, there are four similar assemblies together including four number of brackets (2), four number of springs (3) and four number of adapters (4) mounted on a single base plate (1) as shown in Figure 1.

In general, the base plate acts as an interface between the superstructure and the foundation; thus, completing the load path into the foundation. Base plates provide a uniform distribution of superstructure loads to the foundation, and therefore conform to the shape of the foundation, typically a square or a rectangle. In one embodiment, the base plate (1) is octagonal in shape used for mounting the brackets (2).

Further, there is a circular opening (8) in the centre portion of the base plate (1). The shaft (5) is mounted in the middle portion of said opening (8) of the base plate (1). The shaft (5) having threaded portion (10) is used for supporting the control actuation system (CAS) (200) frame with the help of fixing components such as a nut (9) and a circular plate (11). The shaft (5) supports the control actuation system (CAS) (200) frame during testing of the motors of the control actuation system (CAS) (200).

In one embodiment, there are four brackets (2) placed on the base plate (1). The brackets (2) are mounted on alternate sides of octagonal base plate (1) with the help of screws (12) as shown in Figure 1. Each bracket (2) comprises a specially designed spring (3) mounted on a cylindrical portion as shown in Figure 1A. The cylindrical portion with the spring (3) is attached to the bracket (2) by using a plurality of screws (13) as shown in Figure 1. The springs (3) are designed to produce loads for simulating aerodynamic loads.

Further, each one of the cylindrical portions with the springs (3) mounted on brackets (2) comprises an adapter (4) for mounting in control actuation system (CAS) (200) frame as shown in Figure 1A. In particular, Figure 2 shows that all the adapters (4) are inserted in the slots (7) provided on a cover (6) to lock the control actuation system (CAS) (200) frame in test set up of simulator (100).

Figure 2 shows the exemplary embodiment of load simulator (100) with control actuation system (CAS) (200) connected to shaft (5). The control actuation system (CAS) (200) is surrounded by the cover (6) comprising a plurality of elongated slots (7). In one embodiment, the cover (6) is cylindrical in shape and there are four slots (7) present on the surrounding of the cover (6).

Further, in one embodiment of the present invention, the cover (6) of the control actuation system (CAS) (200) frame is mounted on the shaft (5). The control actuation system (CAS) (200) with cover (6) and the shaft (5) are connected by placing the circular plate (11) on the upper portion of the cover (6) by screwing the nut (9) to be fixed in the threaded portion (10) of shaft (5) as shown in Figure 1 and Figure 2. The upper portion of the cover (6) is the opposite portion of the opening (8) of the base plate (1). The diameter of the circular plate (11) and the diameter of the cylindrical cover (6) are same so as to fix the cover (6) on the shaft (5) tightly.

Similarly, the lower portion of the cover (6) is fixed in the opening (8) of the base plate (1) wherein the diameter of the circular opening (8) of the base plate (1) and the diameter of the lower portion of cylindrical cover (6) are same.

In particular, the cover (6) is used to lock the control actuation system (CAS) (200) in test set up of simulator (100) such that the locking of the system will not allow the free movement of control actuation system (CAS) (200) and requires effort of the operator. Thus, the simulator (100) can be safely used.

Thus, the above-mentioned description can be summarized as, an Aerodynamic Load Simulator (100) for testing Control and Actuation System (CAS) (200) comprises:
- a base plate (1) for mounting a plurality of brackets (2);
- a plurality of springs (3) mounted on brackets (2) to simulate the load;
- a plurality of adapters (4) for mounting in control actuation system (CAS) (200) frame;
- a shaft (5) for supporting control actuation system (CAS) (200) frame;
- a cover (6) for locking the control actuation system (CAS) (200) in the setup; and
- a plurality of elongated slots (7) present in the surrounding of the cover (6);
wherein the aerodynamic load simulator (100) is the test setup designed for lab level testing of control actuation system’s (CAS’s) (200) motors and control system performance; and
wherein the control actuation system (CAS) (200) is to be fixed in the test set-up with the adapters (4).

The control actuation system (CAS) (200) of missile is an Electro-Mechanical Actuation module comprising independently actuated fins Aero-foil with an actuation control unit for executing the command received from on-board computer. The control actuation system (CAS) (200) comprises electric motors, thermal batteries, full digital control, power and control electronics, integrated structure, fins/locks and other necessary electronic components. The control actuation system (CAS) (200) provides in-flight maneuverability and control over the missile for the entire flight envelope. The control actuation system (CAS) (200) has to cater to the requirement of aerodynamic loads experience during the flight of the missile and respond within the specific time-limits without delaying in the maneuver process.

Working Principle:
The aerodynamic load simulator (100) of the present invention is used in the lab for measuring the performance of control actuation system (CAS) (200). The control actuation system (CAS) (200) is to be fixed in the test set-up with the adapters (4). The command is given to the motors for deflecting the fins by a predetermined angle, this deflection is transmitted to the attached springs (3) which opposes the motion due to development of load in form of torsion. The spring (3) is designed to produce loads to simulate aerodynamic loads. Response time is monitored by in-built encoders of the control actuation system (CAS) (200). The response time and the current drawn by the motor for rotation of the given angle creates the basis for acceptance of the control actuation system (CAS) (200).

Thus, the above-mentioned description can be summarized as, a method for testing Control and Actuation System (CAS) (200) by measuring the performance of control actuation system (CAS) (200) with the Aerodynamic Load Simulator (100) as described above comprises the steps:
- fixing the control actuation system (CAS) (200) in the test set-up with the adapters (4);
- providing a command to motors for deflecting fins by a predetermined angle;
- transmitting the said deflection to an attached spring (3) which opposes the motion due to development of load in form of torsion; and
- monitoring response time by in-built encoders of the control actuation system (CAS) (200);
wherein the spring (3) is designed to produce loads to simulate aerodynamic loads; and
wherein the response time and current drawn by the motor for rotation of the provided angle creates the basis for acceptance of the control actuation system (CAS) (200).

Thus, the present invention provides an Aerodynamic Load Simulator which is to be used for testing the control system performance of control actuation system (CAS) and to ensure control actuation system’s (CAS’s) motor static and dynamic load withstanding capability at lab level.

APPLICATION AND/OR ADVANTAGES:

The Aerodynamic load simulator (100) of the present invention provides the following advantages:
a) Load profile for entire flight envelope is simulated using Aerodynamic load simulator (100).
b) The Aerodynamic load simulator (100) is operated with minimum training.
c) The Aerodynamic load simulator (100) is safely used as locking of the system will not allow the free movement of control actuation system (CAS) (200) and requires effort of the operator.
, Claims:1. An Aerodynamic Load Simulator (100) for testing Control and Actuation System (CAS) (200) comprises:
- a base plate (1) for mounting a plurality of brackets (2);
- a plurality of springs (3) mounted on brackets (2) to simulate the load;
- a plurality of adapters (4) for mounting in control actuation system (CAS) (200) frame;
- a shaft (5) for supporting control actuation system (CAS) (200) frame;
- a cover (6) for locking the control actuation system (CAS) (200) in the setup; and
- a plurality of elongated slots (7) present in the surrounding of the cover (6);
wherein the aerodynamic load simulator (100) is the test setup designed for lab level testing of control actuation system’s (CAS’s) (200) motors and control system performance; and
wherein the control actuation system (CAS) (200) is to be fixed in the test set-up with the adapters (4).

2. The Aerodynamic Load Simulator (100) as claimed in claim 1, wherein the base plate (1) is octagonal in shape comprising a circular opening (8) at the centre portion of the base plate (1).

3. The Aerodynamic Load Simulator (100) as claimed in claim 1, wherein the shaft (5) is mounted in the middle portion of the circular opening (8) of the base plate (1) for supporting the control actuation system (CAS) (200) frame during testing of the motors of the control actuation system (CAS) (200).

4. The Aerodynamic Load Simulator (100) as claimed in claim 1, wherein the shaft (5) and the control actuation system (CAS) (200) with the cover (6) are fixed with each other by screwing a nut (9) in threaded portion (10) with a circular plate (11); and
wherein the diameter of the circular plate (11) and the diameter of upper portion of the cylindrical cover (6) are same in dimensions.

5. The Aerodynamic Load Simulator (100) as claimed in claim 1, wherein the diameter of the circular opening (8) of the base plate (1) and the diameter of lower portion of the cylindrical cover (6) are same in dimensions for fixing the cover (6) in opening (8) of base plate (1).

6. The Aerodynamic Load Simulator (100) as claimed in claim 1, wherein the brackets (2) are mounted on alternate sides of octagonal base plate (1) with a plurality of screws (12); and
wherein the bracket (2) comprises the spring (3) mounted on a cylindrical portion with screws (13) to produce loads for simulating the aerodynamic loads.

7. The Aerodynamic Load Simulator (100) as claimed in claim 6, wherein the cylindrical portion for placing the spring (3) comprises the adapter (4) for mounting in control actuation system (CAS) (200) frame.

8. The Aerodynamic Load Simulator (100) as claimed in claim 1, wherein the cover (6) is cylindrical in shape comprising a plurality of elongated slots (7) to adapt the adapters (4) in it.

9. The Aerodynamic Load Simulator (100) as claimed in claim 1, wherein the adapters (4) are to be inserted in elongated slots (7) provided on the cover (6) to lock the control actuation system (CAS) (200) frame in a test set up of simulator (100).

10. A method for testing Control and Actuation System (CAS) (200) by measuring the performance of control actuation system (CAS) (200) with the Aerodynamic Load Simulator (100) as claimed in claim 1 comprises the steps:
- fixing the control actuation system (CAS) (200) in the test set-up with the adapters (4);
- providing a command to motors for deflecting fins by a predetermined angle;
- transmitting the said deflection to an attached spring (3) which opposes the motion due to development of load in form of torsion; and
- monitoring response time by in-built encoders of the control actuation system (CAS) (200);
wherein the spring (3) is designed to produce loads to simulate aerodynamic loads; and
wherein the response time and current drawn by the motor for rotation of the provided angle creates the basis for acceptance of the control actuation system (CAS) (200).