Apparatus and method for assembling a torque tube assembly in an aircraft

Abstract

An apparatus and method for assembling a torque tube assembly in an aircraft is described herein. An exemplary torque tube assembly includes a torque tube and a splined coupler coupled to an end of the torque tube. The splined coupler has an opening to receive a splined gear on a drive shaft of an aircraft high-lift device. The torque tube assembly also includes a retainer coupled to the splined coupler. The retainer blocks at least a portion of the opening in the splined coupler to prevent the splined coupler from separating from the splined gear on the drive shaft.

Description

[0001] Related Applications

[0002] This patent is a continuation-in-part of U.S. Application No. 15 / 875,820, filed on January 19, 2018, entitled “TORQUE TUBE ASSEMBLIES FOR USEWITH AIRCRAFT HIGH LIFT DEVICES”. Technical Field

[0003] The present disclosure relates generally to torque tube assemblies, and more particularly, to torque tube assemblies with U-joints for use with aircraft highlift devices. Background Art

[0004] Aircrafts use lift-enhancing devices, sometimes referred to as auxiliary airfoils, along the leading and trailing edges of the wings. For example, lift-enhancing devices along the leading edge of the wing are referred to as slats, while lift-enhancing devices along the trailing edge of the wing are referred to as flaps. The lift-enhancing devices are actuated to extend outward from the wing, thereby changing the aerodynamic lift of the wing during takeoff and landing. Each lift-enhancing device is actuated by one or more drive mechanisms that are coupled to ribs or support beams in the wing. Specifically, each drive mechanism includes a pinion that rotates to drive a rack coupled to the lift-enhancing device. When the pinion rotates, the rack is driven to move the lift-enhancing device along the guide rail, thereby extending the lift-enhancing device outward from the wing. Each pinion is driven and engaged with a geared rotary actuator (GRA). Each pinion and its corresponding GRA are interconnected with adjacent (e.g., upstream and downstream) pinions and GRAs via a torque tube. In other words, aircrafts typically use a series of torque tubes that transfer torque to each drive mechanism along the leading or trailing edge of the wing. An electric motor may be used to drive one of the drive mechanisms, which thereby transmits torque to each of the other drive mechanisms through a series of torque tubes. Thus, each high-lift device may be controlled to move between the stowed configuration and the extended configuration simultaneously with the other high-lift devices.

[0005] Known torque tube assemblies utilize bolted flanges or plates to couple the torque tube to the pinion or GRA. However, the use of flanges results in a relatively large rotating housing, which requires a relatively large space to accommodate the rotating flange. In addition, in some cases, the bolts of the flanges may loosen, thereby reducing the structural integrity of the torque tube. Moreover, when the wing flexes (e.g., due to changes in the weight of the wing as fuel is reduced), the alignment and distance between the drive mechanisms may change. This flexing of the wing causes additional forces and strains on the torque tube assembly. Summary of the invention

[0006] An exemplary torque tube assembly disclosed herein includes a torque tube and a splined coupler coupled to an end of the torque tube. The splined coupler has an opening to receive a splined gear on a drive shaft of an aircraft high-lift device. The torque tube assembly also includes a retainer coupled to the splined coupler. The retainer blocks at least a portion of the opening in the splined coupler to prevent the splined coupler from separating from the splined gear on the drive shaft.

[0007] An exemplary method disclosed herein includes: coupling a spline coupler to an end of a torque tube; coupling a spline gear to a drive shaft of an actuator of an aircraft high lift device; sliding the spline coupler over the spline gear on the drive shaft so that the spline gear is disposed within an opening of the spline coupler; and coupling a retainer to the spline coupler. The retainer blocks at least a portion of the opening in the spline coupler to prevent the spline coupler from separating from the spline gear on the drive shaft.

[0008] An aircraft disclosed herein includes a geared rotary actuator (GRA) coupled to a wing of the aircraft. The GRA has a drive shaft. The aircraft further includes a spline gear coupled to the drive shaft and a torque tube assembly having a spline coupler and a retainer. The spline gear is disposed within an opening of the spline coupler, and the retainer is coupled to the spline coupler and blocks at least a portion of the opening in the spline coupler to prevent the spline coupler from separating from the spline gear on the drive shaft. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 An example aircraft is shown in which the example torque tube assemblies and associated methods disclosed herein may be implemented.

[0010] Figure 2 yes Figure 1 A partial cross-sectional view of the underside of a wing of an aircraft in FIG. 1 shows an exemplary torque tube assembly constructed in accordance with the teachings of the present disclosure.

[0011] Figure 3 yes Figure 2 A perspective view of an exemplary torque tube assembly having a first exemplary joint and a second exemplary joint.

[0012] Figure 4 yes Figure 3 An enlarged perspective view of a first example joint employing an example spline coupler to receive an example spline gear.

[0013] Figure 5 yes Figure 4 An exploded view of a first exemplary connector.

[0014] Figure 6 yes Figure 4 An isolated perspective view of an exemplary spline connector of FIG.

[0015] Figure 7 yes Figure 4 A cross-sectional view of an exemplary spline connector and an exemplary spline gear.

[0016] Figure 8 yes Figure 4 An enlarged perspective view of a second exemplary joint employing an exemplary sliding spline shaft.

[0017] Fig. 9 yes Figure 8 A cross-sectional view of a second exemplary joint.

[0018] Fig.10 yes Figure 8 An exploded view of a second exemplary connector.

[0019] Fig.11 Yes, you can Figure 8 An exploded view of an exemplary grease retainer implemented on an exemplary sliding spline shaft.

[0020] Fig.12 An exemplary method for constructing and / or assembling an exemplary torque tube assembly is provided.

[0021] Fig.13 An exemplary retainer constructed according to the teachings of the present disclosure is formed in Figure 2 A perspective view of an exemplary joint between an exemplary torque tube assembly and a drive shaft of an aircraft high lift device.

[0022] Fig.14 yes Fig.13 An exploded view of an exemplary connector.

[0023] Fig.15 yes Fig.13 A cross-sectional view of an exemplary joint.

[0024] Fig.16 yes Fig.15 A cross-sectional view of an exemplary joint of , showing an alternative spline fitting that may be utilized with longer threaded fasteners.

[0025] Fig.17 is used Fig.13 An exemplary retainer configuration and / or an exemplary method of assembling a torque tube assembly.

[0026] The drawings are not drawn to scale. Instead, the thickness of a layer or region may be exaggerated in the drawings. Generally, the same reference numerals will be used throughout the drawings and the accompanying written description to represent the same or similar parts. As used in this patent, a statement that any part (e.g., a layer, film, region, area, or plate) is located on another part in any way (e.g., positioned on another part, located on another part, disposed on another part, or formed on another part, etc.) indicates that the referenced part is in contact with the other part, or that the referenced part is above the other part and one or more intermediate parts are located therebetween. A statement that any part is in contact with another part means that there is no intermediate part between the two parts. DETAILED DESCRIPTION

[0027] Disclosed herein are exemplary torque tube assemblies and related methods that can be used to mechanically transmit torque from a driver (such as an output shaft of an electric motor or an actuator of a lift-enhancing device) to a driven device (such as an input shaft of a subsequent (e.g., downstream, outboard) actuator of a lift-enhancing device). An exemplary torque tube assembly disclosed herein includes a first universal joint (U-joint) formed between a first torque tube fitting located on one end of a torque tube and a first spline connector. The first spline connector includes an integral yoke that is coupled to a yoke on the first torque tube fitting to form a first U-joint. The yoke of the first torque tube fitting is integral with the first torque tube fitting and is therefore fixedly attached to the end of the torque tube. The first spline connector includes an opening having a spline (e.g., a rib) to receive a spline gear or a shaft of a drive member (e.g., a first drive shaft). For example, the drive member can be a pinion shaft and / or an output shaft of a geared rotary actuator (GRA).

[0028] The exemplary torque tube assembly also includes a second torque tube fitting located on the end of the torque tube opposite to the first torque tube fitting. The second torque tube fitting is slidably inserted into the passage in the sliding spline shaft. Specifically, the second torque tube fitting includes a spline that meshes with the spline on the inner side of the passage, which enables the second torque tube fitting and the sliding spline shaft to slide axially relative to each other but not rotate relative to each other. The sliding spline shaft includes a yoke that forms a second U-joint with the yoke on the second spline connector. Similar to the first spline connector, the second spline connector includes an opening with a spline (e.g., a rib) to receive another spline gear or a shaft of a drive member (e.g., a second drive shaft). Therefore, one end of the torque tube assembly includes a first spline connector that can be connected to a first drive shaft of a first GRA (e.g., an upstream drive member), and the other end of the torque tube assembly includes a second spline connector that can be connected to a second drive shaft of a second GRA (e.g., a downstream driven member). When the spline gears of the first GRA rotate, rotational power is transmitted from the upstream drive shaft of the first GRA to the downstream driven shaft of the second GRA.

[0029] In some examples, the first spline coupler and the second spline coupler are fixedly coupled (e.g., via threaded fasteners) to the first and second drive shafts, respectively, and the second torque tube fitting is slidably disposed within the sliding spline shaft. Thus, a portion of the torque tube assembly (including the torque tube, the first torque tube fitting, and the first spline coupler) is fixedly coupled to the aircraft, while a second portion of the torque tube assembly (including the sliding spline shaft and the second spline coupler) is fixedly coupled to the aircraft, and the two portions are axially slidably coupled to each other. Thus, the two portions of the torque tube assembly can be axially translated relative to each other while still transmitting rotational motion between the two drive shafts. Thus, when the wing bends, portions of the torque tube assembly can be axially displaced (relative to each other) to reduce strain and force on the torque tube assembly. Moreover, when the wing bends, the U-joint enables the torque tube assembly to be angularly moved relative to the driving member (e.g., the first drive shaft and / or the spline gear) or the driven member (e.g., the downstream drive shaft of the second GRA) while still transmitting rotational motion between the two members. Additionally, the ability to extend and shorten the torque tube assembly is beneficial during installation, for example, when connecting the two ends of a torque tube to be assembled to first and second drive shafts (which, in some cases, have relatively tight tolerances).

[0030] In some examples, the second torque tube fitting includes two spline sections that are spaced apart from each other and engage splines on the inside of the passage of the sliding spline shaft. In some examples, one or more retaining bolts are screwed into the side of the sliding spline shaft and extend into the passage between the first and second spline sections to prevent the second torque tube fitting and the sliding spline shaft from completely separating (e.g., in the event of a failure of one of the parts). For example, if a portion of the torque tube assembly separates from the aircraft, the retaining bolt prevents the second torque tube fitting from separating from the sliding spline shaft, and thus ensures that the failed portion remains connected to the aircraft via other portions of the torque tube assembly. Thus, the exemplary retaining bolt prevents the portion(s) of the torque tube assembly from potentially leaving the aircraft and / or potentially causing damage to the aircraft.

[0031] In some examples, the torque tube assembly includes a grease retainer that covers an opening in which the second torque tube fitting is inserted into the passage of the sliding spline shaft. The grease retainer prevents moisture and / or other unwanted materials from accumulating in the passage, which could otherwise cause corrosion in the passage and potential seizure of parts. Additionally, in some examples, lubricant is injected into the passage to provide lubrication between the splines of the second torque tube fitting and the splines of the sliding spline shaft. The grease retainer prevents the lubricant from leaking out of the passage.

[0032] The exemplary torque tube assembly disclosed herein employs a spline connection, rather than a bolted plate / flange connection as seen in known torque tube assemblies. The spline connection provides excellent torque transmission. In addition, if, for example, the bolts of a known plate / flange connection fail, the plate / flange separates and, therefore, rotational energy cannot be transferred therebetween. However, in the exemplary torque tube assembly disclosed herein, if the bolts fail, the spline connection remains intact, and, therefore, the torque tube assembly can continue to transfer rotational energy (via the interaction between the splines on each component). In addition, in some examples, the exemplary torque tube assembly does not employ flanges (e.g., because they implement smaller housing accessories, such as accessories that form an EMF), and, therefore, the rotating housing is relatively smaller than known torque tube assemblies. Moreover, in such examples, the risk of loose flange bolts is eliminated. In addition, the exemplary torque tube assembly described herein is not susceptible to dynamic imbalance, which may be caused, for example, by missing bolts. The exemplary torque tube assembly described herein also utilizes fewer fasteners than known torque tube assemblies.

[0033] Also disclosed herein is an exemplary retainer that can be used to couple a spline connector to a drive shaft (e.g., an input shaft or an output shaft) of an aircraft lift-enhancing device. For example, as disclosed above, an exemplary torque tube assembly may include a first spline connector coupled to a first end of a torque tube (e.g., via a first torque tube fitting). An exemplary retainer can be used to couple a first spline connector to a drive shaft (e.g., an output shaft of an actuator). A spline gear or fitting is coupled to the drive shaft to connect with the first spline connector. The first spline connector can slide on the spline gear so that the spline gear is disposed within an opening of the first spline connector. The spline gear has a spline that meshes with a spline inside the first spline connector. Thus, rotational motion can be transmitted between the drive shaft and the first spline connector. In order to keep the spline connector on the drive shaft (e.g., not axially separated from the drive shaft), the retainer is coupled to the spline connector and blocks at least a portion of the opening in the first spline connector. The retainer prevents the spline gear from being removed from the first spline coupler and, therefore, prevents the first spline coupler from being separated from the spline gear on the drive shaft. In some examples, the retainer includes an annular portion and a shoulder portion extending radially inward from the annular portion. The annular portion is coupled to an outer surface of the first spline coupler, and the shoulder portion extends radially inward and blocks at least a portion of an opening in the first spline coupler, thereby capturing the spline gear in the first spline coupler.

[0034] In some examples, the retainer is coupled to the first spline coupler via one or more threaded fasteners that extend through the retainer (e.g., through the annular portion) and into the first spline coupler. However, the threaded fasteners do not extend into the spline gear, and the spline gear does not include a threaded hole for any fastener. Thus, during installation of the torque tube assembly, the first spline coupler and the spline gear may be adjusted by one or more spline teeth. In other words, in other designs, the threaded fasteners extend into the spline gear, and therefore the holes in the spline coupler and the spline gear need to be aligned. However, for this exemplary retainer, the first spline coupler can be coupled to the drive shaft at any rotational angle (where the splines are cooperatively aligned with the splines on the spline gear). The splines enable rotational motion to be transmitted between the spline gear and the first spline coupler, and the retainer prevents the first spline coupler from moving axially relative to the spline gear. Therefore, the retainer prevents the torque tube assembly from being removed from the drive shaft. A similar retainer may be used to couple a second splined connector on the opposite end of the torque tube assembly to another drive shaft of the aircraft high-lift device (eg, an input shaft of an actuator).

[0035] Figure 1An exemplary aircraft 100 is shown in which examples disclosed herein may be implemented. In the example shown, the aircraft 100 includes a fuselage 102, a first wing 104 coupled to the fuselage 102, and a second wing 106 coupled to the fuselage 102. The first wing 104 and the second wing 106 of the example shown have control surfaces, such as high-lift devices (e.g., slats, Krueger flaps, trailing edge slats, etc.), located along the leading and trailing edges of the first wing 104 and the second wing 106, and which may be displaced or extended to change the aerodynamic lift of the aircraft 100. When extended from the first wing 104, the high-lift device increases the effective size, arc of curvature, and area of ​​the first wing 104, thereby increasing the lift of the first wing 104. For example, the first wing 104 includes a first slat 108, a second slat 110, a third slat 112, a fourth slat 114, a fifth slat 116, a sixth slat 118 and a seventh slat 120 located along a leading edge 122 and a flap 124 located along a trailing edge 126. The first wing 104 may include more or less slats and flaps. Additionally or alternatively, the first wing 104 may include other control surfaces, such as ailerons, spoilers, flaps, trailing edge slats, Krueger flaps, etc. The second wing 106 may include similar high-lift devices, but not discussed to avoid redundancy.

[0036] Typically, each of the slats 108 to 120 uses two separate but coordinated drive mechanisms or actuators to unfold, one on the inner side of each of the corresponding slats 108 to 120 and one on the outer side thereof. The respective actuators of the slats 108 to 120 are coupled to each other and to adjacent (e.g., upstream or downstream) drive mechanisms via an exemplary torque tube assembly, as disclosed in further detail herein. In the illustrated example, an electric motor or power drive unit (PDU) 128 is employed to drive the actuator for unfolding the seventh slat 120. The output of the actuator is operably coupled to another actuator via an exemplary torque tube assembly for unfolding the seventh slat 120, which is operably coupled to drive another actuator via an exemplary torque tube assembly for unfolding the sixth slat 118, and so on. Therefore, the PDU 128 provides driving power to all actuators via a torque tube assembly along the leading edge 122 of the first wing 104 to unfold the lift-enhancing device. In some examples, the PDU 128 also provides drive power to all actuators for driving the slats on the second wing 106. As a result, all slats along the leading edges of the first wing 104 and the second wing 106 can be deployed simultaneously. Although the torque tube assembly is described with respect to the slats 108 to 120, it should be understood that the examples disclosed herein can be similarly applied to any other high-lift device (e.g., trailing edge flaps).

[0037] Figure 2The underside of the leading edge 122 of the first wing 104 is shown between the first slat 108 and the second slat 110. As disclosed above, each of the slats 108 to 120 is actuated by two actuators (e.g., rack and pinion assemblies) mounted to a raised rib or support in the first wing 104 and the actuators are controlled by the PDU 128 ( Figure 1 ) drive. An exemplary torque tube assembly 200 is shown for transferring rotational energy between one of the actuators of the second slat 110 and one of the actuators of the first slat 108. Specifically, a first actuator 202 is provided for moving the first slat 108. The first actuator 202 includes a first rack 204 (e.g., a gear rack, a rack), a first pinion 206 (e.g., a circular gear) driving the first rack 204, and a first geared rotary actuator (GRA) 208 driving the first pinion 206. The first pinion 206 is rotatably coupled (e.g., mounted) to a first rib or support 210 of the first wing 104. When the first pinion 206 rotates, the first rack 204 is driven outward, thereby extending the first slat 108 outward from the first wing 104. In some examples, the first pinion 206 drives a sector gear, which drives the first rack 204. The first pinion 206 is coupled to and driven by the first GRA 208. The first GRA 208 has an upstream or input shaft 212 and a downstream or output shaft (e.g., a high-lift device drive shaft). The first GRA 208 includes a gear train (e.g., a gear system, a transmission) that can be used to change the gear ratio between the input (e.g., the input shaft 212) and the first pinion 206. Typically, the PDU 128 ( Figure 1 ) rotates at a relatively fast speed (e.g., about 700 revolutions per minute (RPM)). The first GRA 208 reduces the rotation speed provided to the first pinion 206 and thus increases the torque provided to the first pinion 206. Similar to the first slat 108, the second slat 110 includes a second actuator 216 having a second rack 218 and a second pinion 220, which is driven by a second GRA 222 and operably coupled to a second rib or support 224. The second GRA 222 has an upstream or input shaft 226 and a downstream or output shaft 228 (e.g., a high-lift device drive shaft). In order to transfer rotational energy from the output shaft 228 of the second GRA 222 to the input shaft 212 of the first GRA 208, the exemplary torque tube assembly 200 is used. When the output shaft 228 of the second GRA 222 rotates, the rotational power is transferred to the input shaft 212 of the first GRA 208 via the torque tube assembly 200. A torque tube assembly may similarly be employed between each actuator (eg, rack and pinion assembly) of each of the slats 108 to 120. For example, the seventh slat 120 ( Figure 1) includes PDU 128( Figure 1 ) driven actuator (e.g., pinion and GRA). The output of the actuator is operably coupled to another actuator of the seventh slat 120 or an actuator of the sixth slat 118 via a torque tube assembly, and so on. Thus, the input shaft 226 of the second GRA (and therefore the second pinion 220) rotates via an upstream torque tube assembly, which is operably coupled to the inner actuator of the second slat 110 or coupled from the actuator of the third slat 112 (e.g., depending on how many actuators are used for each of the slats 108 to 120). Similarly, the output shaft 214 of the first GRA 208 can be operably coupled to another actuator of the first slat 108 via an exemplary torque tube assembly.

[0038] Figure 3 2 is an isolated view of an exemplary torque tube assembly 200 coupled between the output shaft 228 of the second GRA 222 and the input shaft 212 of the first GRA 208. In the example shown, the torque tube assembly 200 includes a first joint 300 that couples the first end 302 of the torque tube 304 to the output shaft 228 of the second GRA 222. The torque tube assembly 200 also includes a second joint 306 between the second end 308 of the torque tube 304 and the input shaft 212 of the first GRA 208. The torque tube 304 can have any desired length. Although the torque tube assembly 200 is described as being between the drive shafts of two actuators in many of the examples disclosed herein, in other examples, one or more torque tube supports can be located between the two actuators or drive mechanisms (e.g., when the distance between the two actuators is relatively long). Therefore, in some examples, the torque tube assembly 200 can be split or divided into additional torque tube assemblies. For example, instead of coupling to an input / output shaft (e.g., an input / output shaft of an upstream or downstream actuator), the first joint 300 and / or the second joint 306 of the torque tube assembly 200 can be coupled to a splined shaft located at a torque tube support (e.g., a rib or support in a wing).

[0039] Figure 4 is an enlarged view of the first joint 300, and Figure 5is an exploded view of the first joint 300. As shown in the illustrated example, the first end 302 of the torque tube 304 is coupled to a first torque tube fitting 400 (referred to herein as the first fitting 400). In the illustrated example, the first fitting 400 is fixedly coupled to the first end 302 of the torque tube 304 by an electromagnetic fitting or forming (EMF) process. An exemplary EMF process for coupling an end fitting to an end of a torque tube is described in U.S. Pat. No. 5,983,478, the entire contents of which are incorporated herein by reference. The EMF produces an excellent rigid torque transmitting coupling between an end of the torque tube and the end fitting. In other examples, the first fitting 400 can be coupled to the first end 302 of the torque tube 304 using other mechanical and / or chemical techniques (e.g., welding, threaded fasteners, adhesives, etc.).

[0040] In the example shown, the first fitting 400 forms a first U-joint 402 with a first spline connector 404. Figure 5 As more clearly shown in FIG. 4 , the first U-joint 402 includes a cross journal 500 (e.g., a cross joint) and four bearing caps 502 (which include a set of needle bearings) that are coupled between a first yoke 504 (e.g., a fork) on the first fitting 400 and a second yoke 506 on the first spline connector 404. The first fitting 400 has a wall or plate 508 and a first ear 510 and a second ear 512 that extend from the plate 508 to form the first yoke 504. The first ear 510 and the second ear 512 have respective first openings 514 and second openings 516 that are coaxially aligned along an axis 517. The first opening 514 and the second opening 516 receive the two bearing caps 502 of the cross journal 500. In the example shown, the first yoke 504 is integral with the first fitting 400 and thus forms a substantially unitary piece or structure. However, in other examples, the first yoke 504 and the first accessory 400 may be composed of multiple pieces that are operably coupled to each other.

[0041] like Figure 4 and Figure 5 As shown in FIG. 1 , the first spline gear 406 is coupled to the output shaft 228 ( Figure 3 In some examples, the first spline gear 406 is integral with the output shaft 228 (eg, constructed as a single unitary piece or component). The first spline gear 406 is coupled to the first spline coupler 404. Specifically, the first spline gear 406 is received within a hole or opening 410 of the first spline coupler 404.

[0042] Figure 6 is a separate perspective view of the first spline connector 404, and Figure 74 is a cross-sectional view of the first spline gear 406 inserted into the first spline connector 404. Figure 6 and Figure 7 As shown in , the first spline connector 404 includes a wall or plate 600. An annular wall 602 extends from the plate 600 to define an opening 410 that is aligned with the longitudinal axis 604 of the first spline connector 404. The first spline connector 404 includes a first ear 606 and a second ear 608 extending from the plate 600 that form a second yoke 506 (e.g., in a direction opposite to the direction of the annular wall 602). The first ear 606 and the second ear 608 have respective first openings 610 and second openings 612 that are coaxially aligned along an axis 614. In the example shown, the axis 614 is perpendicular to the longitudinal axis 604. The first opening 610 and the second opening 612 receive two bearing caps 502 ( Figure 5 ).like Figure 6 , the opening 410 of the first spline connector 404 includes a spline 616 (e.g., a rib, groove, channel) around the inner surface 618 of the annular wall 602. In the example shown, the first spline connector 404 (including the second yoke 506) is a substantially unitary piece or structure. However, in other examples, the first spline connector 404 can be composed of multiple pieces that are operably coupled to each other.

[0043] In the example shown, the first spline connector 404 includes three holes or apertures 620, 622, 624 that extend through the annular wall 602 into the opening 410 (e.g., in a direction perpendicular to the longitudinal axis 604). The holes 620, 622, 624 are used to receive the threaded fasteners 518 ( Figure 5 ) to couple the first spline gear 406 to the first spline coupler 404. In the example shown, the holes 620, 622, 624 are equally spaced (e.g., spaced 120° apart from each other) around the annular wall 602. In other examples, the first spline coupler 404 may include more or fewer holes and / or the holes may be spaced differently.

[0044] like Figure 5 and Figure 7 As shown in FIG. 1 , the first spline gear 406 has three holes (two of which are in Figure 5 520 and 522), these three holes are aligned with the holes 620, 622, 624 of the first spline connector 404. For example, Figure 7 As shown in FIG. 4 , the first spline gear 406 is inserted into the opening 410 of the first spline connector 404. The three holes of the first spline gear 406 are aligned with the corresponding holes 620, 622, 624 of the first spline connector 404. The threaded fastener 518 ( Figure 5) is screwed into the holes 620, 622, 624 and into the corresponding holes of the first spline gear 406 to couple the first spline gear 406 and the first spline coupler 404. The threaded fastener 518 may be a bolt, a screw, or any other suitable fastening mechanism.

[0045] Figure 8 is an enlarged view of the second joint 306, Fig. 9 is a cross-sectional view of the second joint 306, and Fig.10 306. In the example shown, a second torque tube fitting 800 (referred to herein as second fitting 800, and which may also be referred to as a slider or spline) is coupled to the second end 308 of the torque tube 304. Similar to the first fitting 400 ( Figure 4 ), the second fitting 800 can be coupled to the second end 308 of the torque tube 304 by an EMF process. In other examples, the second fitting 800 can be coupled to the second end 308 of the torque tube 304 via another mechanical and / or chemical fastening technique. In the example shown, the second fitting 800 includes a shaft 802 that is slidably received within a sliding spline shaft 804, which will be discussed in further detail below.

[0046] exist Figures 8 to 10 In the illustrated example of , the second joint 306 of the torque tube assembly 200 includes a sliding spline shaft 804. The sliding spline shaft 804 forms a second U-shaped joint 806 with a second spline connector 808. Specifically, the sliding spline shaft 804 includes a third yoke 810, the second spline connector 808 includes a fourth yoke 812, and a cross journal 814 and four bearing caps 816 are disposed between the third yoke 810 and the fourth yoke 812.

[0047] like Fig. 9 and Fig.10 As shown in FIG. 1 , the input shaft 212 ( Figure 2 and Figure 3 ) is received within and coupled to the second spline coupler 808. Thus, the second spline coupler 808 is coupled to the input shaft 212 of the first GRA 208. The second spline coupler 808 may be fixedly coupled to the second spline gear 900 via threaded fasteners (e.g., three bolts), similar to the first spline coupler 404 ( Figures 5 to 7 ) and the first spline gear 406. In fact, in this example, the third yoke 810 of the sliding spline shaft 804 is connected to the first accessory 400 ( Figure 5 ) of the first yoke 504 ( Figure 5 ) are substantially the same, the cross journal 814 and the bearing cap 816 are substantially the same as the cross journal 500 and the bearing cap 502 ( Figure 5) is substantially the same, and the second spline connector 808 is substantially the same as the first spline connector 404 ( Figures 5 to 7 ), and the second spline gear 900 is substantially identical to the first spline gear 406 (e.g., the second spline gear 900 includes splines and openings for receiving threaded fasteners). Therefore, in order to avoid redundancy, a description of the second U-joint 806 and the connection between the sliding spline shaft 804, the second spline coupler 808, and the second spline gear 900 is not provided herein. Instead, the interested reader is referred to the above description of the first U-joint 402 ( Figure 4 ) and a description of the connection between the first fitting 400, the first splined coupler 404, and the first splined gear 406 on the output shaft 228. In some examples, instead of using the first splined gear 406 and the second splined gear 900, the input shaft 212 and the output shaft 228 can be splined and sized to fit within the first splined coupler 404 and the second splined coupler 808, respectively.

[0048] Thus, in this example, the first spline connector 404 ( Figure 4 ) (one end of the torque tube assembly 200) is fixedly coupled to the output shaft 228 of the second GRA 222 ( Figure 3 ), while the second spline connector 808 is fixedly coupled to the input shaft 212 of the first GRA 208. In some examples, six threaded fasteners (e.g., bolts) are used to fixedly couple the end of the torque tube assembly 200 to the aircraft 100 (three threaded fasteners for the first spline connector 404 and three threaded fasteners for the second spline connector 808). Thus, in some examples, only one screwdriver or socket wrench may be required to attach the end of the torque tube assembly 200 to the aircraft 100, compared to known bolted flange / plate assemblies that require multiple screwdrivers or wrenches (one for the bolt head and one for the nut) and require additional space to assemble additional tools. In other examples, more or fewer threaded fasteners may be used to couple the end of the torque tube assembly 200 to the aircraft 100.

[0049] The second fitting 800 can move axially within a passage (e.g., an opening, a passage, etc.) formed in the sliding spline shaft 804. Fig. 9 As shown in FIG. 8 , a passage 902 (e.g., a spline passage) is formed between a first opening 904 (on one end of the sliding spline shaft 804) and a second opening 906 (on the opposite end of the sliding spline shaft 804, which opens between the ears of the third yoke 810). The passage 902 and the first opening 904 are also Fig.10 Shown in.

[0050] like Fig. 9 and Fig.10As shown in , the sliding spline shaft 804 includes splines 908 (e.g., ribs, grooves, channels) located on the inner surface of the channel 902. The second accessory 800 includes a first spline section 910 and a second spline section 912 extending radially from the shaft 802. The first spline section 910 and the second spline section 912 engage with the splines 908 in the channel 902, which enables the second accessory 800 and the sliding spline shaft 804 to slide relative to each other while still transmitting rotational motion between each other. In other words, the shaft 802 of the second accessory 800 can slide axially within the channel 902, but cannot rotate within the channel 902. When the first wing 104 ( Figure 2 ) bends, this sliding interaction enables the torque tube assembly 200 to extend or shorten, thereby reducing the longitudinal load on the torque tube assembly 200. For example, the torque tube assembly 200 can be considered to be two parts: a first part including the first spline connector 404, the first fitting 400, the torque tube 304 and the second fitting 800; and a second part including the sliding spline shaft 804 and the second spline connector 808. When the first part is coupled to the aircraft 100 at the second GRA 222 and the second part is coupled to the aircraft 100 at the first GRA 208, the two parts can slide or move axially relative to each other, thereby enabling the torque tube assembly 200 ( Figure 2 ) can be on the first wing 104 ( Figure 2 ) is bent or flexed while still transmitting rotational motion between the second GRA 222 and the first GRA 208. In addition, the first U-joint 402, the second U-joint 806 enable the torque tube assembly 200 to move angularly relative to the output shaft 228 of the second GRA 222 and the input shaft 212 of the first GRA 208 (for example, if the output shaft 228 and the input shaft 212 are not aligned). Therefore, the torque tube assembly 200 can be displaced angularly and / or axially, and thus less strain or adverse force is applied to the torque tube assembly 200 than is experienced by known assemblies.

[0051] In some examples, in order to prevent the second fitting 800 and the sliding spline shaft 804 from completely separating from each other, the exemplary torque tube assembly 200 may include one or more retaining elements. The retaining elements may block, contact, and / or otherwise prevent the second fitting 800 from completely leaving the sliding spline shaft 804 and separating from it. In some examples, the retaining elements may be implemented as one or more bolts. For example, Fig. 9 and Fig.10 As shown in FIG. 1 , a first retaining bolt 914 and a second retaining bolt 916 are screwed into a first opening 918 and a second opening 920 in the sliding spline shaft 804, respectively. The first retaining bolt 914 is also Figure 8802 . The first retaining bolt 914 and the second retaining bolt 916 extend into the channel 902 between the first spline section 910 and the second spline section 912 (however, in some examples, do not engage the side of the shaft 802). If the second fitting 800 or the sliding spline shaft 804 moves relative to the other beyond a threshold distance (e.g., defined by the distance between the first spline section 910 and the second spline section 912), the first spline section 910 or the second spline section 912 engages the first retaining bolt 914 and / or the second retaining bolt 916. For example, if the first portion of the torque tube assembly 200 is separated from the aircraft 100, the first portion remains connected to the second portion, and thus, the second portion (which is still connected to the aircraft 100) prevents the first portion from being separated from the aircraft 100. The same is true when the second portion is separated from the aircraft 100. In some examples, the first spline section 910 and the second spline section 912 are spaced apart by a distance greater than the axial bending that occurs during normal operation (e.g., approximately 0.6 inches). As a result, during normal operation, neither the first spline section 910 nor the second spline section 912 contacts the first retaining bolt 914 and the second retaining bolt 916. In contrast, if one or more portions of the torque tube assembly 200 fail, only the first retaining bolt 914 and the second retaining bolt 916 are contacted.

[0052] In the example shown, the first retaining bolt 914 and the second retaining bolt 916 are disposed on opposite sides of the sliding spline shaft 804 (e.g., 180° apart). However, in other examples, the first retaining bolt 914 and the second retaining bolt 916 may be spaced differently. In the example shown, two retaining bolts are implemented, which in some examples provide dual redundancy (in case one retaining bolt fails). However, in other examples, only one retaining bolt may be used, or more than two retaining bolts may be used. In addition, in other examples, another retaining element, such as a pin (e.g., a non-threaded pin), may be used in addition to or in place of the first retaining bolt 914 and the second retaining bolt 916.

[0053] In some examples, lubricant is used in passage 902 to lubricate the sliding interaction between second fitting 800 and sliding spline shaft 804. In some examples, lubricant can be supplied via first lubricant port 818 and second lubricant port 820 ( Figure 8 and 10) is injected into the channel 902. When the lubricating oil is injected into the channel 902, the lubricating oil penetrates the channel 902, which provides sliding lubrication between the first spline section 910 and the second spline section 912 and the spline 908 of the sliding spline shaft 804. In the example shown, the first lubricating oil port 818 and the second lubricating oil port 820 are located on opposite sides of the sliding spline shaft 804. The first lubricating oil port 818 and the second lubricating oil port 820 are arranged along the same cross section of the sliding spline shaft 804 as the first retaining bolt 914 and the second retaining bolt 916 and are offset from the bolt by 90°. In other examples, only one lubricating oil port may be provided or more than two lubricating oil ports may be provided and / or a plurality of lubricating oil ports may be provided in other positions.

[0054] like Figures 8 to 10 As shown in FIG. 1 , the torque tube assembly 200 includes a grease retainer 822 (e.g., a cover) to prevent lubricating oil from leaking out of the first opening 904 of the passage 902 while still allowing the second fitting 800 to move into and out of the passage 902. The grease retainer 822 is coupled to the sliding spline shaft 804 and covers the first opening 904 of the passage 902, at which the second fitting 800 is inserted into the passage 902 (e.g., the junction of the first and second portions of the torque tube assembly 200). The grease retainer 822 has a first end 824 and a second end 826 opposite the first end 824. The grease retainer 822 can be constructed of a relatively lightweight material such as, for example, nylon. In other examples, the grease retainer 822 can be constructed of other materials.

[0055] like Fig. 9 and Fig.10 As shown in FIG. 8 , the sliding spline shaft 804 includes a first rib 922 and a second rib 924 that form a groove 926. The grease retainer 822 includes an inwardly extending collar 928 near the first end 824 that fits within the groove 926. In some examples, a strap, webbing, cable, and / or other clamping member is wrapped around the exterior of the collar 928 to retain the grease retainer 822 on the sliding spline shaft 804. In other examples, no strap, webbing, cable, or clamping member may be used. Instead, the grease retainer 822 may be sufficiently rigid to remain mounted in the groove 926 and, therefore, remain coupled to the sliding spline shaft 804.

[0056] like Fig. 9As shown in FIG. 1 , the second end 826 of the grease ring 822 (which is disposed outside (beyond) the end of the sliding spline shaft 804 (e.g., about 0.5 inches)) extends inwardly toward the shaft 802 of the second fitting 800. The second end 826 of the grease ring 822 includes a seal 930 (e.g., an o-ring) that provides a sealing engagement between the grease ring 822 and the shaft 802 to retain lubricant within the passage 902 (and / or contained in a small area outside the passage 902). In addition, the grease ring 822 prevents moisture and other unwanted materials from accumulating in the passage 902 and adversely affecting the surface of the splines (e.g., corroding the splines).

[0057] In some examples, to prevent lubricating oil from flowing out of the second opening 906 (at Fig. 9 The right side of the plug 932 ( Fig. 9 and 10 ) is inserted from the second opening 906 into the passage 902. In some examples, the plug 932 is press-fit into the passage 902. In other examples, the plug 932 can be coupled to the sliding spline shaft 804 via another mechanical and / or chemical fastening technique.

[0058] like Fig. 9 and Fig.10 As shown in , in some examples, in order to prevent over-pressurization of the channel 902, the sliding spline shaft 804 includes a first lubricant release port 934 and a second lubricant release port 936 (e.g., drain ports). The first lubricant release port 934 and the second lubricant release port 936 are relatively small openings or orifices. The size of the first lubricant release port 934 and the second lubricant release port 936 is designed so that if the pressure inside the channel 902 becomes too high, the lubricant can leak out of the channel 902. Otherwise, the pressure inside the channel 902 may cause the plug 932 and / or the grease retainer 822 to pop out. Although two lubricant release ports are implemented in the example shown, in other examples, only one lubricant release port may be implemented or more than two lubricant release ports may be implemented. In addition, in other examples, the lubricant ports may be located in other positions and / or spaced differently. In addition, as Figure 8 and Fig.10 As shown in FIG. 1 , in some examples, the grease retainer 822 includes one or more lubricant release ports 828 (two of which are in FIG. Figure 8 and two of them are mentioned in Fig.10), which is located near the second end 826. The lubricant release port 828 similarly releases overpressure or excess lubricant. In some examples, the grease retainer 822 includes four lubricant release ports 828 (e.g., evenly spaced around the grease retainer 822). In other examples, the grease retainer 822 may include more or fewer lubricant release ports and / or the lubricant release ports may be disposed in other locations.

[0059] In some examples, grease retainer 822 is comprised of two pieces or portions that are coupled together to form grease retainer 822 . Fig.11 An exemplary embodiment of a grease retainer 822 consisting of a first portion 1100a and a second portion 1100b is shown. The first portion 1100a and the second portion 1100b are the same type of parts (i.e., have the same shape, size, dimensions, features, etc.). The first portion 1100a and the second portion 1100b are semi-cylinders that interlock to form a complete cylinder when coupled. Thus, during manufacturing, only one type of part needs to be manufactured (e.g., one mold can be used to manufacture multiple parts), and the two parts can be assembled to form the grease retainer 822. Therefore, the exemplary grease retainer 822 can be manufactured inexpensively by manufacturing multiple copies of the same part. To avoid redundancy, only the details of the first portion 1100a are described below. However, it should be understood that the second portion 1100b includes the same features.

[0060] In the example shown, the first portion 1100a includes a first end 1102 and a second end 1104, which, when connected to the second portion 1100b, respectively form a first end 824 ( Figure 8 ) and the second end 826 ( Figure 8 ). The first portion 1100a first includes a first groove 1106 at or near the first end 1102 to receive the first rib 922 ( Fig. 9 and Fig.10 The first portion 1100a further includes a second groove 1108 to receive the second rib 924 on the sliding spline shaft 804 ( Fig. 9 and Fig.10 ). The collar portion 1110 is formed between the first groove 1106 and the second groove 1108. When the first part 1100a and the second part 1100b are coupled, the collar portion forms a collar 928 ( Fig. 9 and Fig.10), the collar is sized to be received in the groove 926 on the sliding spline shaft 804. In the example shown, the first portion 1100a also includes a third groove 1112 formed at or near the second end 1104. When the first portion 1100a and the second portion 1100b are coupled, the third groove forms a sealing gland to receive the seal 930 ( Fig. 9 ). Fig.11 Also shown in FIG. 1 is one of the exemplary lubricant release ports 828 on the first portion 1100a.

[0061] To couple the first and second portions 1100a, 1100b, the first portion 1100a includes a protrusion 1114 (e.g., a male extension) extending from one side of the collar portion 1110 and a slot 1116 (e.g., a female opening for receiving a male extension such as the protrusion 1114 of the second portion 1100b) formed on the opposite side of the collar portion 1110. When the first and second portions 1100a, 1100b are coupled, the protrusion 1114 will be inserted into a corresponding groove 1116 on the second portion 1100b, and the groove 1116 receives the corresponding protrusion 1114 of the second portion 1100b. To hold the first and second parts 1100a, 1100b together, the protrusion 1114 includes a clip 1118 (e.g., a flange, a lip, a tang, etc.) extending radially inward from the protrusion 1114 and extending rearward from the protrusion 1114 (in a direction opposite to the direction in which the protrusion 1114 extends). In addition, the slot 1116 includes a clip opening 1120 to receive a corresponding clip 1118 on the second part 1100b. When the corresponding protrusion 1114 of the second part 1100b is inserted into the slot 1116 of the first part 1100a (or vice versa), the corresponding clip 1118 slides into the clip opening 1120 and prevents the first and second parts 1100a, 1100b from being pulled apart (unless the clip 1118 is moved outward from the clip opening 1120, for example). In other examples, the grease retainer 822 may be constructed from a single unitary piece (eg, using a flexible material such as rubber) or from more than two pieces.

[0062] Fig.12 is a flow chart representing an exemplary method 1200 that may be implemented to construct and / or assemble an exemplary torque tube assembly, such as Figure 21202, a first fitting 400 is coupled to the first end 302 of the torque tube 304, and a second fitting 800 is coupled to the second end 308 of the torque tube 304. In some examples, the first fitting 400 and / or the second fitting 800 are coupled to the torque tube 304 via EMF. In some examples, the torque tube 304 is constructed of aluminum, and the first fitting 400 and the second fitting 800 are constructed of steel. However, in other examples, the torque tube 304 and / or the first fitting 400 and / or the second fitting 800 may be constructed of other materials. Furthermore, in other examples, the first fitting 400 and the second fitting 800 may be coupled to the torque tube 304 via other coupling techniques (e.g., welding, threaded fasteners, etc.).

[0063] At frame 1204, the first yoke 504 of the first fitting 400 is coupled to the second yoke 506 of the first spline connector 404 (e.g., via the cross journal 500 and the bearing cap 502) to form the first U-joint 402. At frame 1206, the second fitting 800 is inserted into the channel 902 of the sliding spline shaft 804. Specifically, the first spline segment 910 and the second spline segment 912 are inserted into the splines 908 of the channel 902. At frame 1208, the third yoke 810 of the sliding spline shaft 804 is coupled to the fourth yoke 812 of the second spline connector 808 (e.g., via the cross journal 814 and the bearing cap 816) to form the second U-joint 806.

[0064] At block 1210, the first spline connector 404 is coupled to the aircraft 100 via the output shaft 228 of the second GRA 222. For example, the first spline connector 404 may be slid over the first spline gear 406 to insert the first spline gear 406 into the opening 410 of the first spline connector 404. In some examples, after the first spline gear 406 is inserted into the first spline connector 404, the threaded fastener 518 is threaded into the first spline connector 404 and the first spline gear 406 to fixedly couple the first spline connector 404 (and therefore, the first portion of the torque tube assembly 200) to the aircraft 100.

[0065] At block 1212, the second spline coupler 808 is coupled to the aircraft 100 via the input shaft 212 of the first GRA 208. For example, after coupling the first spline coupler 404 to the first spline gear 406, the sliding spline shaft 804 (e.g., the second portion) may be moved toward the torque tube 304 to compress or shorten the torque tube assembly 200. The second spline coupler 808 may be lifted to a position aligned with the second spline gear 900, and the sliding spline shaft 804 may be moved away from the torque tube 304 (extending the torque tube assembly 200) to slide the second spline coupler 808 over the second spline gear 900. In other examples, the second spline coupler 808 may first be coupled to the input shaft 212 of the first GRA 208. After second spline gear 900 is inserted into second spline connector 808 , one or more threaded fasteners may be threaded into second spline connector 808 and second spline gear 900 to fixedly couple second spline connector 808 (and, therefore, the second portion of torque tube assembly 200 ) to aircraft 100 .

[0066] At frame 1214, the first retaining bolt 914 and the second retaining bolt 916 are inserted into the passage 902 of the sliding spline shaft 804, which prevents the second accessory 800 and the sliding spline shaft 804 from being completely separated. For example, the first retaining bolt 914 and the second retaining bolt 916 can be screwed into the first opening 918 and the second opening 920 in the sliding spline shaft 804, respectively. At frame 1216, the grease ring 822 is coupled to the sliding spline shaft 804 to cover the first opening 904. In some examples, the grease ring 822 is composed of two parts that are connected (interlocked). In some examples, a strip or belt is placed around the grease ring 822 to ensure that the grease ring 822 does not loosen. In other examples, a strip or belt may not be used. At frame 1218, lubricating oil can be injected into the passage 902 through the first lubricating oil port 818 and / or the second lubricating oil port 820. The lubricating oil provides lubrication between the first spline section 910 and the second spline section 912 of the second fitting 800 and the splines 908 of the passage 902 .

[0067] Although the reference Fig.12 The flowchart shown in describes an exemplary method 1200, but may alternatively use a manufacturing and / or assembly method. Figure 2 Many other methods of the exemplary torque tube assembly 200 may be described. For example, the order of execution of the blocks may be changed, and / or some of the blocks described may be changed, eliminated, or combined. Similarly, Fig.12Additional operations are included in the manufacturing and / or assembly process before, between, or after the boxes shown in . In addition, although the first spline connector 404 is described as being coupled to the output of the driving member and the second spline connector 808 is described as being coupled to the driven member, it should be understood that the torque tube assembly 200 can be used in reverse. In other words, the second spline connector 808 can be coupled to a spline shaft of the driving member, which thereby drives the second spline connector 808. In addition, although the exemplary torque tube assembly 200 is disclosed with respect to a high-lift device for an aircraft, the exemplary torque tube assembly 200 can be used in any industry or application in which rotational energy is transferred from one driving member (e.g., a drive shaft) to another driving member.

[0068] In some cases, this may be desirable when the torque tube assembly 200 is to be assembled to enable one spline tooth of the torque tube assembly 200 to be adjusted (e.g., rotated) relative to the input shaft and / or the output shaft. For example, when installing the torque tube assembly 200 between the output shaft 228 and the input shaft 212, an operator or technician attempts to align the first slat 108 and the second slat 110 and install the torque tube assembly 200 on the input shaft 212 and the output shaft 228 so that when the torque tube assembly 200 rotates, the movement of the first slat 108 and the second slat 110 is aligned and synchronized. The operator or technician performs this task for each torque tube assembly upstream and downstream. However, by using a connection between a spline connector (e.g., the first spline connector 404) and a drive shaft (e.g., the output shaft 228) that utilizes a fastener that extends into a corresponding hole in the drive shaft, the connection can only be adjusted based on the spacing between the openings (e.g., 120°). For example, for Figures 4 to 6 4, the holes 620, 622, 624 in the first spline coupler 404 need to be aligned with the corresponding holes in the first spline gear 406. Thus, when connecting the first spline coupler 404 to the output shaft 228, the first spline coupler 404 (and therefore the torque tube assembly) and / or the output shaft 228 must be rotated to one of three positions in which the holes are aligned.

[0069] Fig.13 An exemplary connection or joint 1300 for coupling the end of a torque tube to a drive shaft (such as an input shaft or an output shaft) of an aircraft high lift device is shown. The exemplary joint 1300 enables adjustment of a spline tooth of the torque tube relative to the input shaft or the output shaft. Figure 2 ) shows and describes the exemplary joint 1300. Specifically, the exemplary joint 1300 can be used as Figure 3The exemplary joint 1300 is an alternative to the first joint 300 for fixedly coupling the first spline connector 404 to the output shaft 228 of the second GRA 222. Additionally or alternatively, the exemplary joint 1300 can be similarly used to couple the second spline connector 808 ( Figure 8 ) is fixedly coupled to the input shaft 212 of the first GRA 208.

[0070] exist Fig.13 In the illustrated example of FIG. 1 , the torque tube assembly 200 includes a retainer 1302. The retainer 1302 prevents the first spline connector 404 from being removed from (e.g., axially moved relative to) the output shaft 228 of the second GRA 222. In this example, the retainer 1302 is secured to the output shaft 228 of the second GRA 222 via three threaded fasteners 1304 (two of which are in the Fig.13 ) is coupled to the first spline connector 404. The threaded fastener 1304 does not extend into the output shaft 228. Thus, when the torque tube assembly 200 is assembled, the first spline connector 404 can be adjusted by one spline tooth relative to the output shaft 228, and vice versa.

[0071] Fig.14 1 is an exploded view of the joint 1300. The first spline connector 404 is to be coupled to the output shaft 228 via a spline fitting 1400. In this example, the spline fitting 1400 is implemented as a spline gear 1400. Specifically, the spline gear 1400 is to be coupled to the output shaft 288, and the spline gear 1400 is to be inserted into the opening 410 ( Figure 4 ). The spline gear 1400 includes a spline 1402 that engages with an inner surface 618 ( Figure 6 ) on the spline 616 ( Figure 6 )Cooperate.

[0072] In the example shown, the output shaft 228 includes a spline section 1404. A spline gear 1400 is to be coupled to the spline section 1404 on the output shaft 228. The spline gear 1400 has an internal spline opening 1406 that cooperates with the spline section 1404 on the output shaft 228. Thus, rotational motion is transmitted between the output shaft 228 and the spline gear 1400. The spline gear 1400 is retained on the output shaft 228 by a retaining nut 1408. The spline gear 1400 has a first end 1410 and a second end 1412 opposite the first end 1410. When the spline gear 1400 slides on the spline section 1404 of the output shaft 228, the first end 1410 engages a step 1414 (e.g., a surface formed between changes in diameter) on the output shaft 228. The retaining nut 1408 is screwed onto the output shaft 228, which constrains the spline gear 1400 between the step 1414 on the output shaft 228 and the retaining nut 1408. In some examples, a washer 1416 is disposed between the retaining nut 1408 and the second end 1412 of the spline gear 1400. In other examples, the spline gear 1400 can be coupled to the output shaft 228 via other chemical and / or mechanical fasteners (e.g., welding).

[0073] Once the spline gear 1400 is coupled to the output shaft 228, the first spline coupler 404 slides over the spline gear 1400. The retainer 1302 is then coupled to the first spline coupler 404 and prevents the spline gear 1400 from sliding out of the opening 410 ( Figure 4 ) slides out, thereby preventing the first spline connector 404 from being removed from the output shaft 228. In the example shown, the retainer 1302 includes an annular portion 1418 and a shoulder portion 1420. The shoulder portion 1420 extends radially inward from the annular portion 1418. The size of the annular portion 1418 is designed to fit around the annular wall 602 of the first spline connector 404. The opening 410 ( Figure 4 ) extends into the end 1422 of the first spline coupler 404. The annular portion 1418 is to be coupled to the outer surface 1423 of the first spline coupler 404 at or near the end 1422 of the first spline coupler 404. Thus, when the annular portion 1418 is coupled to the first spline coupler 404, the shoulder portion 1420 extends radially inwardly and at least partially covers the opening 410 ( Figure 4 The shoulder portion 1420 includes an opening 1424. The opening 1424 in the shoulder portion 1420 has a diameter smaller than the opening 410 in the first spline connector 404 ( Figure 4) and the outer diameter of the spline 1402 of the spline gear 1400. Thus, when the spline gear 1400 is disposed in the opening 410 of the first spline coupler 404 and the retainer 1302 is coupled to the first spline coupler 404, the shoulder portion 1420 prevents the spline gear 1400 from being removed from the opening 410.

[0074] In the example shown, the retainer 1302 is to be coupled to the first splined coupler 404 via three threaded fasteners 1304. The retainer 1302 includes three holes 1426, 1428, 1430 that are respectively aligned with the holes 620, 622, 624 ( Fig.14 In the example shown, holes 1426, 1428, 1430 are equidistant (120°) from each other. In other examples, first spline connector 404 and retainer 1302 may include more or fewer holes and / or may be coupled using more or fewer threaded fasteners. Figure 4 Compared to the first spline gear 406 shown in FIG. 1 , the spline gear 1400 does not have a threaded hole for receiving a threaded fastener. As a result, the spline gear 1400 can be inserted into the first spline connector 404 at any rotational angle of the spline alignment. In addition, by using the retainer 1302, the axial load on the torque tube assembly 200 is transferred between the first spline connector 404 and the spline gear 1400 through the retainer 1302, rather than acting directly on the threaded fastener. In other examples, the retainer 1302 can be coupled to the first spline connector 404 by other chemical and / or mechanical fastening techniques.

[0075] In one exemplary assembly operation, the retainer 1302 is placed on the output shaft 228 (so that the output shaft 228 extends through the opening 1424 in the retainer 1302). The spline gear 1400 is then slid over the spline section 1404. Next, the washer 1416 and retaining nut 1408 are coupled to the output shaft 228, which captures the spline gear 1400 on the spline section 1404 of the output shaft 228 between the retaining nut 1408 and the step 1414. The first spline connector 404 is then slid over the spline gear 1400 on the output shaft 228 so that the spline gear 1400 is disposed within the first spline connector 404. The retainer 1302 is then placed on the first spline connector 404, and the holes 1426, 1428, 1430 in the retainer 1302 are aligned with the holes 620, 622, 624 in the first spline connector 404. Then, the threaded fastener 1304 is inserted (threaded) through the retainer 1302 and into the first spline connector 404 to couple the retainer 1302 to the first spline connector 404. Thus, in some examples, the retainer 1302 is placed on the output shaft 228 before the spline gear 1400 is coupled to the output shaft 228.

[0076] Fig.15 is an assembled cross-sectional view of the connector 1300. Fig.15 As shown in FIG. 1 , the spline gear 1400 is disposed on the output shaft 228. The spline gear 1400 is retained between the retaining nut 1408 and the step 1414 on the output shaft 228. In the example shown, the spline gear 1400 is inserted into the first spline connector 404. The splines 1402 of the spline gear 1400 mesh with the splines 616 on the inner surface 618 of the annular wall 602 of the first spline connector 404. The splines 616, 1402 enable the transmission of rotational motion between the spline gear 1400 and the first spline connector 404, and thus the output shaft 228 and the torque tube assembly 200 ( Figure 2 ) to transmit rotational motion.

[0077] like Fig.15 , the retainer 1302 prevents the first spline coupler 404 from moving axially away from the output shaft 228. The annular portion 1418 of the retainer 1302 is coupled to the first spline coupler 404 near the end 1422 of the first spline coupler 404. The shoulder portion 1420 extends radially inward and blocks at least a portion of the opening 410. The diameter D1 of the opening 1424 in the shoulder portion 1420 is smaller than the outer diameter D2 of the splines 1402 on the spline gear 1400 (which is substantially the same as the diameter of the opening 410 in the first spline coupler 404). Thus, the spline gear 1400 is prevented from moving axially outward (to the outer diameter D2 of the splines 1402 on the spline gear 1400). Fig.15 on the left side of the image).

[0078] In the example shown, the second end 1412 of the spline gear 1400 engages with a flange 1500 formed on the inner surface 618 of the first spline coupler 404. Thus, the spline gear 1400 is trapped between the shoulder portion 1420 of the retainer 1302 and the flange 1500 in the first spline coupler 404. In some examples, the distance between the shoulder portion 1420 and the flange 1500 is the same as the length of the splines 1402 on the spline gear 1400, so that axial movement is not allowed. In other examples, the distance between the shoulder portion 1420 and the flange 1500 is greater than the length of the splines 1402 on the spline gear 1400, so that some axial movement is allowed.

[0079] In the example shown, the threaded fastener 1304 ( Fig.15 1400. In one embodiment, the first spline coupler 404 and the spline gear 1400 may be adjusted one spline tooth. For example, when assembling the torque tube assembly 200, the first spline coupler 404 may be removed from the spline gear 1400, rotated one or more spline teeth in either direction, and then reinstalled on the spline gear 1400. The retainer 1302 may then be coupled to the first spline coupler 404 to prevent the first spline coupler 404 from axially separating from the output shaft 228.

[0080] Additionally or alternatively, another retainer may be used to similarly secure the second spline connector 808 ( Figure 8 ) is connected to the input shaft 212 ( Figure 2 ). In other words, the second spline gear can be coupled to the input shaft 212 of the first GRA 208. The second retainer can be coupled to the second spline coupler 808, wherein the second retainer blocks at least a portion of the opening in the second spline coupler 808 to prevent the second spline coupler 808 from being separated from the second spline gear on the input shaft 212. Furthermore, while the example retainer 1302 is shown and described in conjunction with the torque tube assembly 200, the example retainer 1302 can be used with other types of torque tube assemblies.

[0081] In some examples, it may be desirable to utilize the same type of threaded fasteners used on other components of the aircraft 100 so that the same type of fasteners can be used for multiple purposes. Fig.16 As shown in FIG, the longer threaded fastener 1600 ( Fig.16 Only one of them is shown in the figure) is used to connect the retainer 1302 to the first spline connector 404. In order to prevent the threaded fastener 1600 from extending into the spline gear 1400, Fig.16The spline gear 1400 in FIG. 1 includes a groove 1602 formed circumferentially around the spline gear 1400. The groove 1602 extends into the spline 1402 and forms a recess or cavity into which the threaded fastener 1600 can extend. In this example, the threaded fastener 1600 does not engage or contact the spline gear 1400.

[0082] Fig.17 1 is a flow chart representing an exemplary method 1700 that may be implemented to construct and / or assemble an exemplary torque tube assembly using the exemplary retainer 1302. The exemplary method 1700 is described in conjunction with the first spline connector 404 and the output shaft 228 of the torque tube assembly 200. However, it should be understood that the exemplary method 1700 may be similarly performed using the second spline connector 808 and the input shaft 212 of the first GRA 208 or any other type of torque tube assembly.

[0083] At block 1702, the first spline coupler 404 is coupled to the first end 302 of the torque tube 304. For example, as described in conjunction with blocks 1202 and 1204, the first spline coupler 404 may be coupled to the first end 302 via the first fitting 400. At block 1704, the retainer 1302 is placed on the output shaft 228 of the second GRA 222 (so that the output shaft 228 extends through the retainer 1302). At block 1706, the spline gear 1400 is coupled to the output shaft 228. For example, the spline gear 1400 may be slid over the spline section 1404 on the output shaft 228. Then, the washer 1416 may be slid over the output shaft 228, and then the retaining nut 1408 may be threaded onto the output shaft 228 to capture the spline gear 1400 between the step 1414 and the retaining nut 1408.

[0084] At block 1708, the first spline coupler 404 is slid onto the spline gear 1400. In some examples, the first spline coupler 404 is slid onto the spline gear 1400 until the spline gear 1400 contacts the flange 1500 in the first spline coupler 404. At block 1710, the retainer 1302 is coupled to the first spline coupler 404. For example, the holes 1426, 1428, 1430 in the annular portion 1418 of the retainer 1302 are aligned with the holes 620, 622, 624 in the first spline coupler 404, and the threaded fastener 1304 is screwed into the corresponding hole. The exemplary method can be similarly performed to couple the second spline coupler 808 ( Figure 8 ) is coupled to a spline fitting (eg, a spline gear) on the input shaft 212 of the first GRA 208 .

[0085] Although the reference Fig.17The flowchart shown in FIG. 17 depicts an exemplary method 1700 , but may alternatively be used to manufacture and / or assemble the retainer 1302 . Figure 2 Many other methods of the exemplary torque tube assembly 200 may be described. For example, the order of execution of the blocks may be changed, and / or some of the blocks described may be changed, eliminated, or combined. Similarly, Fig.17 Additional operations are included in the manufacturing and / or assembly process before, between, or after the boxes shown in . In addition, although the first spline connector 404 is described as being coupled to the output of the driving member and the second spline connector 808 is described as being coupled to the driven member, it should be understood that the torque tube assembly 200 can be used in reverse. In other words, the second spline connector 808 can be coupled to a spline shaft of the driving member, which thereby drives the second spline connector 808. In addition, although the exemplary torque tube assembly 200 is disclosed with respect to a high-lift device for an aircraft, the exemplary torque tube assembly 200 can be used in any industry or application in which rotational energy is transferred from one driving member (e.g., a drive shaft) to another driving member.

[0086] From the foregoing, it will be appreciated that the above-disclosed torque tube assembly and method of manufacturing the same provide a more flexible attachment between an upstream drive shaft and a downstream drive shaft in a wing of an aircraft. Specifically, the exemplary torque tube assembly can move axially and angularly to accommodate any bending and / or bending that may occur in the wing of the aircraft or other structures to which the torque tube assembly is connected. As a result, less force or tension is concentrated along the torque tube assembly, thereby improving the structural integrity of the torque tube assembly. Moreover, the exemplary torque tube assembly is easier to install than known torque tube assemblies because the exemplary torque tube assembly can be shortened and extended while attaching the end of the torque tube assembly to the drive shaft. In addition, the exemplary torque assembly includes a retaining feature that prevents the portion from leaving the aircraft if a portion of the torque tube assembly fails.

[0087] Also disclosed herein is an exemplary retainer for coupling a splined coupling and a splined fitting or splined gear on a drive shaft. The exemplary retainer enables the splined coupling to be coupled to the splined gear at any rotational angle of the splined engagement and thus enables finer control when assembling the torque tube assembly. This capability also reduces the time it takes an operator to assemble the torque tube assembly.

[0088] Although certain exemplary methods, apparatus, and articles of manufacture have been disclosed herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus, and articles of manufacture that legally fall within the scope of the claims of this patent.

Claims

1. A torque tube assembly (200), comprising: Torque tube (304); A spline connector (404) coupled to the end (302) of the torque tube (304), the spline connector (404) having an opening (410) for receiving a spline gear (1400) on a drive shaft (228) of an aircraft high-lift device; and a retainer (1302) coupled to the spline coupler (404), the retainer (1302) blocking at least a portion of the opening (410) in the spline coupler (404) to prevent the spline coupler (404) from separating from the spline gear (1400) on the drive shaft (228), wherein the opening (410) is formed in an end (1422) of the spline connector (404), and wherein the retainer (1302) includes an annular portion (1418) coupled to an outer surface (1423) of the spline connector (404) at or near the end (1422) of the spline connector (404), and The torque tube assembly further comprises a plurality of threaded fasteners (1304), which extend through the annular portion (1418) of the retainer (1302) and into the outer surface (1423) of the spline connector (404), so that the retainer (1302) is connected to the spline connector (404).

2. The torque tube assembly according to claim 1, wherein: The retainer (1302) includes a shoulder portion (1420) extending radially inwardly from the annular portion (1418) and covering at least a portion of the opening (410) in the spline connector (404).

3. The torque tube assembly according to claim 2, wherein: The shoulder portion (1420) includes an opening (1424), the diameter of the opening (1424) in the shoulder portion (1420) being smaller than the diameter of the opening (410) in the spline connector (404).

4. The torque tube assembly according to claim 1, wherein: The threaded fastener (1304) does not extend into the opening (410) in the spline connector (404).

5. The torque tube assembly according to claim 1 further comprises a first torque tube fitting (400) coupled to the end portion (302) of the torque tube (304), the first torque tube fitting (400) having a first yoke (504), the spline connector (404) having a second yoke (506), the first yoke (504) of the first torque tube fitting (400) being coupled to the second yoke (506) of the spline connector (404) to form a U-joint (402).

6. The torque tube assembly according to claim 5, wherein: The end (302) of the torque tube (304) is a first end, the spline connector (404) is a first spline connector, the drive shaft (228) is a first drive shaft, and the U-joint (402) is a first U-joint, the torque tube assembly further comprising: a second torque tube fitting (800) coupled to the second end (308) of the torque tube (304), the second torque tube fitting (800) having a spline section (910); a sliding spline shaft (804) having a passage (902), wherein the second torque tube fitting (800) is slidably received in the passage (902), and wherein the sliding spline shaft (804) has a third yoke (810); and A second spline connector (808) has a fourth yoke (812), wherein the fourth yoke (812) of the second spline connector (808) is connected to the third yoke (810) of the sliding spline shaft (804) to form a second U-shaped joint (806), and the second spline connector (808) is connected to a second spline gear on a second drive shaft (212) of the aircraft high-lift device (208).

7. The torque tube assembly according to claim 6, wherein: The retainer (1302) is a first retainer, and the torque tube assembly further includes a second retainer connected to the second spline connector (808), the second retainer blocking at least a portion of the opening in the second spline connector (808) to prevent the second spline connector (808) from separating from the second spline gear on the second drive shaft (212).

8. The torque tube assembly of claim 6, further comprising a retaining bolt (914) extending into the passage (902), the retaining bolt (914) preventing the second torque tube fitting (800) from sliding beyond a threshold distance into or out of the passage (902) of the sliding spline shaft (804).

9. A method comprising: coupling a spline connector (404) to an end (302) of a torque tube (304); Connecting the spline gear (1400) to a drive shaft (228) of an actuator (222) of an aircraft high-lift device; Sliding the spline connector (404) over the spline gear (1400) on the drive shaft (228) such that the spline gear (1400) is disposed within an opening (410) in the spline connector (404); and coupling a retainer (1302) to the spline coupler (404), the retainer (1302) blocking at least a portion of the opening (410) in the spline coupler (404) to prevent the spline coupler (404) from separating from the spline gear (1400) on the drive shaft (228), Wherein, coupling the retainer (1302) to the spline connector (404) includes inserting a plurality of threaded fasteners (1304) into corresponding holes extending through the retainer (1302) and into the spline connector (404).

10. The method of claim 9, further comprising placing the retainer (1302) on the drive shaft (228) prior to coupling the spline gear (1400) to the drive shaft (228).

11. The method according to claim 9 or 10, wherein: Coupling the spline gear (1400) to the drive shaft (228) includes sliding the spline gear (1400) over a spline section (1404) on the drive shaft (228) and coupling a retaining nut (1408) to the drive shaft (228).

12. An aircraft comprising: a geared rotary actuator (222) coupled to a wing (104) of the aircraft (100), the geared rotary actuator (222) having a drive shaft (228); A spline gear (1400) coupled to the drive shaft (228); as well as A torque tube assembly (200) having a spline connector (404) and a retainer (1302), the spline gear (1400) being disposed within an opening (410) in the spline connector (404), the retainer (1302) being coupled to the spline connector (404) and blocking at least a portion of the opening (410) in the spline connector (404) to prevent the spline connector (404) from being separated from the spline gear (1400) on the drive shaft (228), wherein the opening (410) is formed in an end (1422) of the spline connector (404), and wherein the retainer (1302) includes an annular portion (1418) coupled to an outer surface (1423) of the spline connector (404) at or near the end (1422) of the spline connector (404), and The torque tube assembly further comprises a plurality of threaded fasteners (1304), which extend through the annular portion (1418) of the retainer (1302) and into the outer surface (1423) of the spline connector (404), so that the retainer (1302) is connected to the spline connector (404).

13. The aircraft of claim 12, wherein: The spline gear (1400) does not have a threaded hole for receiving a threaded fastener.

14. An aircraft according to claim 12 or 13, wherein: The spline gear (1400) includes an internal spline opening (1406) to mate with a spline section (1404) on the drive shaft (228).

15. The aircraft of claim 12 or 13, further comprising a retaining nut (1408) coupled to the drive shaft (228), the spline gear (1400) being captured between the retaining nut (1408) and a step (1414) in the drive shaft (228).

16. An aircraft according to claim 12 or 13, wherein: The retainer (1302) includes a shoulder portion (1420) having an opening (1424), the opening (1424) in the shoulder portion (1420) having a diameter that is smaller than an outer diameter of the spline gear (1400).

17. An aircraft according to claim 12 or 13, wherein: The spline gear (1400) includes a groove (1602) formed circumferentially around the spline gear (1400), the groove (1602) providing space for a plurality of threaded fasteners (1600) extending into the opening in the spline coupler (404).

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