System and method for attaching a lift valve to an electromechanical actuator device

Abstract

An assembly having a connecting member and a lift valve is disclosed. The connecting member has a first end. The first end has an opening extending into the connecting member, such that the connecting member has a sidewall extending around and defining the opening, the sidewall being at least partially constructed of a ductile material. The lift valve is positioned within the opening. The lift valve has a first end outside the opening, a second end inside the opening, and an outer surface extending between the first end and the second end. The lift valve has a recess positioned between the first end and the second end, the recess being defined by a bottom and at least one sidewall. At least a portion of the ductile material of the sidewall is positioned within the recess to secure the lift valve to the opening.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 62 / 859,980, filed June 1, 2019, the entire contents of which are incorporated herein by reference. Background Technology

[0003] Electromechanical actuator systems are generally well-known and have been around for many years. In the downhole industry (oil, gas, mining, water, exploration, construction, etc.), electromechanical actuators can be used as part of tools or systems, including but not limited to: drill bits, adjustable instrument stabilizers, vertically maneuverable tools, rotary maneuverable tools, bypass valves, packers, downhole valves, directional drilling devices, latching or release mechanisms, anchoring mechanisms, or measurement-while-drilling (MWD) pulse generators. For example, in an MWD pulse generator, the actuator can be used to actuate a pilot / servo valve mechanism for operating a large mud hydraulic actuation valve. Such a valve can be used as part of a system that transmits data from the bottom of the borehole near the drill bit (referred to as downhole) back to the surface. The downhole portion of these communication systems is called a mud pulse generator because these systems generate programmable pressure pulses in the mud or fluid column, which can be used to transmit digital data from downhole to the surface. Mud pulse generators are generally well known, and there are many different implementations of mud pulse generators and mechanisms that can be used to generate mud pulses.

[0004] Many existing systems feature cylindrical valve components constructed from hard and brittle materials that are attached to the actuator shaft. These hard and brittle materials are ceramics or carbides. The actuator shaft, on the other hand, is made from different types of materials, such as steel alloys, stainless steel alloys, or nickel alloys, which are more ductile and have higher tensile strength than lift valves. Attaching very hard and brittle materials to the more ductile and tensile-strength shaft of the actuator has proven challenging, especially in harsh environments. Furthermore, the small size of some components, such as servo lift valves, has increased the difficulty of attaching them to the actuator shaft. A typical servo lift valve is cylindrical in shape, with a length of 1 / 2 and a width of 5 / 16.

[0005] Numerous attempts have been made to attach the lift valve to the actuator shaft. Past methods included threading, screw fixing, pin fixing, brazing / welding, press fitting, and clamping with retaining screws. Furthermore, it has been proposed to manufacture the lift valve and actuator shaft as a single, rigid, and brittle structure. Combinations of these techniques have also been used.

[0006] Manufacturing threads in hard and brittle materials requires grinding, electrical discharge machining, or bushings made of one or more ductile materials. These characteristics also create stress concentrations, where cracks can develop. Threaded fasteners can loosen in high-vibration and high-temperature cycling environments. Threadlockers such as Loctite can degrade in drilling fluids. The relatively small shear area of ​​screws and pins can create stress concentrations in lift valves, leading to failure.

[0007] Confining the hard, brittle material of a lift valve between other components, such as component shoulders or retaining rings, is not always feasible. Brazing or soldering the lift valve to the actuator shaft can be unreliable due to process sensitivity and corrosion. Brazing or soldering introduces additional dissimilar metals, leading to anodic corrosion. This corrosion is accelerated by commonly used drilling fluids. Press-fitting or clamping the lift valve to the actuator shaft is unreliable due to the low coefficient of friction of these hard materials and the difference in thermal expansion rates between carbide / ceramic and metal alloys. Roughening the outer surface of the lift valve to enhance frictional engagement can cause additional problems, as roughened surfaces also create sites for crack initiation and failure.

[0008] Therefore, it is desirable to increase the reliability and strength of the connection between the lift valve and the actuator shaft. This disclosure is a solution to the above-mentioned problems. Attached Figure Description

[0009] Figure 1 This is a cross-sectional view of an exemplary electromechanical actuator according to the present disclosure, which has a lift valve fixed to a servo shaft of an actuator.

[0010] Figure 2 This is a side view of an embodiment of a lift valve for an electromechanical actuator constructed according to the present disclosure.

[0011] Figure 3 is a cross-sectional view of an exemplary embodiment of the servo axis of an electromechanical actuator constructed according to the present disclosure.

[0012] Figure 3A is a cross-sectional view of the sidewall of the servo axis as shown by lines 3A-3A in Figure 3.

[0013] Figure 4 This is a cross-sectional view of an exemplary embodiment of a servo shaft connected to an actuator of a lift valve according to the present disclosure.

[0014] Figure 5 yes Figure 4 An enlarged view showing the interconnection between the servo axis and the lift valve according to this disclosure. Detailed Implementation

[0015] The following detailed description refers to the accompanying drawings. The same reference numerals in different drawings may identify the same or similar elements.

[0016] The apparatus and method proposed in this disclosure solve the aforementioned problems. The apparatus and method are suitable for the actuation of downhole tools, such as in drilling, workover, and production, and will be described in this context. Downhole tools that can be actuated and controlled using the apparatus and method may include, but are not limited to: drill bits, adjustable instrument stabilizers, vertically operable tools, rotary operable tools, bypass valves, packers, control valves, latching or release mechanisms, and / or anchoring mechanisms. For example, in one application, the actuator may be used to actuate a pilot / servo valve mechanism for operating, for example, a larger mud-hydraulic actuated valve in a MWD pulse generator.

[0017] As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” or any other variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Furthermore, unless expressly stated to the contrary, “or” refers to inclusive “or” rather than exclusive “or.” For example, conditions A or B satisfy either of the following conditions: A is true (or exists) and B is false (or does not exist); A is false (or does not exist) and B is true (or exists); and both A and B are true (or exist).

[0018] Furthermore, the terms "a" or "an" are used to describe elements and components in the embodiments herein. This is done merely for convenience and to give a general meaning to the inventive concepts. This description should be understood to include one or more, and the singular includes the plural, unless it is obvious otherwise.

[0019] Furthermore, unless explicitly stated otherwise, the term "multiple" is used to mean "more than one".

[0020] Furthermore, certain parts of the implementation have been described as “components” or “circuits” that perform one or more functions. The terms “component” or “circuit” can include hardware such as a processor, an application-specific integrated circuit (ASIC), or a field-programmable gate array (FPGA), or a combination of hardware and software. The software includes one or more computer-executable instructions that, when executed by one or more components, cause the component or circuit to perform a specified function. It should be understood that the algorithms described herein are stored on one or more non-transitory memories. Exemplary non-transitory memories include random access memory, read-only memory, flash memory, etc. Such non-transitory memories can be electrical or optical. Furthermore, the messages described herein can be generated by the components and cause various physical transformations.

[0021] Finally, as used herein, any reference to "an embodiment" or "one embodiment" means that a particular element, feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. The phrase "in one embodiment" appearing in different places in the specification does not necessarily refer to the same embodiment.

[0022] Figure 1 This is an illustration of an electromechanical actuator assembly 20 that can be used, for example, in a downhole MWD pulse generator tool. The electromechanical actuator assembly 20 may include a housing 22, a rotary actuator 24, and a guide or ball screw 25 that actuates a servo shaft 28. The electromechanical actuator assembly 20 may also have one or more vibration-absorbing and self-aligning members 29 that absorb shocks from the rotary actuator 24 and can compensate for misalignment. The vibration-absorbing and self-aligning members 29 may also absorb vibrations applied to the servo shaft 28 by external forces. In one embodiment (for a specific set of load and temperature requirements), the vibration-absorbing and self-aligning members 29 (such as...) Figure 1 (As shown) can be a machined helical spring made of metal, integrated with the connection between the reciprocating nut of the ball screw 25 and the servo shaft 28. However, the vibration absorption and self-alignment member 29 can also take other forms and can be made of different materials selected by those skilled in the art according to the load and temperature requirements of the specific application.

[0023] The servo axis 28 of the electromechanical actuator assembly 20 can also pass through the pressure compensation system 32 and one or more buffer disks 34, optionally such as a buffer disk or a stack of buffer disks, arranged through or connected to the housing 22, whose function is described in more detail below. Buffer disk 34 (see also...) Figure 2 It can be made of high-temperature thermoplastics, but it can also be made of other materials, depending on the load and temperature requirements of the specific application.

[0024] The electromechanical actuator assembly 20 may also include a fluid mud removal and pressure compensation system 36 that balances the pressure within the housing 22 with the borehole pressure. The electromechanical actuator assembly 20 may also include a pressure-sealed power supply passage 38 that allows the rotary actuator 24 to be electrically connected to electronic control components, but isolates the electronic control components from the fluid and pressure. Specifically, when downhole, the pressure within the oil-filled pressure compensation system is substantially equal to the pressure in the borehole, and this pressure is primarily a result of the fluid column in the borehole. The pressure-sealed power supply passage 38 may have a metal body with sealing features, a metal conductor for the power supply passage, and electrical insulation and pressure sealing components (typically glass or ceramic) between the body and each conductor. Alternatively, the pressure-sealed power supply passage 38 may be a plastic body with sealing features and a metal conductor for the power supply passage.

[0025] As described in more detail below, the electromechanical actuator assembly 20 may also have a set of electronic control components 42a and 42b that control the overall operation of the electromechanical actuator assembly 20. This set of electronic control components 42 is powered by an energy source (not shown), which may be, for example, one or more batteries or another power source.

[0026] In the electromechanical actuator assembly 20, a rotary actuator 24 (such as, but not limited to, an electric motor, a rotary solenoid, a hydraulic motor, a piezoelectric motor, etc.) is mounted, for example, with a ball or guide screw 25, which is integral with or attached to the output shaft (not shown) of the rotary actuator 24. The screw 25 rotates and a nut 44 on the guide screw 25 moves linearly and reciprocally. The nut 44 is coupled to one or more actuated / reciprocating components / parts, such as a servo shaft 28, a vibration-absorbing and self-aligning component 29, a coupling 50, an anti-rotation feature or component 52. Alternatively, the shaft of the rotary actuator 24 may incorporate features of the ball or guide screw 25, nut 44, or be attached to the ball or guide screw, nut, such that the screw moves axially as the nut rotates, and the screw 25 is integrated with or connected to one or more actuated / reciprocating components / parts such as servo shaft 28, vibration absorption and self-aligning member 29, coupling 50, anti-rotation feature or member 52. Figure 1In the illustrated embodiment, the nut 44 is attached to or integral with a reciprocating member that moves back and forth with the screw, but rotation of the reciprocating, axially moving member(s) is prevented by an anti-rotation feature or member 52. This feature or member can be, for example, a pin, key, screw head, ball, or an integrally machined feature that slides along an elongated stop or slot 54 in the surrounding actuator guide or surrounding housing. Alternatively, the anti-rotation feature or member 52 can be attached to or integral with the guide / housing or other adjacent structure and will prevent rotation of the vibration-absorbing and self-aligning member(s) 29 by sliding along the slot / groove or elongated stop. Alternatively, the anti-rotation feature or member 52 can be trapped within an elongated stop or slot or key in both the reciprocating member(s) and the retaining member(s). The guide and / or surrounding housing and / or reciprocating and / or rotating components can be discharged to allow fluid transfer between various cavities whose volumes change as the servo shaft 28 of the electromechanical actuator assembly 20 reciprocates.

[0027] In one embodiment, the thrust generated by or applied to the vibration-absorbing and self-aligning member 29 is counteracted by a component, which is a combined thrust / radial bearing within the rotary actuator 24. This component (e.g., a bearing) can accommodate axial and radial loads while minimizing the torque requirements of the rotary actuator 24. This type of bearing is well known. However, typically and in existing downhole actuators, it is possible to implement one or more thrust bearings external to the rotary actuator 24, while the rotary actuator 24 contains only radial support bearings. Combining radial and thrust bearings into the rotary actuator 24, as described in the device, reduces the number of parts and the overall length of the assembly, improves reliability, and simplifies assembly / disassembly. However, as is generally the case, the thrust bearing may optionally or additionally be attached to or integrated into the non-reciprocating components of the shaft or ball / guide screw 25 of the rotary actuator 24.

[0028] According to this disclosure, the electromechanical actuator assembly 20 is further provided with a lift valve 60 connected to the servo axis 28 to form such that... Figure 4 and Figure 5The servo axis assembly 61 is shown. A lift valve 60 is moved by the servo axis 28 to alternately cover and expose an opening 62 in the housing 22. The lift valve 60 is typically constructed of a material having a first hardness greater than the second hardness of the servo axis 28. This increased hardness of the lift valve 60 compared to the servo axis 28 gives it enhanced wear resistance. However, as mentioned above, this increased hardness also makes it difficult to connect the lift valve 60 to the servo axis 28. For example, the lift valve 60 may be constructed of a material having a first hardness in the range of approximately 90 to 92.8 as measured in Rockwell “A” values. The lift valve 60 may be constructed of a variety of materials, such as tungsten carbide, which is also known as a hard alloy. In other embodiments, the lift valve 60 may be a ceramic material or a cobalt alloy. The second hardness of the servo axis 28 is typically less than 90 as measured in Rockwell “A” values, and more generally can be in the range of approximately 44 to 60 (measured in Rockwell “A” values). Furthermore, the lift valve 60 is constructed from a material with an elastic modulus significantly greater than that of the servo shaft 28. For example, when the lift valve 60 is constructed from cemented carbide, the elastic modulus can be as high as 94 million pounds per square inch, which is 2 to 3 times higher than that of steel. This property is used to resist deflection and is very useful for preventing the lift valve 60 from deflecting. However, the increased stiffness and / or brittleness also lead to the possibility of fracture at any stress point within the lift valve 60. The fracture toughness of the cemented carbide and ceramics that can be used to manufacture the lift valve 60 can be in the range of approximately 8-12 MPa-m1 / 2. The ductile materials that can be used to form the servo shaft 28, such as stainless steel and / or nickel alloys, can have a fracture toughness in the range of approximately 112-278 MPa-m1 / 2.

[0029] Now for reference Figure 2The diagram shows a side view of an embodiment of a lift valve 60 of an electromechanical actuator 20 constructed according to the present disclosure. In this embodiment, the lift valve 60 has a cylindrical shape and has a first end 64, a second end 68, and an outer surface 70 extending between the first end 64 and the second end 68. The outer surface 70 of the lift valve 60 is shaped to provide at least one recess 74 positioned between the first end 64 and the second end 68. The recess 74 may be an annular recess (e.g., a groove) extending around the entire circumference of the outer surface 70 of the lift valve 60. In this example, the recess 74 has no ends due to the continuous nature of the annular recess. In other examples, the recess 74 may not be an annular recess. In this case, the recess 74 may extend only partially around the circumference of the lift valve 60, rather than extending around the entire outer surface 70 of the lift valve 60. In other words, in this case, the recess 74 may have a first end spaced apart from the second end of the recess 74. At least one recess 74 can be formed within the lift valve 60 by any suitable process, such as grinding, electrical discharge machining, or other suitable processes capable of precisely forming the lift valve 60 in the manner described herein. For example, unprocessed carbide / ceramic powder can be pressed into shape and conventionally machined prior to in-kiln heat treatment. In other embodiments, the lift valve 60 can be manufactured additively. As will be detailed below, at least one recess 74 is sized to receive a portion of the servo shaft 28 that has been deformed into the recess 74 to form a mechanical connection between the lift valve 60 and the servo shaft 28. Therefore, conventional methods such as screwing, screw fixing, pin fixing, brazing / welding, press fitting, clamping with locating screws, etc., can be avoided. In other words, in some embodiments, the portion of the servo shaft 28 that has been deformed into the recess 74 is the sole mechanical connection between the lift valve 60 and the servo shaft 28. In some embodiments, the outer surface 70 of the lift valve 60 is smooth (approximately 60 RMS or smoother), for example, it is not roughened or threaded to avoid creating areas within the lift valve 60 that could lead to cracks or breakage.

[0030] As those skilled in the art will understand, the dimensions of the lift valve 60 may vary depending on its intended use. In one embodiment, the lift valve 60 has a width 80 and a length 82. For example, the width 80 may be 5 / 16 inch and the length 82 may be 1 / 2 inch.

[0031] The recess 74 may be defined by at least one sidewall 84 and at least one bottom 86. For example, as Figure 2As shown, the recess 74 is provided with two spaced-apart sidewalls 84a and 84b and a bottom 86. The recess 74 may also have a width 88 and a depth 90. Although the width 88 and depth 90 can vary, in one embodiment, the width 88 is 1 / 32 inch and the depth 90 is 1 / 32 inch. To help reduce the possibility of breakage within the lift valve 60, the lift valve 60 may also be provided with a first root radius 92 located at the intersection of the sidewalls 84a and the bottom 86, and a second root radius 94 located at the intersection of the sidewalls 84b and the bottom 86. When the recess 74 is as follows... Figure 2 When the annular groove is shown, this construction of the outer surface 70 of the lift valve 60 results in the outer surface 70 having a first outer diameter 95 outside the recess 74 and a second outer diameter 96 perpendicular to the bottom 86 of the recess 74. The second outer diameter 96 is smaller than the first outer diameter 95.

[0032] like Figure 2 As shown, the lift valve 60 is also provided with a longitudinal axis 100 extending from the first end 64 to the second end 68, and located at the center of the first outer diameter 95 and the second outer diameter 96. In the illustrated embodiment, the recess 74 extends perpendicular to the longitudinal axis 100. However, it should be understood that the recess 74 does not need to extend perpendicular to the longitudinal axis 100, but may extend at other angles relative to the longitudinal axis 100. Furthermore, Figure 2 The example of the recess 74 shown has sidewalls 84a and 84b that are generally linear in shape and equidistant. However, it should be understood that sidewalls 84a and 84b may have other shapes, such as serrated, etc., as long as a portion of the servo shaft 28 can be positioned within the recess 74 to provide a connection between the mechanical servo shaft 28 and the lift valve 60 as described herein.

[0033] To further reduce the likelihood of cracks causing rupture within the lift valve 60, the outer surface 70 may optionally be provided with a third root radius 102 and a fourth root radius 104. The third root radius 102 is located at the intersection of the outer surface 70 and the first end 64. The fourth root radius 104 is located at the intersection of the outer surface 70 and the second end 68. In other embodiments, the third root radius 102 and / or the fourth root radius 104 may be omitted.

[0034] Figure 3 is a cross-sectional view of an exemplary embodiment of the servo axis 28 of the electromechanical actuator 20. As described above, the servo axis 28 can be connected to the rotary actuator 24, for example, via a screw 25, such that the rotational movement of the rotary actuator 24 is converted into linear movement of the servo axis 28. The servo axis 28 has a first end 110 and a second end 112 (see Figure 112). Figure 1The servo shaft 28 includes a first end 110 and a second end 112, extending along a longitudinal axis 114. The first end 110 has an opening 116 extending into the servo shaft 28, such that the servo shaft 28 has a sidewall 120 extending around and defining the opening 116. The sidewall 120 is at least partially constructed of a ductile material. In some embodiments, the servo shaft 28 includes a coupling member 113 and a shaft member 115. The coupling member 113 and the shaft member 115 may be separate devices made of ductile material, joined together by any suitable method, such as threads and retaining screws. In some embodiments, the coupling member 113 and the shaft member 115 are integrally formed to form a monolithic structure. Generally, the coupling member 113 is located at the first end of the servo shaft 28 and includes the opening 116 and the sidewall 120. The shaft member 115 is connected to the coupling member 113 and extends toward the second end 112. In some embodiments, the coupling member 113 and the shaft member 115 are collinear.

[0035] As best shown in Figure 3A, the sidewall 120 is provided with an inner surface 122 having internal dimensions, which will be described herein by way of example as an inner diameter 124. The inner surface 122 may have a circular shape as shown in Figure 3A, with the center located on the longitudinal axis 114. It should be understood that the sidewall 120 may have a cylindrical shape to correspond to the cylindrical shape of the outer surface 70 of the lift valve 60. However, it should be understood that the inner surface 122 of the sidewall 120 may have other shapes, such as hexagons, provided that the size and dimensions of the inner surface 122 are designed to allow the lift valve 60 to be positioned within the opening 116, and a portion of the sidewall 120 may be deformed into a recess 70.

[0036] In one embodiment, the distance 130 from the opening 116 extending into the coupling member 113 of the servo shaft 28 is less than the length 82 of the lift valve 60, such that when the lift valve 60 is placed into the opening 116 such that the second end 68 engages the servo shaft 28 at the bottom 132 of the opening 116, the first end 64 of the lift valve 60 extends from the first end 110 of the servo shaft 28. In one embodiment, the inner diameter 124 is equal to, and / or slightly larger than, the first outer diameter 95, for example, one-thousandth or one-two-thousandth of an inch larger than the first outer diameter 95, to allow the lift valve 60 to be positioned within the opening 116. If the opening 116 has a shoulder or other structure (e.g., a spacer) to provide length adjustment for the lift valve 60, thereby supporting / reacting the lift valve 60 to prevent the lift valve 60 from unintentionally moving further within the opening 116, the distance 130 of the opening 116 may be greater than the length 82 of the lift valve 60. In some embodiments, a vibration-absorbing component, such as a spring, may be disposed within the opening 116, between the lift valve 60 and the bottom 132, to provide length adjustment of the lift valve 60 and to absorb energy applied to the lift valve 60.

[0037] Figure 4 This is a cross-sectional view of an exemplary embodiment of the electromechanical actuator 20 of the present disclosure, which is connected to the servo shaft 28 of the lift valve 60. Figure 5 yes Figure 4 An enlarged view shows the interconnection between the servo axis 28 and the lift valve 60 according to the present disclosure. In one embodiment, longitudinal axes 100 and 114 are co-located and aligned such that the lift valve 60 and the servo axis 28 are positioned concentrically.

[0038] like Figure 4 and Figure 5 As shown, the lift valve 60 is positioned within the opening 116 such that a first end 64 of the lift valve 60 extends from a first end 110 of the servo shaft 28. Desiredly, the lift valve 60 can be positioned within the opening 116 such that a second end 68 of the lift valve 60 engages the servo shaft 28 at the bottom 132 to prevent movement of the lift valve 60 in the direction toward the servo shaft 28. Once the lift valve 60 is positioned within the opening 116, one or more connecting portions 140 of the sidewall 120 are positioned within the recess 74 to secure the lift valve 60 to the servo shaft 28. In one embodiment, the sidewall 120 is made of a ductile material capable of being deformed into the recess 74 to form the connecting portions 140. The connecting portions 140 of the sidewall 120 can be formed using any suitable process, such as hydroforming. In other embodiments, a device such as a forming tool can be used to deform the sidewall 120 into the recess 74. In one embodiment, the sidewall 120 is pressed into the entire recess 74 to form a loop connecting the lift valve 60 to the servo shaft 28. In this embodiment, the connecting portion 140 of the sidewall 120, positioned within a recess 74 having two sidewalls 84a and 84b, provides bidirectional attachment. If the recess 74 has only one sidewall, the connecting portion 140 of the sidewall 120, positioned within the recess 74, forms a unidirectional attachment that engages only one sidewall 84.

[0039] In other embodiments, only a portion of the sidewall 120 may be pressed into a portion of the recess 74, rather than the entire recess 74, to form a plurality of connecting portions 140 in the recess 74. In another embodiment where the lift valve 60 has more than one recess 74, a plurality of connecting portions 140 may be formed by deforming multiple portions of the sidewall 120 into the recess 74, for example, one or more connecting portions 140 may be provided in each recess 74.

[0040] The servo axis assembly 61 can be manufactured by positioning at least a portion of the lift valve 60 into an opening 116 in a first end 110 of a connecting member extending into the servo axis 28, such that a recess 74 formed within the lift valve 60 is positioned within the opening 116 and surrounded by a sidewall 120 of the first end 110 of the servo axis 28. At least a portion of the sidewall 120 is constructed of a ductile material as described above. The ductile material is aligned with the recess 74. Once the lift valve 60 is positioned within the opening 116, the ductile material can be deformed into the recess 74 to secure the lift valve 60 to the opening 116.

[0041] Compared to conventional electromechanical actuators and shaft assemblies, the electromechanical actuator assembly 20 and the servo shaft assembly 61 offer several advantages, including a higher load capacity than any other method. For example, a lift valve attached to a servo shaft via a pin or screw can achieve a pull force of approximately two or three hundred pounds. The servo shaft assembly 61 of this disclosure achieves a pull force exceeding one thousand pounds between the lift valve 60 and the servo shaft 28.

[0042] The following numbered paragraphs describe exemplary embodiments of this disclosure.

[0043] 1. An electromechanical actuator assembly, comprising:

[0044] A rotary actuator having an actuator shaft;

[0045] A servo axis is coupled to the rotary actuator shaft such that rotational movement of the actuator shaft is converted into linear movement of the servo axis. The servo axis has a first end with an opening extending into the servo axis, such that the servo axis has sidewalls extending about and defining the opening, the sidewalls being at least partially constructed of a ductile material.

[0046] A housing having an opening aligned with the first end of the servo axis; and

[0047] A lift valve is positioned within an opening extending into a first end of the servo shaft. The lift valve has a first end outside the opening, a second end inside the opening, and an outer surface extending between the first and second ends. The lift valve has a recess positioned between the first and second ends, the recess being defined by a bottom and at least one sidewall, at least a portion of the ductile material of the sidewall being positioned within the recess to secure the lift valve to the opening.

[0048] 2. The electromechanical actuator assembly according to Embodiment 1, wherein the recess is an annular recess without any ends and extends continuously around the outer surface of the lift valve.

[0049] 3. The electromechanical actuator assembly according to Embodiment 2, wherein the outer surface has a first outer diameter and a second outer diameter, the first outer diameter being outside the annular recess, the second outer diameter being adjacent to the bottom of the annular recess, and the second outer diameter being smaller than the first outer diameter.

[0050] 4. The electromechanical actuator assembly according to Embodiment 1, wherein the lift valve includes a first longitudinal axis extending between the first end and the second end, and the servo axis includes a second longitudinal axis extending from the first end of the servo axis, and the first longitudinal axis and the second longitudinal axis are co-located and aligned such that the lift valve is concentric with the servo axis.

[0051] 5. The electromechanical actuator assembly according to Embodiment 1, wherein the recess is defined by a bottom and two sidewalls arranged at intervals.

[0052] 6. A component comprising:

[0053] A connecting member having a first end having an opening extending into the connecting member, such that the connecting member has a sidewall extending around the opening and defining the opening, the sidewall being at least partially constructed of a ductile material;

[0054] A lift valve is positioned within an opening extending into the first end of the connecting member, the lift valve having a first end outside the opening, a second end inside the opening, and an outer surface extending between the first end and the second end, the lift valve having a recess positioned between the first end and the second end, the recess being defined by a bottom and at least one sidewall, at least a portion of the ductile material of the sidewall being positioned within the recess to secure the lift valve to the opening.

[0055] 7. The component according to embodiment 6, wherein the recess is an annular recess without any ends and extends continuously around the outer surface of the lift valve.

[0056] 8. The component according to embodiment 7, wherein the outer surface has a first outer diameter and a second outer diameter, the first outer diameter being outside the annular recess, the second outer diameter being adjacent to the bottom of the annular recess, and the second outer diameter being smaller than the first outer diameter.

[0057] 9. The component according to embodiment 6, wherein the lift valve includes a first longitudinal axis extending between the first end and the second end, and the connecting member is part of a servo axis including a second longitudinal axis, and the first longitudinal axis and the second longitudinal axis are co-located and aligned such that the lift valve is concentric with the servo axis.

[0058] 10. The component according to embodiment 6, wherein the recess is defined by a bottom and two sidewalls arranged at intervals.

[0059] 11. The component according to embodiment 6, wherein the connecting part is part of a servo axis.

[0060] 12. A method of manufacturing a component, comprising:

[0061] At least a portion of the lift valve is positioned into an opening that extends into a first end of the connecting member, such that a recess formed within the lift valve is positioned within the opening and surrounded by a sidewall of the first end of the connecting member, at least a portion of which is constructed of a ductile material aligned with the recess; and

[0062] The ductile material is deformed into the recess to secure the lift valve to the opening.

[0063] 13. The method according to embodiment 12, wherein the recess is an annular recess without any ends and extends continuously around the outer surface of the lift valve, and the deformation is further defined as deforming the ductile material into the recess to form a connecting portion having an annular shape.

[0064] 14. The method according to embodiment 13, wherein the lifting valve has an outer surface having a first outer diameter and a second outer diameter, the first outer diameter being outside the annular recess, the second outer diameter being adjacent to the bottom of the annular recess, and the second outer diameter being smaller than the first outer diameter.

[0065] 15. The method according to embodiment 12, wherein the lift valve includes a first longitudinal axis extending between the first end and the second end, and the servo axis includes a second longitudinal axis extending from the first end of the servo axis, and positioning the lift valve into the opening is further defined as positioning at least a portion of the lift valve into the opening such that the first longitudinal axis and the second longitudinal axis are co-located and aligned, and such that the lift valve is concentric with the servo axis.

[0066] 16. The method according to embodiment 12, wherein the recess is defined by a bottom and two sidewalls arranged at intervals.

[0067] 17. The method according to embodiment 12, wherein the connecting component is connected to the shaft component of the servo axis.

[0068] As can be clearly seen from the above description, the inventive concepts disclosed and claimed herein are well suited for achieving the objectives and advantages mentioned herein, as well as those inherent in the invention. While exemplary embodiments of the inventive concepts have been described for the purposes of this disclosure, it should be understood that many modifications can be made, which are readily apparent to those skilled in the art and within the spirit of the inventive concepts disclosed and claimed herein.

Claims

1. An electromechanical actuator assembly, comprising: A rotary actuator having an actuator shaft; A servo axis is coupled to the actuator axis such that rotational movement of the actuator axis is converted into linear movement of the servo axis. The servo axis has a first end with an opening extending into the servo axis, such that the servo axis has sidewalls extending about and defining the opening, the sidewalls of the servo axis being at least partially constructed of a ductile material. A housing having an opening aligned with the first end of the servo axis; as well as A lift valve is positioned within the opening of the servo shaft. The lift valve has a first end outside the opening of the servo shaft, a second end inside the opening of the servo shaft, and an outer surface extending between the first end and the second end of the lift valve. The lift valve has a recess formed in the outer surface and positioned between the first end and the second end of the lift valve. The recess of the lift valve is defined by a bottom and at least one sidewall. At least a portion of the ductile material of the sidewall of the servo shaft is positioned within the recess of the lift valve to secure the lift valve to the opening of the servo shaft, thereby preventing the lift valve from moving relative to the servo shaft.

2. The electromechanical actuator assembly according to claim 1, characterized in that, The recess of the lift valve is an annular recess without any ends, and extends continuously around the outer surface of the lift valve.

3. The electromechanical actuator assembly according to claim 2, characterized in that, The outer surface of the lift valve has a first outer diameter and a second outer diameter. The first outer diameter is outside the annular recess of the lift valve, and the second outer diameter is adjacent to the bottom of the annular recess of the lift valve. The second outer diameter is smaller than the first outer diameter.

4. The electromechanical actuator assembly according to claim 1, characterized in that, The lift valve includes a first longitudinal axis extending between the first end and the second end of the lift valve, and the servo axis includes a second longitudinal axis extending from the first end of the servo axis, and the first longitudinal axis and the second longitudinal axis are co-located and aligned such that the lift valve is concentric with the servo axis.

5. The electromechanical actuator assembly according to claim 1, characterized in that, The recess of the lift valve is defined by the bottom and two sidewalls, which are arranged at intervals.

6. A servo axis assembly, comprising: A connecting member having a first end having an opening extending into the connecting member, such that the connecting member has a sidewall extending around the opening and defining the opening, the sidewall of the connecting member being at least partially constructed of a ductile material; A lift valve is positioned within the opening of the connecting member, the lift valve having a first end outside the opening of the connecting member, a second end inside the opening of the connecting member, and an outer surface extending between the first end and the second end of the lift valve, the lift valve having a recess formed in the outer surface and positioned between the first end and the second end of the lift valve, the recess being defined by a bottom and at least one sidewall, at least a portion of the ductile material of the sidewall of the connecting member being positioned within the recess of the lift valve to secure the lift valve to the opening of the connecting member, thereby preventing the lift valve from moving relative to the connecting member.

7. The servo axis assembly according to claim 6, characterized in that, The recess of the lift valve is an annular recess without any ends, and extends continuously around the outer surface of the lift valve.

8. The servo axis assembly according to claim 7, characterized in that, The outer surface of the lift valve has a first outer diameter and a second outer diameter. The first outer diameter is outside the annular recess of the lift valve, and the second outer diameter is adjacent to the bottom of the annular recess of the lift valve. The second outer diameter is smaller than the first outer diameter.

9. The servo axis assembly according to claim 6, characterized in that, The lift valve includes a first longitudinal axis extending between the first end and the second end of the lift valve, the connecting component is part of a servo axis including a second longitudinal axis, and the first longitudinal axis and the second longitudinal axis are co-located and aligned such that the lift valve is concentric with the servo axis.

10. The servo axis assembly according to claim 6, characterized in that, The recess of the lift valve is defined by the bottom and two sidewalls, which are arranged at intervals.

11. The servo axis assembly according to claim 6, characterized in that, The connecting component is part of the servo axis.

12. A method for manufacturing a servo axis assembly, comprising: At least a portion of the lift valve is positioned into an opening in a connecting member that extends into a first end of the connecting member, such that a recess formed in the outer surface of the lift valve is positioned within the opening of the connecting member and surrounded by a sidewall of the first end of the connecting member, at least a portion of the sidewall of the connecting member being constructed of a ductile material aligned with the recess of the lift valve. as well as The ductile material of the connecting member is deformed into the recess of the lift valve to fix the lift valve into the opening of the connecting member, thereby preventing the lift valve from moving relative to the connecting member.

13. The method according to claim 12, characterized in that, The recess of the lift valve is an annular recess without any ends and extends continuously around the outer surface of the lift valve, and the deformation is further defined as deforming the ductile material of the connecting member into the recess of the lift valve to form a connecting portion having an annular shape.

14. The method according to claim 13, characterized in that, The outer surface of the lift valve has a first outer diameter and a second outer diameter. The first outer diameter is outside the annular recess of the lift valve, and the second outer diameter is adjacent to the bottom of the annular recess of the lift valve. The second outer diameter is smaller than the first outer diameter.

15. The method according to claim 12, characterized in that, The outer surface of the lift valve extends between a first end and a second end of the lift valve, the lift valve includes a first longitudinal axis extending between the first end and the second end of the lift valve, the connecting member includes a second longitudinal axis extending from the first end of the connecting member, and positioning the lift valve into the opening of the connecting member is further defined as positioning at least a portion of the lift valve into the opening of the connecting member such that the first longitudinal axis and the second longitudinal axis are co-located and aligned, and such that the lift valve is concentric with the connecting member.

16. The method according to claim 12, characterized in that, The recess of the lift valve is defined by a bottom and two sidewalls that are spaced apart.

17. The method according to claim 12, characterized in that, The connecting component is connected to the shaft component of the servo axis.

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