The present invention relates generally to the field of airplane engine and propeller controllers. The present invention relates specifically to a single input engine controller that simultaneously controls the fuel supplied to an engine and the revolutions per minute (RPM) of a propeller powered by that engine. Aircraft engines typically employ two separate control inputs. The first input controls the amount of fuel fed into the engine which correlates to the amount of horsepower output by the engine. The second input controls a propeller governor, which continually adjusts the angle of the propeller to maintain a specific propeller RPM set by the second input. Separately controlling the RPM of the propeller allows for improved fuel efficiency when compared with a fixed angle propeller because the minimum RPM required for operation varies as a function of the horsepower of the engine and the needed horsepower of the engine varies depending on the desired mode of operation of the aircraft. For example, the greatest amount of horsepower is required during takeoff and significantly less horsepower even up to 50% less is required once cruising altitude is reached. Leaving the propeller at the RPM setting corresponding to the max horsepower wastes fuel by spinning the propeller more than is required to propel the aircraft.
The typical two input system requires pilots to consult charts or remember the complex relationship between the horsepower setting and the propeller RPM that achieves the maximum fuel efficiency. Unfortunately, most pilots do not take the time to remember or consult such charts and simply leave the propeller RPM setting at the level required for takeoff. This results in wasted fuel and shorter flight distances because FAA regulations require planes to maintain a specific amount of fuel upon landing. What is needed then is a system that varies the propeller RPM setting to the ideal fuel efficient setting in response to a single input from the standard fuel controller.
One embodiment of the invention relates to a single input aircraft engine and propeller control system including a fuel control interface to produce a first mechanical signal corresponding to a specific amount of fuel to be fed to an engine to produce a specific amount of horsepower. The specific amount of horsepower has a corresponding RPM setting for a propeller coupled to the engine and the RPM setting corresponds to maximum fuel efficiency. The control system also includes a single input engine controller coupled to the fuel control interface to receive the first mechanical signal, translate the first mechanical signal into a second mechanical signal indicative of the RPM setting corresponding to the specific amount of horsepower, and output a third mechanical signal indicative of the specific amount of fuel. The third mechanical signal is induced by the first mechanical signal. The system also includes a fuel distribution system coupled to the single input engine controller to receive the third mechanical signal. The third mechanical signal triggers the fuel distribution system to feed the specific amount of fuel to the engine. The system also includes a propeller RPM controller coupled to the single input engine controller to receive the second mechanical signal. The second mechanical signal triggers the RPM controller to set the RPM of the propeller to the corresponding RPM setting.
Another embodiment of the invention relates to a single input aircraft engine and propeller control system including a fuel control interface to produce a first mechanical signal corresponding to a specific amount of fuel to be fed to an engine to produce a specific amount of horsepower. The specific amount of horsepower has a corresponding RPM setting for a propeller coupled to the engine. The RPM setting corresponds to maximum fuel efficiency. The system also includes a housing having a first pivot point and a second pivot point. The system also includes a fuel control lever pivotably coupled to the first pivot point. The system also includes an RPM control lever having a cammed slot. The RPM control lever is pivotably coupled to the second pivot point, the fuel control lever, and the fuel control interface such that the first mechanical signal induces the RPM control lever and the fuel control lever to pivot about the first and second pivot points. The cammed slot is shaped and sized to translate the pivoting of the RPM control lever into a second mechanical signal indicative of the RPM setting corresponding to the specific amount of horsepower. The system also includes a fuel distribution system pivotably coupled to the fuel control lever to receive a third mechanical signal induced by the pivoting of the fuel control lever. The third mechanical signal triggers the fuel distribution system to feed the specific amount of fuel to the engine. The system also includes a propeller RPM controller slidably coupled to the cammed slot to receive the second mechanical signal induced by the pivoting of the RPM control lever. The second mechanical signal triggers the RPM controller to set the RPM of the propeller to the corresponding RPM setting.
Another embodiment of the invention relates to a single input engine controller including a housing having a first pivot point and a second pivot point. The controller also includes a fuel control lever pivotably coupled to the first pivot point. The controller also includes an RPM control lever having a cammed slot. The RPM control lever is pivotably coupled to the second pivot point and the fuel control lever to receive a first mechanical signal indicative of a specific amount of fuel, pivot about the second pivot point in response to the first mechanical signal, and induce the fuel control lever to pivot about the first pivot point. The cammed slot is shaped and sized to translate the pivoting of the RPM control lever into a second mechanical signal indicative of an RPM setting corresponding to the specific amount of fuel. The pivoting of the fuel control lever induces a third mechanical signal proportional to the first mechanical signal. The third mechanical signal is indicative of the specific amount of fuel.
This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:
Referring generally to the figures, various embodiments of a single input engine controller alone and in combination with additional engine control components are shown. The single input engine controller receives an input from a standard fuel or power controller for an engine and outputs one signal for setting the engine fuel amount to achieve a specific amount of horsepower and a second signal for setting the RPM of a propeller to the value corresponding to the ideal fuel efficient RPM setting for the specific power to be output by the engine in response to the fuel setting. This configuration eliminates the pilots need to manually adjust the RPM, ensuring the aircraft is operating at or very near the ideal fuel efficiency level.
Referring to
Referring to
Referring now to
Referring now to
Clevis 40 is pivotably coupled to RPM control lever 34 and when single input controller 20 is placed in a system such as system 10 clevis 40 receives and secures a mechanical link from the fuel control interface 22 within mounting hole 68. Clevis 41 is pivotably coupled to fuel control lever 36 and when single input controller 20 is placed in a system such as system 10, clevis 41 receives and secures a mechanical link to either the fuel distribution system 24 or idle control module 30 (see
In one embodiment as shown in
Cover 70 of RPM control linkage 42 is positionally fixed and secured to back plate 56 by first bracket 44. Fixing cover 70 allows for cable 72 to slide freely within cover 70. Cable link 72 passes through a hole in second bracket 46 mounted to back plate 56 to guide cable link 72. One end of cable link 72 is secured to connector 48. In one embodiment, the end of cable link 72 is threaded and is secured to connector 48 by a nut. The opposite end of cable 72 is coupled to a propeller RPM controller such as propeller RPM controller 26 when single input controller 20 is placed in a system such as system 10. Coupling member 50 passes partially through cammed slot 66 and is secured into mounting hole 74 thereby coupling RPM control lever 34 to RPM control linkage 42. Coupling member 50 is slidably movable within cammed slot 66. Back securing members 53 partially pass through a subset of mounting holes 60 on back plate 56 and are received within through bore 76 of standouts 52. Likewise, front securing members 54 partially pass through a subset of mounting holes 60 on front plate 58 and are received within through bore 76 of standouts 52. Front and rear securing members 54 and 56 are tightened to secure back plate 56 to front plate 58 to contain and protect the components of single input controller 20. Various alternative methods of securing back plate 56 to front plate 58 are contemplated including replacing rear securing members 56 with standouts 52 that screw into back plate 56.
Referring now to
In operation from minimum fuel to full fuel, movement of fuel control interface 22 produces a first mechanical signal (i.e. mechanical motion) indicative of a specific amount of fuel (i.e. max fuel) to be provided to the engine. The first mechanical signal travels down the mechanical links (not shown) coupling fuel control interface 22 to RPM control lever 34 of single input controller 20. The first mechanical signal induces RPM control lever 34 to pivot about first pivot point 62 in the direction of arrow A. Pivoting RPM control lever 34 engages coupling member 50 within cammed slot 66 and induces a second mechanical signal in cable 72 of RPM control linkage 42. Because cable 72 is guided by second bracket 46 and sheath 70 is secured by first bracket 44, cable 72 can only move in a substantially horizontal direction. This limit along with the specific shape of cammed slot 66 translates the first mechanical signal into a signal indicative of the fuel efficient RPM setting that corresponds to the specific amount of power that the engine will produce when fed the specific amount of fuel. Cammed slot 66 is sized and shaped such that the translated second mechanical signal follows the specific fuel efficiency curve for propeller RPM vs engine horsepower for the engine controlled by single input controller 20.
Pivoting RPM control lever 34 also induces fuel control lever 36 to pivot about second pivot point 64 by transferring the mechanical signal received from fuel control interface 22 through linkage 38. Pivoting fuel control lever 36 induces a third mechanical signal which is passed by mechanical linkage to the component coupled to fuel control lever 36 (e.g. fuel distribution system 24, idle control module 30, etc.). In embodiments where fuel control lever 36 is coupled to both fuel control interface 22 and fuel distribution system 24 or idle control module 30 (see
In various embodiments, the mechanical transfer of signals is performed at a ratio. Transferring the signals at a ratio allows for easier placement of components and especially a more compact configuration. When a transfer ratio is employed, the ratio is reversed prior to the mechanical signal triggering the function of the system it is terminated at. For example, where a ratio of 1:2 is used in transferring the first mechanical signal through fuel control lever 34 and into the third mechanical signal the third mechanical signal will be transferred back at a ratio of 2:1 before it is terminated at fuel distribution system 24. Reversing the ratio ensures that there is a direct relationship between the movement of fuel control interface 22 and the resulting action performed by the engine.
Referring now to
Idle control module 30 includes an idle control lever 78 and devises 80, 82, and 84. Clevises 80, 82, and 84 include mounting holes and are pivotably coupled to idle control lever 78 at pivot points 86, 88, and 90 respectively. Single input engine controller 20 is coupled to idle control module 30 by a mechanical link or cable 92 having one end secured in the mounting hole of clevis 80 and the other secured in mounting hole 69 of clevis 41. Idle governor 28 includes a connector 94. Connector 94 is secured within the mounting hole of clevis 82 to couple idle governor 28 to idle control module 30. Clevis 84 couples idle control module 30 to fuel distribution system 24 by a cable or mechanical link (not shown). In one embodiment, devises 80, 82, and 84 are omitted and the mechanical links and/or connectors are pivotably coupled directly to idle control lever 78.
In operation, single input controller 20 operates as described above in reference to
When single input controller 20 is positioned for minimum fuel output as shown in
It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.
For purposes of this disclosure, the term “coupled” means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.
Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.
This application claims priority to U.S. Provisional Application No. 62/364,660, filed Jul. 20, 2016, the entire contents of which are incorporated by reference.
Number | Date | Country | |
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62364660 | Jul 2016 | US |