IP Library Granted Patent US 12673768
Granted Patent B2
US 12673768 · App. 18/930,815 · Granted Jul 7, 2026

Propeller impact detection and force reduction

Inventor: Christopher Scott Saunders (San Jose, CA)
Assignee: Kitty Hawk Corporation
B64C27/006B64D17/80B64D31/10B64D45/00B64D2045/0085
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Quick Facts
Patent No.
US 12673768
App. No.
18/930,815
Granted
Jul 7, 2026
Kind
B2
Abstract

In various embodiments, a motor controller includes a rotor strike detector and a drive and control unit. The motor controller generates a plurality of phase-shifted sinusoidal signals. The rotor strike detector detects a rotor strike including by comparing a commanded control signal and an adaptive control signal. The adaptive control signal is associated with controlling the rotor and includes the phase-shifted sinusoidal signals. A rotor strike is detected based on a change in a plurality of sinusoidal signals. The drive and control unit, in response to detecting that the aircraft is above a threshold altitude and detecting the rotor strike, sets a value of the adaptive control signal to keep the aircraft airborne, and reduces a striking force applied to an object being struck by the rotor including by prioritizing the keeping the aircraft airborne over the reducing the striking force applied to the object being struck by the rotor.

Claims (41)

1 . An aircraft, comprising:

a rotor; and

a motor controller configured to generate a plurality of phase-shifted sinusoidal signals, wherein the motor controller includes:

a rotor strike detector configured to detect a rotor strike including by comparing a commanded control signal and an adaptive control signal, wherein:

the adaptive control signal is associated with controlling the rotor and includes the plurality of phase-shifted sinusoidal signals;

a rotor strike is detected based at least on a change in a plurality of sinusoidal signals; and

a drive and control unit coupled to the rotor and the motor controller, the drive and control unit being configured to, in response to detecting that the aircraft is above a threshold altitude and detecting the rotor strike:

set a value of the adaptive control signal to keep the aircraft airborne, and

to reduce a striking force applied to an object being struck by the rotor including by prioritizing the keeping the aircraft airborne over the reducing the striking force applied to the object being struck by the rotor.

2 . The aircraft recited in claim 1 , wherein the plurality of phase-shifted sinusoidal signals is generated in response to detecting the rotor strike including by setting values of the plurality of phase-shifted sinusoidal signals to at least one of: brake the rotor or exert no additional torque on the rotor.

3 . The aircraft recited in claim 1 , wherein the plurality of phase-shifted sinusoidal signals indicates a directionality of rotation of the rotor.

4 . The aircraft recited in claim 3 , wherein the directionality of rotation of the rotor includes a direction associated with default operation and another direction associated with braking the rotor in response to the detection of the rotor strike.

5 . The aircraft recited in claim 1 , wherein the motor controller is configured to generate the plurality of phase-shifted sinusoidal signals.

6 . The aircraft recited in claim 5 , wherein the plurality of phase-shifted sinusoidal signals is generated by the drive and control unit based on at least one of: the commanded control signal, state information from sensors, and a strike indication signal from the rotor strike detector.

7 . The aircraft recited in claim 5 , wherein the plurality of phase-shifted sinusoidal signals is generated in response to detecting the rotor strike including by setting values of the plurality of phase-shifted sinusoidal signals to at least one of: brake the rotor or exert no additional torque on the rotor.

8 . The aircraft recited in claim 1 , wherein the change in the phase-shifted sinusoidal signals includes at least one of a change corresponding to an increase in an amount of torque or a reduction in rotations per minute.

9 . The aircraft recited in claim 8 , wherein the comparison of the commanded control signal and the adaptive control signal includes the change in the phase-shifted sinusoidal signals not matching the commanded control signal.

10 . A method, comprising:

generating a plurality of phase-shifted sinusoidal signals;

detecting a rotor strike including by comparing a commanded control signal and an adaptive control signal, wherein:

the adaptive control signal is associated with controlling a rotor and includes the plurality of phase-shifted sinusoidal signals;

a rotor strike is detected based at least on a change in a plurality of sinusoidal signals; and

in response to detecting that an aircraft is above a threshold altitude and detecting the rotor strike:

setting a value of the adaptive control signal to keep the aircraft airborne, and reducing a striking force applied to an object being struck by the rotor including by prioritizing the keeping the aircraft airborne over the reducing the striking force applied to the object being struck by the rotor.

11 . The method recited in claim 10 , wherein the plurality of phase-shifted sinusoidal signals indicates a directionality of rotation of the rotor.

12 . The method recited in claim 11 , wherein the directionality of rotation of the rotor includes a direction associated with default operation and another direction associated with braking the rotor in response to the detection of the rotor strike.

13 . The method recited in claim 10 , wherein the plurality of phase-shifted sinusoidal signals includes a first signal, a second signal with a 120 degree phase offset from the first signal, and a third signal with a 240 degree offset from the first signal.

14 . The method recited in claim 10 , further comprising generating the plurality of phase-shifted sinusoidal signals.

15 . The method recited in claim 14 , wherein the plurality of phase-shifted sinusoidal signals is generated based on at least one of: the commanded control signal, state information from sensors, and a strike indication signal.

16 . The method recited in claim 14 , wherein the plurality of phase-shifted sinusoidal signals is generated in response to detecting the rotor strike including by setting values of the plurality of phase-shifted sinusoidal signals to at least one of: brake the rotor or exert no additional torque on the rotor.

17 . The method recited in claim 10 , wherein the change in the phase-shifted sinusoidal signals includes at least one of a change corresponding to an increase in an amount of torque or a reduction in rotations per minute.

18 . The method recited in claim 17 , wherein the comparison of the commanded control signal and the adaptive control signal includes the change in the phase-shifted sinusoidal signals not matching the commanded control signal.

19 . A computer program product, the computer program product being embodied in a non-transitory computer readable storage medium and comprising computer instructions for:

generating a plurality of phase-shifted sinusoidal signals;

detecting a rotor strike including by comparing a commanded control signal and an adaptive control signal, wherein:

the adaptive control signal is associated with controlling a rotor and includes the plurality of phase-shifted sinusoidal signals;

a rotor strike is detected based at least on a change in a plurality of sinusoidal signals; and

in response to detecting that an aircraft is above a threshold altitude and detecting the rotor strike:

setting a value of the adaptive control signal to keep the aircraft airborne, and

reducing a striking force applied to an object being struck by the rotor including by prioritizing the keeping the aircraft airborne over the reducing the striking force applied to the object being struck by the rotor.

20 . The computer program product recited in claim 19 , wherein the plurality of phase-shifted sinusoidal signals indicates a directionality of rotation of the rotor, the directionality including a direction associated with default operation and another direction associated with braking the rotor in response to the detection of the rotor strike.