Flap actuator, method for manufacturing an actuator housing of a flap actuator and aircraft

Abstract

A flap actuator, in particular a servo / spoiler actuator, comprising at least one electro-hydraulic servo valve and at least one actuator which are hydraulically interconnected, wherein the actuator has at least one actuator housing (10) in and / or on which at least one channel (16) is arranged, by means of which one or more components, preferably also arranged in and / or on the actuator housing (10), are hydraulically interconnected, and in that no valve block is arranged between the actuator and the servo valve, characterized in that the functions and components contained in the second stage of the servo valve are partially or completely integrated into the actuator housing (10) and hydraulically interconnected through it.

Description

[0001] The present invention relates to a flap actuator, in particular a servo / spoiler actuator, especially for aircraft, comprising at least one electro-hydraulic servo valve and at least one actuator which are hydraulically interconnected.

[0002] Prior art servo / spoiler actuators consist of the following main components: an electro-hydraulic servo valve (EHSV), the valve block, and the actuator (cylinder or piston), which is moved according to the position of the servo valve. This movement is converted into the desired flap movement. In prior art spoiler actuators, the valve blocks are provided with connecting and transverse bores for transferring the fluid from the servo valve to the actuator. To create closed hydraulic circuits, the bores are subsequently sealed to the environment with press-fit plugs.

[0003] A servo / spoiler actuator of this type is known from US Patent 6,626,205. In this case, the flow channels are machined onto the surface of a core located in the valve block.

[0004] US 5,121,042 A and US 3,902,318 A disclose a flap actuator comprising at least one electrohydraulic servo valve and at least one actuator hydraulically interconnected, wherein the actuator has at least one actuator housing in which at least one channel is arranged by means of which a component preferably also arranged in the actuator housing is hydraulically interconnected, wherein no valve block is arranged between the actuator and the servo valve.

[0005] US 2005 / 0199298 A1 and US 2009 / 0183790 A1 disclose the manufacture of fluid housings using additive manufacturing processes.

[0006] If the flow circuits are created by drilling, as is the case according to the state of the art, transitions at the intersections and interfaces are flow-unfavorable and difficult to define in terms of strength. These transitions must be reworked, for example, by comparatively complex rounding or deburring. In positions where the bores cannot be reached, the interfaces remain sharp-edged. This is disadvantageous because the flow is unfavorable in these areas. Furthermore, sealing the hydraulic circuits with press-fit plugs is disadvantageous because it increases the potential for failures. To ensure the necessary material cross-sections for the press-fit plugs and bores, it is necessary to design the valve blocks to be comparatively large.This has the disadvantage of a correspondingly large height and weight, which are particularly undesirable in the case of aviation applications.

[0007] The present invention is therefore based on the objective of further developing a flap actuator of the type mentioned at the outset in such a way that its height, complexity and weight are reduced compared to known flap actuators.

[0008] This problem is solved by a flap actuator according to the features of claim 1. According to this claim, the actuator has at least one actuator housing in which at least one channel is arranged, by means of which one or more components, preferably also arranged in and / or on the actuator housing, are hydraulically connected, and no valve block is arranged between the actuator and the servo valve.

[0009] The problem is further solved by a method having the features of claim 7.

[0010] The present invention is therefore based on arranging one or more channels in or on the actuator housing, which serve for the hydraulic interconnection of components that may also be arranged in the actuator housing.

[0011] This offers the advantage that the valve block, which is otherwise located between the servo valve and the actuator, can be eliminated, resulting in reduced complexity, weight, and height of the entire flap actuator, particularly the servo / spoiler actuator. The function of the valve block according to the prior art is now partially or completely taken over by the actuator housing. A significant advantage of the present invention is that the flap actuator or servo / spoiler actuator is smaller and lighter than flap actuators known from the prior art. Preferably, all fluid-carrying channels, bores, and lines are designed for optimal flow and integrated into and / or on the cylinder housing, i.e., the actuator housing, in a space-saving manner.

[0012] The term "flap actuator" preferably refers to an arrangement by means of which one or more arbitrary flaps, preferably spoilers, of an aircraft wing can be actuated.

[0013] The components in question, at least one of which is arranged in and / or on the actuator housing, may be one or more of the following: Advanced Blocking Valve (ABV), Maintenance Operator (MO), Thermal Relief Valve (TRV), Check Valve (CV), and Filter (Fi). One or more, or preferably all, of these components are preferably integrated in and / or on the housing of the actuator or cylinder and hydraulically connected.

[0014] Preferably, the actuator housing has a layered structure, either partially or entirely. It is conceivable that the actuator housing is manufactured using an additive manufacturing process. Selective Laser Melting (SLM), for example, is a suitable method.® ), Direct Metal Laser Sintering (DMLS), Lasercusing ® Selective laser sintering, rapid manufacturing, electron beam melting, etc. These processes enable the layer-by-layer construction of the actuator housing or cylinder housing. These processes allow for the creation of bore patterns or channels that cannot be produced using conventional drilling methods. The manufacturing technique according to the invention thus avoids the disadvantages of conventionally manufactured bores. Furthermore, press-fit and sealing plugs are preferably omitted, since the layer-by-layer production of the channels through additive manufacturing can be carried out in such a way that no openings requiring press-fit or sealing plugs are created.

[0015] In a further embodiment of the invention, one or more channels for receiving a hydraulic fluid and / or one or more channels for receiving electrical lines and / or cables and / or one or more receptacles for components, such as valves and filters, are arranged in and / or on the actuator housing. Preferably, the cylinder housing, i.e., the actuator housing with all its channels and component receptacles, is manufactured by selective melting or another layer-by-layer process. This eliminates the need for a valve block.

[0016] As explained, in a preferred embodiment, the actuator housing serves not only to guide the hydraulic fluid, but also to accommodate cables or electrical lines that can be pulled into the channels.

[0017] In a further embodiment of the invention, it is provided that the channel(s) are integrated into the actuator housing and / or run on its surface.

[0018] Instead of the manufacturing processes mentioned above, the invention also includes all processes that operate according to a similar principle.

[0019] According to the invention, the functions and components contained in the 2nd stage (power stage) of the servo valve are integrated into the actuator housing and hydraulically interconnected.

[0020] Furthermore, it may be provided that the supply line and / or the return line are located in the bearing bolt near the pivot axis.

[0021] The present invention further relates to a method for manufacturing an actuator housing of a flap actuator according to the present invention, wherein the manufacturing of the actuator housing is carried out partially or entirely by means of an additive manufacturing process. Examples of such processes include selective laser melting (SLM). ® ), Direct Metal Laser Sintering (DMLS), Lasercusing ® , Selective Laser Sintering, Rapid Manufacturing and Electron Beam Melting.

[0022] A general term for generative processes is "Additive Manufacturing Technologies" (see ASTM International Standard F2792). The terms "Rapid Technologies" or "Rapid Prototyping" are also used (see VDI Guideline VDI 3404).

[0023] It should be noted here that the term "actuator housing" refers to the housing of the actual actuator, in which the hydraulically driven movable element, in particular a piston or the like, is located. The complete flap or servo / spoiler actuator thus comprises at least one servo valve and at least the actual actuator, which in turn includes the actuator housing and the component movably arranged within it. The latter, when installed, is in contact with the flap to be moved.

[0024] The present invention further relates to an aircraft, in particular an airplane, with at least one flap, preferably with at least one spoiler, and at least one flap actuator controlling the flap, the flap actuator being a flap actuator according to the present invention. According to the invention, the flap actuator comprises at least one servo valve and at least one actual actuator, which in turn is directly or indirectly connected to the flap to be moved. This actual actuator can, for example, be designed as a piston-cylinder unit, wherein the cylinder is formed by the actuator housing. A piston or the like can be movably arranged in the cylinder, the piston rod of which is directly or indirectly connected to the flap to be moved. The entire flap actuator is preferably arranged in the wing(s) and / or the vertical stabilizer of the aircraft.Due to the lower overall height of the flap actuator according to the invention, which is essentially due to the elimination of the valve block, a reduction in the wing height of aircraft and a resulting fuel saving can be achieved.

[0025] Further details and advantages of the invention are explained in more detail with reference to an embodiment illustrated in the drawing. The drawing shows: Fig. 1: Different perspective views of the actuator housing with external cables, Fig. 2: Different sectional views through the actuator housing according to Fig. 1, Fig. 3: another sectional view through the actuator housing according to Fig. 1, Fig. 4: a circuit diagram of a spoiler actuator according to the invention and Fig. 5: a circuit diagram of a spoiler actuator according to the invention in a further embodiment.

[0026] In Fig. Figure 1 shows the actuator housing 10, i.e. the cylinder housing of a servo / spoiler actuator according to the present invention, in different perspective views.

[0027] The in Fig. The actuator housing shown in section 1 is manufactured, for example, by selective laser melting (SLM). ® )) manufactured.

[0028] In this process, the material is applied in powder form to a plate and completely melted by laser radiation. After solidification, it forms a solid layer of material. After each layer is created, more powder is applied and the process is repeated, resulting in a multi-layered structure.

[0029] However, the invention also encompasses any other additive manufacturing processes. In these manufacturing processes, the component is generally produced from shapeless materials, such as liquids or powders, or from shape-neutral materials, such as strip or wire-shaped materials, by means of chemical and / or physical processes. Generally, no special tools that define the finished shape of the component, such as molds, are required for the production of a product.

[0030] At the in Fig. The actuator housing shown in Figure 1 is a component of a complete actuator assembly, which includes the actual actuator and a servo valve and is located in a wing of an aircraft.

[0031] The actuator includes the part in Fig. Figure 1 shows an actuator housing 10 and an element guided in its cylinder chamber 14, in particular a piston, the movement of which is transferred to the flap to be moved, in particular to the spoiler. How this is shown from Fig. As can be seen from Figure 1, the actuator housing 10 has a surface 12 onto which the servo valve is placed and attached to it, e.g. by screwing.

[0032] Hydraulic channels 16, and optionally channels 16 through which electrical lines and cables run, are integrated into and on the actuator housing 10. Furthermore, the actuator housing contains the functions and components typically found in the valve block. These include, for example, components such as the Advanced Blocking Valve, Maintenance Operator, Thermal Relief Valve, Check Valve, and Filter. These are located in the Fig. The housing shown in section 1 is integrated with the actuator and hydraulically connected. Furthermore, the cylinder housing contains, according to... Fig. 1. All pipe channels, bores and component mounts are provided. A conventional valve block, as arranged between the servo valve and the actuator in prior art, is omitted, as are press-fit or sealing plugs for sealing hydraulic channels.

[0033] As can be seen from the sectional views according to Fig. As can be seen from Figure 2, the channels 16 of the actuator housing 10 are partially arranged on the surface of the actuator housing, as is also shown in Fig. 1 is evident and is partially integrated into the base body of the actuator housing 10. The channels 16 according to the present invention can therefore be arranged on or in the actuator housing 10.

[0034] Fig. Figure 3 shows another sectional view through the actuator housing 10 according to Fig. Figure 1 illustrates the arrangement of the cylinder chamber 14 in the actuator housing, in which a piston (not shown) is arranged to move back and forth. Reference numeral 12 again designates the mounting surface for fixing or placing a servo valve. A valve block between the servo valve and the actuator housing 10 shown is omitted.

[0035] Fig. Figure 4 shows a circuit diagram that schematically represents the hydraulic lines in the actuator housing. The area enclosed by the dashed line shows the actuator housing. As this is shown from Fig. As can be seen from Figure 4, the actuator housing contains, for example, valves and hydraulic lines. Reference numerals C1 and C2 identify the two hydraulic lines running to the cylinder chambers, and reference numerals BP and RP identify the supply line and return lines, respectively, which may be located in the bearing pin near the pivot axis. As can be seen from... Fig. As can be seen in Figure 4, the electro-hydraulic servo valve (EHSV) with its two stages is mounted directly on the cylinder housing or actuator housing 10. It is conceivable to also house the power stage, i.e., the second stage of the electro-hydraulic servo valve, in the actuator housing 10, as is done in Figure 4. Fig. 5 is shown schematically. In this case, only the first stage of the electro-hydraulic servo valve is placed on or fixed to the actuator housing 10.

[0036] Due to the elimination of the valve housing, the servo / spoiler actuator or flap actuator according to the invention is smaller and lighter than those known from the prior art. Preferably, all fluid-carrying channels, bores, and lines are manufactured with optimized flow characteristics and integrated into or onto the cylinder housing 10 in a space-saving manner. As described above, electrical lines and cables can also be routed through the channels. The preferred additive manufacturing of the cylinder housing 10 allows for the creation of channels that cannot be produced using conventional drilling methods. This offers not only the advantage of optimal flow guidance but also the benefit of eliminating the need for press-fit and sealing plugs, which are required when using conventional valve blocks.

Claims

[1] Flap actuator, in particular servo / spoiler actuator, comprising at least one electro-hydraulic servo valve and at least one actuator which are hydraulically interconnected, wherein the actuator has at least one actuator housing (10) in and / or on which at least one channel (16) is arranged, by means of which one or more components, preferably also arranged in and / or on the actuator housing (10), are hydraulically interconnected, and wherein no valve block is arranged between the actuator and the servo valve. characterized by , that the functions and components contained in the 2nd stage of the servo valve are partially or completely integrated into the actuator housing (10) and hydraulically interconnected through it. [2] Valve actuator according to claim 1, characterized bythat the components are one or more of the following: Advanced Blocking Valve, Maintenance Operator, Thermal Relief Valve, Check Valve and Filter. [3] Valve actuator according to claim 1 or 2, characterized by , that the actuator housing (10) has a layered structure in some areas or overall. [4] Valve actuator according to any of the preceding claims, characterized by , that the actuator housing (10) is partially or completely manufactured by an additive manufacturing process, in particular by selective laser melting, direct metal laser sintering, laser cusing ® , Selective Laser Sintering, Rapid Manufacturing and Electron Beam Melting. [5] Valve actuator according to any of the preceding claims, characterized by, that in and / or on the actuator housing (10) one or more channels (16) for receiving a hydraulic fluid and / or one or more channels (16) for receiving electrical lines and / or cables and / or one or more receptacles for components, such as valves and filters, are arranged and / or that the channel(s) (16) are integrated into the actuator housing (10) and / or run on its surface. [6] Valve actuator according to any of the preceding claims, characterized by that the inlet line and / or the return line are arranged in the bearing bolt near the pivot axis of the flap controlled by the flap actuator. [7] Method for manufacturing an actuator housing (10) of a flap actuator according to any one of claims 1 to 6, characterized by , that the manufacture of the actuator housing (10) is carried out partly or entirely by means of an additive manufacturing process. [8] Method according to claim 7, characterized by, that the manufacture of the actuator housing (10) is carried out using Selective Laser Melting, Direct Metal Laser Sintering, Lasercusing ® , Selective Laser Sintering, Rapid Manufacturing and Electron Beam Melting takes place. [9] Aircraft, in particular airplane, with at least one flap, preferably with at least one spoiler, and at least one flap actuator controlling the flap, characterized by , that the flap actuator is a flap actuator according to one of claims 1 to 6.

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