Aircraft windshield wiper installation system

A windshield wiper installation system is configured to be used to install a wiper on a windshield of an aircraft. The windshield wiper installation system includes a housing, an installation control unit contained within the housing, at least one positioning member secured to the housing, wherein the installation control unit is operatively coupled to the positioning member(s), and at least one position-setting member secured to the housing, wherein the installation control unit is operatively coupled to the position-setting member(s). The positioning member(s) is configured to be engaged to move the wiper to one or more desired positions on the windshield. The position-setting member is configured to set the desired position(s) when the wiper is at the desired position(s).

FIELD OF THE DISCLOSURE

Embodiments of the present disclosure generally relate to systems and methods for installing aircraft windshield wipers.

BACKGROUND OF THE DISCLOSURE

Various vehicles such as commercial aircraft include cockpits that define an internal operating environment and one or more windshields that shield the cockpit from an outside environment. Windshield wipers are operatively connected to windshields and are configured to wipe water, ice, and the like from the windshields.

During a manufacturing process for an aircraft, a windshield wiper is installed (for example, rigged) in relation to a windshield of the aircraft. Typically, a windshield wiper of an aircraft is installed by supervised and experienced mechanics. Nevertheless, at a later date, the windshield wiper may be removed, such as when an aircraft is painted. The windshield wiper may then be reinstalled by personnel other than specially-trained wiper installation mechanics.

A known windshield wiper system includes an electric motor, a converter, and a windshield wiper. The converter reduces a rotary output speed of the motor and converts it into an oscillating motion through a four linkage mechanism driving the arm and wiper blade back and forth across the windshield.

In order to install (for example, rig) the known windshield wiper system, a bushing is positioned on an outward shaft of the converter. The bushing includes teeth on an outer edge that match the pattern on a wiper arm hub, thereby allowing the bushing and the wiper arm hub to rotate together during operation. After the wiper arm hub is positioned on the bushing, a wiper arm hub bolt is tightened. Then, the wiper arm is raised up to a lift block assembly, so the wiper arm sits on a lift block assembly.

If the wiper arm is raised up to the lift block assembly with too much force, a park position may be inadvertently defined below the lift bock assembly. As such, during operation, when the wiper is signaled to park, the wiper arm may collide with the lift block assembly as the motor forces the wiper past the lift block assembly to an incorrect park position. Conversely, if the wiper arm is raised up to the lift block assembly with insufficient force, the park position may be defined above the lift bock assembly causing the wiper to insufficiently park in relation to the lift block assembly.

To verify proper installation, a mechanic sprays water on the windshield and activates the wiper. As the windshield wiper moves, the mechanic checks that a lower sweep limit of the wiper is between two lines on a piece of tape the mechanic previously placed on the windshield, as per instructions in an installation manual. Additionally, the mechanic checks that the windshield wiper parks correctly. If the mechanic determines that the windshield wiper does not satisfy operational requirements, the mechanic removes the wiper arm and the bushing form the outward shaft, rotates the bushing accordingly, and then repeats the installation process. The amount of rotation of the bushing for proper rigging may be intuitive for an experienced mechanic. However, an unexperienced mechanic may have to rely on trial and error, thereby prolonging the installation process.

As can be appreciated, the wiper installation or rigging process is labor and time intensive, complex, and is typically performed by mechanics who are specifically trained in such process.

SUMMARY OF THE DISCLOSURE

A need exists for a simple and efficient system and method of installing a windshield wiper on a windshield of an aircraft. Further, a need exists for a quicker and easier process of installing a wiper in relation to a windshield of an aircraft.

With those needs in mind, certain embodiments of the present disclosure provide a windshield wiper installation system that is configured to be used to install a wiper on a windshield of an aircraft. The windshield wiper installation system includes a housing, an installation control unit contained within the housing, at least one positioning member secured to the housing (wherein the installation control unit is operatively coupled to the positioning member(s)), and at least one position-setting member secured to the housing (wherein the installation control unit is operatively coupled to the position-setting member(s)). The positioning member(s) is configured to be engaged to move the wiper to one or more desired positions on the windshield. The position-setting member(s) is configured to be engaged to set the desired position(s) when the wiper is at the desired position(s).

The one or more desired positions may include a plurality of desired positions. In at least one embodiment, the plurality of desired positions include a lower limit position of the wiper on the windshield, an upper limit position of the wiper on the windshield, and a park position of the wiper in relation to the windshield. A park lock may be used to secure the wiper in the park position.

In at least one embodiment, the installation control unit is in communication with an actuator that is coupled to the wiper through a gearbox. The installation control unit is configured to operate the actuator to move the wiper based on signals received from the positioning member(s). The installation control unit may be configured to be removably coupled to the actuator through one or more electrical couplings. In at least one embodiment, the actuator includes a stepper motor. In at least one other embodiment, the actuator includes an electric torque motor.

A first position-setting member may be associated with a first desired position. A second position-setting member may be associated with a second desired position. A third position-setting member may be associated with a third desired position.

The windshield wiper installation system may also include at least one speed member that is configured to control a speed of the wiper. The windshield wiper installation system may also include at least one power member that is configured to selectively activate and deactivate the windshield wiper installation system.

Certain embodiments of the present disclosure provide an aircraft that includes a fuselage including an internal cockpit, a windshield that shields the internal cockpit from an outside environment, at least one wiper mounted to the windshield, at least one actuator that is coupled to the wiper(s) through at least one gearbox, and a windshield wiper installation system that is configured to be used to install the wiper(s) on the windshield of the aircraft.

Certain embodiments of the present disclosure provide a windshield wiper installation method that is configured to be used to install a wiper on a windshield of an aircraft. The windshield wiper installation method includes using at least one positioning member that is in communication with an installation control unit contained within a housing to move the wiper to a plurality of desired positions on the windshield, and using at least one position-setting member that is in communication with the installation control unit to set the plurality of desired positions when the wiper is placed at the plurality of desired positions. The plurality of desired positions include a lower limit position of the wiper on the windshield, an upper limit position of the wiper on the windshield, and a park position of the wiper in relation to the windshield.

DETAILED DESCRIPTION OF THE DISCLOSURE

Certain embodiments of the present disclosure provide a windshield wiper installation (for example, rigging) system for an aircraft. In at least one embodiment, the windshield wiper installation system is in electrical communication with an actuator (such as a stepper motor, an electric torque motor, or a linear induction motor) that operatively connects to a gearbox, such as a planetary gearbox. The gearbox operatively connects to a windshield wiper. During installation, the windshield wiper system is operated to define a plurality of positions. For example, an upper limit position, a lower limit position, and a park position are defined. The actuator may then be alternated between sending upper and lower limit position signals to the stepper motor resulting in a sweeping motion of the windshield wiper. A locking member (such as a clip, ratchet gear and pawl, solenoid lock, and/or the like) may be used to secure the windshield wipers in the parked position.

FIG. 1is a diagrammatic representation of a front perspective view of a vehicle, such as an aircraft10, according to an exemplary embodiment of the present disclosure. The aircraft10includes a propulsion system12that may include two turbofan engines14, for example. Optionally, the propulsion system12may include more engines14than shown. The engines14are carried by wings16of the aircraft10. In other embodiments, the engines14may be carried by a fuselage18and/or an empennage20. The empennage20may also support horizontal stabilizers22and a vertical stabilizer24.

The fuselage18of the aircraft10defines an interior cabin, which includes a cockpit30. The cockpit30defines an internal operating environment in which a pilot and associated crew control operation of the aircraft. One or more windshields32are used to shield the cockpit30from an outside environment. Windshield wipers34are operatively positioned on the windshields32.

Alternatively, instead of an aircraft, embodiments of the present disclosure may be used with various other vehicles, such as automobiles, buses, locomotives and train cars, seacraft, spacecraft, and the like.

FIG. 2is a schematic representation of a wiper installation system100that is used to install a wiper102(such as the wipers34, shown inFIG. 1) on a windshield104(such as the windshields32, shown inFIG. 1) of an aircraft (such as the aircraft10, shown inFIG. 1), according to an exemplary embodiment of the present disclosure. The wiper installation system100includes a housing106that retains an installation control unit108that is operatively coupled to a positioning member110and a position-setting member112, such as through wired or wireless connections, circuit boards, electrical traces, and/or the like. The positioning member110may be or otherwise include one or more of a knob(s), button(s), switch(s), slider(s), roller(s), and/or the like. Similarly, the position-setting member112may be or otherwise include one or more of a knob(s), button(s), switch(s), slider(s), roller(s), and/or the like.

The wiper installation system100electrically communicates with an actuator114through one or more electrical couplings116, such as a wired or wireless connection. In at least one embodiment, the actuator114is or includes a stepper motor. In at least one other embodiment, the actuator114is or includes a linear induction motor, and/or an electric torque motor. The actuator114is operatively coupled to a gearbox118that is, in turn, operatively connected to a hub120of the wiper102.

In operation, in order to install or rig the wiper102in relation to the windshield104, the positioning member110is operated to position the wiper102at a plurality of desired positions. For example, the positioning member110is operated by an individual to move the wiper102to a first position, such as a lower limit position on the windshield104. The installation control unit108receives a positioning signal from the positioning member110that corresponds to the desired motion of the wiper102. The installation control unit108then operates the actuator114to move the wiper102to the desired first position via the gearbox118interacting with the hub120. When the wiper102is moved to the desired first position, the positioning member110is disengaged to cease motion of the wiper102. At the desired first position, the position-setting member112is then engaged to establish the desired first position, such as the lower limit position. The installation control unit108receives a desired first position signal from the position-setting member112, and then establishes the current position of the wiper102in relation to the windshield104as the desired first position. The installation control unit108then stores the desired first position in memory.

The wiper installation system100may be operated to establish additional desired positions, such as a desired second position (for example, an upper limit position), and a park position in a similar fashion. For example, the positioning member110is operated by an individual to move the wiper102to a second position, such as an upper limit position on the windshield104. The installation control unit108receives a positioning signal from the positioning member110that corresponds to the desired motion of the wiper102. The installation control unit108then operates the actuator114to move the wiper102to the desired second position via the gearbox118interacting with the hub120. When the wiper102is moved to the desired second position, the positioning member110is disengaged to cease motion of the wiper102. At the desired second position, the position-setting member112is then engaged to establish the desired second position, such as the upper limit position. The installation control unit108receives a desired second position signal from the position-setting member112, and then establishes the current position of the wiper102in relation to the windshield104as the desired second position. The installation control unit108then stores the desired second position in memory.

Further, the positioning member110may be operated by an individual to move the wiper102to a third position, such as a park position in relation to the windshield104. The installation control unit108receives a positioning signal from the positioning member110that corresponds to the desired motion of the wiper102. The installation control unit108then operates the actuator114to move the wiper102to the desired third position via the gearbox118interacting with the hub120. When the wiper102is moved to the desired third position, the positioning member110is disengaged to cease motion of the wiper102. At the desired third position, the position-setting member112is then engaged to establish the desired third position, such as the park position. The installation control unit108receives a desired third position signal from the position-setting member112, and then establishes the current position of the wiper102in relation to the windshield104as the desired third position. The installation control unit108then stores the desired third position in memory.

In at least one embodiment, the wiper installation system100is removably coupled to the actuator114, such as through the electrical couplings116. For example, the installation control unit108of the wiper installation system100may be electrically tapped into an electrical control system of the windshield wiper via the electrical coupling(s)116, which may include one or more plugs, receptacles, or the like that are configured to electrically connect into an electrical control interface (for example, wires, circuit boards, or the like) that connect to the actuator114. After the installation (for example, rigging) process is completed, the wiper installation system100may be removed from the electrical control system, so that the electrical control system may be used to control operation of the wiper102. In this manner, the wiper installation system100may be used by an individual outside of the cockpit to properly install or rig the wiper102without the need for another individual inside of the cockpit to assist in controlling motion of the wiper102, for example. Alternatively, the wiper installation system100may be part of a windshield wiper control system within a cockpit of an aircraft.

As used herein, the term “control unit,” “central processing unit,” “unit,” “CPU,” “computer,” or the like may include any processor-based or microprocessor-based system including systems using microcontrollers, reduced instruction set computers (RISC), application specific integrated circuits (ASICs), logic circuits, and any other circuit or processor including hardware, software, or a combination thereof capable of executing the functions described herein. Such are exemplary only, and are thus not intended to limit in any way the definition and/or meaning of such terms. For example, the installation control unit108may be or include one or more processors that are configured to control operation of the wiper installation system100, as described herein.

The installation control unit108is configured to execute a set of instructions that are stored in one or more data storage units or elements (such as one or more memories), in order to process data. For example, the installation control unit108may include or be coupled to one or more memories. The data storage units may also store data or other information as desired or needed. The data storage units may be in the form of an information source or a physical memory element within a processing machine.

The diagrams of embodiments herein may illustrate one or more control or processing units, such as the installation control unit108. It is to be understood that the processing or control units may represent circuits, circuitry, or portions thereof that may be implemented as hardware with associated instructions (e.g., software stored on a tangible and non-transitory computer readable storage medium, such as a computer hard drive, ROM, RAM, or the like) that perform the operations described herein. The hardware may include state machine circuitry hardwired to perform the functions described herein. Optionally, the hardware may include electronic circuits that include and/or are connected to one or more logic-based devices, such as microprocessors, processors, controllers, or the like. Optionally, the installation control unit108may represent processing circuitry such as one or more of a field programmable gate array (FPGA), application specific integrated circuit (ASIC), microprocessor(s), and/or the like. The circuits in various embodiments may be configured to execute one or more algorithms to perform functions described herein. The one or more algorithms may include aspects of embodiments disclosed herein, whether or not expressly identified in a flowchart or a method.

As used herein, the terms “software” and “firmware” are interchangeable, and include any computer program stored in a data storage unit (for example, one or more memories) for execution by a computer, including RAM memory, ROM memory, EPROM memory, EEPROM memory, and non-volatile RAM (NVRAM) memory. The above data storage unit types are exemplary only, and are thus not limiting as to the types of memory usable for storage of a computer program.

FIG. 3is a diagrammatic representation of a top perspective view of the wiper installation system100, according to an exemplary embodiment of the present disclosure. The housing106may be configured to be held within a hand of an operator. The housing106contains the installation control unit108. As shown, the positioning member110may be a rotary control knob, while the position-setting member112may be a button. The wiper installation system100may also include additional position-setting members112a,112b, and112c, each of which may be specifically designated with respect to a particular desired position of the wiper102(shown inFIG. 2) in relation to the windshield104(shown inFIGS. 2 and 4, for example). The installation control unit108is in communication with the position-setting members112a,112b, and112c.

Referring toFIGS. 2 and 3, in at least one embodiment, the position-setting member112ais associated with a lower limit of the wiper102in relation to the windshield104, while the position-setting member112bis associated with an upper limit of the wiper102in relation to the windshield104, and the position-setting member112cis associated with a park position of the wiper102in relation to the windshield104. Optionally, the position-setting member112amay be associated with the upper limit or the park position, while the position-setting member112bmay be associated with the lower limit or the park position, and the position-setting member112cmay be associated with the lower limit or the upper limit. The wiper installation system100may include additional position-setting members associated with additional positions of the wiper102in relation to the windshield104. In at least one other embodiment, the wiper installation system100may not include the position-setting members112a-112c, but may instead include only the position-setting member112, which may be used to set various desired positions of the wiper102in relation to the windshield104.

In at least one embodiment, positions may be set by moving the wiper to a desired position, engaging the position-setting member112(such as by pressing the set button), and then engaging the desired position-setting member112a,112b, or112cto associate the set position with a particular set position associated with the position-setting members112a,112b, or112c. For example, the set button (as indicated by the position-setting member112) may be pressed, followed by the A button (as indicated by the position-setting member112a) being pressed to set and store a particular desired position.

The wiper installation system100may also include one or more speed members130and132, such as control knobs, that are in communication with the installation control unit108. The speed members130and132may be used to control a speed of the wiper102as it is being moved between desired positions. The multiple speed members130and132may be used with respect to multiple wipers (such as right and left wipers). For example, one speed member130may be associated with a left wiper, while another speed member132may be associated with a right wiper.

The wiper installation system100may also include one or more power members134,136such as control knobs, buttons, toggle switches, or the like, that are in communication with the installation control unit108. The power members134,136are used to selectively activate and deactivate one or more components of the wiper installation system100. For example, at least one of the power members134,136may be used to selectively activate and deactivate the wiper installation system100. The multiple power members134,136may be used with respect to multiple wipers (such as right and left wipers). For example, one power member134may be associated with a left wiper, while another power member136may be associated with a right wiper.

FIG. 4is a diagrammatic representation of a front perspective view of the wiper installation system100operatively coupled to the wiper102on the windshield104of the aircraft10, according to an exemplary embodiment of the present disclosure. A wiper system101includes the wiper installation system100coupled to the wiper102on the windshield104. As described above, the wiper installation system100is used to move the wiper102between a plurality of desired positions, and to set the desired positions. For example, the wiper installation system100is used to set a first desired position150(such as a lower limit), a second desired position152(such as an upper limit), and a third desired position154(such as a park position) for the wiper102.

FIG. 5is a diagrammatic representation of a front view of the windshield104of the aircraft10, according to an exemplary embodiment of the present disclosure. Referring toFIGS. 2-5, the wiper installation system100may be used to set a lower limit minimum position150a, a lower limit maximum position150b, an upper limit minimum position152a, an upper limit maximum position152b, and the park position154. The maximum and minimum positions are defined because a wiper moves back and forth at a relatively high velocity, and may not stop at the exact same spot with each sweep due to friction on the windshield (which may change based on different environmental conditions, such as rain, ice, condensation, etc.). The lower limit minimum position150adefines a minimum lower position at which the wiper102is to reach during operation. The lower limit maximum position defines150bdefines a maximum lower position at which the wiper102is to reach during operation. The upper limit minimum position152adefines a minimum upper position at which the wiper102is to reach during operation. The upper limit maximum position152bdefines a maximum upper position at which the wiper102is to reach during operation.

As shown inFIG. 5, an angular difference α between the lower limit maximum position150band the upper limit maximum position152bmay be 37.3 degrees. Optionally, the angular difference α may be greater or less than 37.3 degrees. Further, the angular difference β between the lower limit maximum position150band the park position154may be 8 degrees. Optionally, the angular difference β may be greater or less than 8 degrees.

FIG. 6is a schematic representation of the actuator114in a first position, according to an exemplary embodiment of the present disclosure.FIG. 7is a schematic representation of the actuator114in a second position.FIG. 8is a schematic representation of the actuator in a third position.FIG. 9is a schematic representation of the actuator114in a fourth position.

Referring toFIGS. 6-9, the actuator114may be a stepper motor. A stepper motor is a brushless direct current motor that includes a round magnetic rotor with polarized alternating teeth surrounded by multiple electromagnets that are organized in phases. The actuator114, as a stepper motor, may include four electromagnets200,202,204, and206. A magnetically-polarized rotor208is positioned between the electromagnets200,202,204, and206. Each of the electromagnets200-206is selectively energized and de-energized to move the rotor208between the four positions shown inFIGS. 6-9. The rotor208rotates one step when pole tooth210is attracted to an energized electromagnet200,202,204, or206of opposite polarity. When the electromagnets200-206are selectively energized and de-energized in sequence (as shown inFIGS. 6-9), the rotor continuously moves according to such sequence. The rotor208is operatively coupled to the gear box118(shown inFIGS. 2 and 4) to effect a corresponding motion of the wiper102(shown inFIGS. 2 and 4).

Referring toFIGS. 2, 4, and 6-9, in at least one embodiment, the actuator114is mounted to an input shaft of the gearbox118, while the hub120of the wiper102is coupled to an output shaft of the gearbox118. The gearbox118may be a planetary gearbox that includes epi-cyclic gears inside a ring gear. In at least one embodiment, a gear arm (also known as a carrier) is free to rotate, holds the gears, and revolves the gear system around a central sun gear. The planet gears mesh with the inner edge of the ring gear and also with the sun gear located at the center of the ring gear. A planetary gearbox allows for a relatively compact, small, and light stepper motor to be used.

In at least one other embodiment, the actuator114may be a linear induction motor and/or a torque motor, instead of a stepper motor. A linear induction motor is an alternating current, asynchronous linear motor. A linear induction motor has a finite primary or secondary length, which generates end-effects. In this embodiment the actuator114may also serve as a park lock when stalled against a parking block, for example. A torque motor is a type of electric motor that is operable even while stalled, such as when a rotor of the torque motor is blocked from turning. In this condition, the torque motor applies a steady torque to a load.

Embodiments of the present disclosure provide a wiper system101(shown inFIG. 4, for example) for the aircraft10. The wiper system101includes an actuator114, such as a stepper motor, operatively coupled to the wiper102. The wiper installation system100is used to set various positions of the wiper102in relation to the windshield104, as described herein. After the desired positions of the wiper102are set, the wiper installation system100may be removed, and the actuator114may be coupled to a separate control unit (not shown) and source of power to control operation of the wiper102.

FIG. 10is a schematic representation of a front view of the wiper102in relation to a park lock300, according to an exemplary embodiment of the present disclosure. The park lock300may be a latch that is configured to securely lock onto a complementary protuberance302(such as a hook, barb, clasp, stud, or the like) of the wiper102in the park position. In this manner, the wiper102may be passively secured in the park position, so that the actuator114need not be active in order to maintain the wiper in the park position. As such, power may be conserved when the park lock300secures the wiper102in the park position.

In at least one embodiment, the park lock300may be or include a ratchet gear and pawl mechanism, a solenoid lock/bolt, and/or the like. For example, a ratchet gear may be directly attached to a shaft of a stepper motor. During operation, the ratchet gear and pawl are not in contact, so the shaft is free to rotate. Once the windshield wiper102is stowed away and power is turned off, the solenoid mechanism forces the pawl toward the ratchet gear, thereby preventing the system from rotating. In at least one other embodiment, when the power to the motor is turned off, a solenoid bolt mechanism directly locks with the ratchet gear.

In at least one other embodiment the locking mechanism may be integrally formed with an actuator. For example, an electric torque motor may be configured to operate normally while in a stalled configuration. The stalled configuration may be used as a parking mechanism.

FIG. 11illustrates a flow chart of a method of installing a wiper in relation to a windshield of an aircraft, according to an exemplary embodiment of the present disclosure. Referring toFIGS. 1 and 11, the method begins at400, at which the wiper installation system100is coupled to the actuator114(such as through one or more electrical couplings116) that is operatively connected to the wiper102positioned on the windshield104of the aircraft10(shown inFIG. 1). Next, at402, one or more positioning members110of the wiper installation system100are engaged or otherwise used to move the wiper102to one or more desired positions on the windshield104. At404, one or more position-setting members112are engaged or otherwise used when the wiper102is at the desired position(s) to set the desired position(s) of the wiper102in relation to the windshield104.

As described herein, embodiments of the present disclosure provide simple and efficient systems and methods of installing a windshield wiper on a windshield of an aircraft. Further, embodiments of the present disclosure provide a quick and easy process of installing a wiper in relation to a windshield of an aircraft. The wiper installation systems and methods described herein allow for precise positioning and setting of wiper positions, repeatability of movements, quick starting and stopping, and, in general, eliminate or otherwise reduce rigging failures (such as jiggling and over-sweeps).

The windshield wiper systems and methods described herein simplify a wiper rigging process. An individual may utilize the windshield wiper systems and methods to define various positions (such as a park position, an upper limit, and a lower limit).