Windshield wiper system with an internal trigger

1. A windshield wiper system for use on a windshield of an aircraft, the windshield wiper system comprising:

a wiper comprising a wiper arm and a wiper blade coupled to a first end of the wiper arm;

an actuator comprising a body and an output shaft, wherein the output shaft is coupled to a second end of the wiper arm, and wherein the actuator is configured to rotate the output shaft to sweep the wiper arm and wiper blade in an arc across the windshield of the aircraft;

a gear reduction coupled to and positioned between the output shaft and the actuator;

a trigger coupled to the output shaft of the actuator, wherein the trigger is configured to rotate with the output shaft;

a sensor coupled to the body of the actuator, wherein the sensor is configured to detect a magnetic field produced by the trigger; and

a controller electrically coupled to the actuator and electrically coupled to the sensor,

wherein the controller is configured to:

send electrical signals to and receive electrical signals from the actuator to control rotation of the output shaft of the actuator; and

receive electrical signals from the sensor indicating a magnitude of the magnetic field detected by the sensor

wherein the controller is further configured to:

determine, based on electrical signals from the sensor, if under sweep is occurring with the output shaft rotating in a first direction and if the controller determines under sweep is occurring with the output shaft rotating in the first direction to instruct the actuator to continue rotating the output shaft in the first direction until the wiper reaches a pre-determined end of sweep limit;

determine, based on electrical signals from the sensor, whether under sweep is occurring with the output shaft rotating in a second direction and if the controller determines under sweep is occurring with the output shaft rotating in the second direction to instruct the actuator to continue rotating the output shaft in the second direction until the wiper reaches a pre-determined begin of sweep limit;

determine, based on electrical signals from the sensor, whether over sweep is occurring with the output shaft rotating in the first direction and if the controller determines over sweep is occurring with the output shaft rotating in the first direction to instruct the actuator to stop rotating the output shaft in the first direction when the wiper reaches the pre-determined end of sweep limit;

determine, based on electrical signals from the sensor, whether over sweep is occurring with the output shaft rotating in the second direction and if the controller determines over sweep is occurring with the output shaft rotating in the second direction to instruct the actuator to stop rotating the output shaft in the second direction when the wiper reaches the pre-determined begin of sweep limit;

wherein the controller is further configured to output user-understandable information indicating the position of the wiper arm and the wiper blade on the windshield.

2. The windshield wiper system of claim 1 , wherein the gear reduction is integral with the actuator such that the actuator, gear reduction, and output shaft are a single assembly.

3. The windshield wiper system of claim 1 , wherein the trigger is a magnetic trigger constructed from a metallic material.

4. The windshield wiper system of claim 1 , wherein the trigger is press-fit into the output shaft of the actuator and extends outward from the output shaft in a radial direction, and wherein the trigger is prism shaped such that a height of the trigger is greater than a length and width of a cross-section of the trigger.

5. The windshield wiper system of claim 1 , wherein the sensor is a hall effect sensor configured to detect a magnitude of a magnetic field.

6. The windshield wiper system of claim 1 , wherein the sensor is coupled to a flat end surface of the body of the actuator and the sensor is arc shaped to conform to a curvature of the body of the actuator, and wherein the sensor is stationary with respect to the output shaft of the actuator.

7. The windshield wiper system of claim 1 , wherein the trigger and the sensor are positioned adjacent an inner end of the output shaft, and wherein the trigger is continuously positioned adjacent the sensor.

8. The windshield wiper system of claim 1 , wherein the magnetic field produced by the trigger and detected by the sensor indicates a position of the wiper arm and wiper blade on the windshield of the aircraft.

9. The windshield wiper system of claim 1 and further comprising a housing positioned adjacent the trigger and positioned adjacent the sensor, wherein the housing is configured to cover and protect the trigger and the sensor from environmental conditions.

10. A method of operating a windshield wiper system for use on a windshield of an aircraft, the method comprising:

transferring, by a controller, a command signal to an electrically coupled actuator to control rotation of an output shaft of the actuator;

rotating, by the actuator, the output shaft in an oscillatory motion;

detecting, by a sensor, a magnetic field produced by a trigger coupled to the rotating output shaft; and

transferring, by the sensor, a feedback signal to the electrically coupled controller indicating a magnitude of the magnetic field detected by the sensor;

wherein the magnitude of the magnetic field is indicative of a position of a wiper arm and a wiper blade coupled to the output shaft;

receiving, by the controller, the feedback signal transferred from the sensor;

storing, by the controller, the feedback signal within a memory of the controller;

processing, by a processor of the controller, the stored feedback signal; and

transferring, by the controller, a user-understandable communication signal indicating the results of the processed feedback signal;

further comprising:

determining, by the controller based the feedback signal transferred from the sensor, if under sweep is occurring with the output shaft rotating in a first direction and if the controller determines under sweep is occurring with the output shaft rotating in the first direction instructing the actuator to continue rotating the output shaft in the first direction until the wiper reaches a pre-determined end of sweep limit;

determining, by the controller based the feedback signal transferred from the sensor, whether under sweep is occurring with the output shaft rotating in a second direction and if the controller determines under sweep is occurring with the output shaft rotating in the second direction instructing the actuator to continue rotating the output shaft in the second direction until the wiper reaches a pre-determined begin of sweep limit;

determining, by the controller based the feedback signal transferred from the sensor, whether over sweep is occurring with the output shaft rotating in the first direction and if the controller determines over sweep is occurring with the output shaft rotating in the first direction instructing the actuator to stop rotating the output shaft in the first direction when the wiper reaches the pre-determined end of sweep limit;

determining, by the controller based the feedback signal transferred from the sensor, whether over sweep is occurring with the output shaft rotating in the second direction and if the controller determines over sweep is occurring with the output shaft rotating in the second direction instructing the actuator to stop rotating the output shaft in the second direction when the wiper reaches the pre-determined begin of sweep limit.

11. The method of claim 10 , wherein the results of the processed feedback signal include one or more of a sweep angle performed by the wiper arm and the wiper blade, a parking position of the wiper arm and the wiper blade, and a rotational speed of the output shaft of the actuator.

12. The method of claim 11 and further comprising:

adjusting, by the controller, the sweep angle of the wiper arm and the wiper blade upon determining the sweep angle of the wiper arm and the wiper blade is not within predefined sweep angle limits;

wherein the controller adjusts the sweep angle of the wiper arm and the wiper blade by adjusting the rotational limits of the output shaft of the actuator.

13. The method of claim 11 and further comprising:

adjusting, by the controller, the parking position of the wiper arm and the wiper blade upon determining the parking position of the wiper arm and the wiper blade is not at a predefined zero-degree parking position;

wherein the controller adjusts the parking position of the wiper arm and the wiper blade by rotating the output shaft of the actuator until the predefined zero-degree parking position is reached by the wiper arm and the wiper blade.

14. The method of claim 10 , wherein the trigger:

is a magnetic trigger constructed from a metallic material;

is press-fit into the output shaft of the actuator and extends outward from the output shaft in a radial direction;

is prism shaped such that a height of the trigger is greater than a length and width of a cross-section of the trigger;

is positioned adjacent an inner end of the output shaft of the actuator; and

is continuously positioned adjacent the sensor during operation of the windshield wiper system.

15. The method of claim 10 , wherein the sensor:

is a hall effect sensor configured to detect the magnitude of a magnetic field;

is coupled to a flat end surface of a body of the actuator and the sensor is arc shaped to conform to a curvature of the body of the actuator;

is stationary with respect to the output shaft of the actuator; and

is positioned adjacent an inner end of the output shaft of the actuator.

16. The method of claim 10 , wherein the windshield wiper system further comprises a housing positioned adjacent the trigger and positioned adjacent the sensor, wherein the housing is configured to cover and protect the trigger and the sensor from environmental conditions.

17. The method of claim 10 , wherein:

the wiper blade is coupled to a first end of the wiper arm;

the output shaft of the actuator is coupled to a second end of the wiper arm;

the actuator is configured to rotate the output shaft to sweep the wiper arm and the wiper blade in an arc across the windshield of the aircraft;

the trigger is configured to rotate with the output shaft; and

the sensor is coupled to a body of the actuator.