Flap Actuation System and Related Methods

Abstract

To provide a flap actuation system and an associated method.SOLUTION: An example flap actuation system includes a first actuator, a second actuator, a first drive arm coupled to the first actuator and to a flap, a second drive arm coupled to the second actuator and to the flap, a first cam, and a first output shaft. The first cam is to couple to the first drive part so as to enable the first actuator to actuate the flap via the first drive arm. The example flap actuation system also includes a second cam and a second output shaft. The first cam is to be uncoupled from the first drive arm in response to a failure of the first actuator. The second actuator is to actuate the flap via the first drive arm and the second drive arm in response to the failure of the first actuator.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] This disclosure generally relates to airflow control surfaces of an aircraft vehicle, and more particularly to a flap actuation system and related methods.

Background Art

[0002] An aircraft vehicle (e.g., a fixed-wing aircraft) includes control surfaces coupled to the wings of the aircraft vehicle that are selectively moved to affect the behavior of the aircraft vehicle during takeoff, flight, and / or landing. For example, flaps may be extended during takeoff or landing to increase the lift of the wings and may retract, for example, to reduce drag when the aircraft vehicle reaches cruise altitude. Control surfaces (such as flaps) are coupled to the wings via a support structure.

Summary of the Invention

[0003] An exemplary flap actuation system includes a first actuator, a second actuator, a first drive arm coupled to the first actuator and to the flap, a second drive arm coupled to the second actuator and to the flap, a first cam, and a first output shaft. The first cam is coupled to the first drive arm via the first output shaft during operation of the first actuator to enable the first actuator to move the flap via the first drive arm. The exemplary flap actuation system also includes a second cam and a second output shaft. The second cam is coupled to the second drive arm via the second output shaft during operation of the second actuator to enable the second actuator to move the flap via the second drive arm. The first cam is to be decoupled from the first drive arm in response to a malfunction of the first actuator. The second actuator is to move the flap via the first drive arm and the second drive arm in response to a malfunction of the first actuator.

[0004] An exemplary aircraft includes a flap, a first actuator, a second actuator, a first drive arm coupled to the flap, a second drive arm coupled to the flap, a first coupler for selectively coupling the first actuator to the flap via the first drive arm, and a second coupler for selectively coupling the second actuator to the flap via the second drive arm.

[0005] An exemplary system includes a first actuator, a second actuator, a drive arm coupled to a flap of a vehicle, and a coupler disposed between the first actuator and the drive arm. The coupler includes a cam. The cam is selectively coupled to the drive arm to operably couple the first actuator to the drive arm. This exemplary system also includes a controller for controlling the coupling of the first actuator to the drive arm via the coupler. The controller commands the second actuator to drive the movement of the flap when the cam is decoupled from the drive arm.

Brief Description of the Drawings

[0006]

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DETAILED DESCRIPTION OF THE INVENTION

[0007] The figures are not necessarily to scale. Instead, in the drawings, the thickness of layers or regions may be exaggerated. In general, throughout the drawings (s) and the accompanying description, the same reference numerals are used to indicate the same or similar parts. References to connections (such as attached, coupled, connected, and joined) should be construed broadly and may include intermediate members between sets of elements and relative movement between elements unless otherwise indicated. Thus, references to connections do not necessarily mean that two elements are directly connected and in a fixed relationship to each other.

[0008] Descriptive terms such as "first," "second," "third," etc. are used in this document to identify multiple elements or components that may be referred to separately. Unless otherwise specified or understood based on the context in which they are used, such descriptive terms are not intended to complement any meaning of priority, physical order or arrangement in a listing, or temporal order, and are simply used as labels to refer separately to multiple elements or components to facilitate understanding of the disclosed examples. In some examples, the descriptive term "first" may be used to refer to an element in the detailed description of the invention, while the same element may be referred to by a different descriptive term (such as "second" or "third") in the claims. In such examples, it should be understood that such descriptive terms are used only to facilitate reference to multiple elements or components.

[0009] Some aircraft (such as airplanes) include airflow control wing surfaces (such as flaps) connected to the wings of the aircraft. The flaps can be selectively moved to affect the behavior of the aircraft during one or more flight phases (such as takeoff and / or landing). For example, the flaps can be extended during takeoff or landing to increase the lift of the wings. When the aircraft is in the cruise phase of flight, the flaps can be retracted to reduce drag. The movement of the flaps is controlled by a drive system that includes one or more actuators (such as motors), and the flaps are moved between an extended position and a retracted position via a mechanical support linkage that operably connects the one or more actuators to the flaps.

[0010] For example, the operation of one or more actuators can introduce asymmetry into the flap drive system, thereby applying twisting forces to the one or more flap support linkages. The distortion of the flaps can disrupt the airflow control provided by the flaps. For example, an angular misalignment between two flap support linkages can occur due to distortion conditions, resulting in asymmetry between flap positions during flap deployment. Some known aircraft include one or more sensors for detecting distortion conditions in the flaps, such as by monitoring misalignment between support linkages. If a distortion condition is detected based on sensor data, the flaps may not be deployed. Although distortion can be prevented by stopping flap deployment, the behavior of the aircraft can be affected. For example, the speed at which the aircraft lands can increase because the flaps are not deployed to maintain lift and increase drag to slow down the aircraft.

[0011] Disclosed herein is an exemplary dual drive system for moving the control surfaces (such as flaps) of an aircraft, which reduces cases of distortion conditions and enables the control surface to be moved even when a malfunction occurs in one of the actuators of the drive system. The examples disclosed herein include a first drive system for controlling a first support linkage of a flap and a second drive system for controlling a second support linkage of the flap. The exemplary dual drive system disclosed herein includes a first subsystem including a first actuator and a second drive subsystem including a second actuator. When a malfunction occurs in one of the actuators of the drive subsystem, the actuator of the other drive subsystem can be used to control the movement of the flap via the support linkage. Thus, in the examples disclosed herein, distortion is reduced by the dual drive system associated with each of the flap support linkages. This distortion, if not reduced, could result in a situation where one of the support linkages is unable to provide the movement of the flap due to a malfunctioning actuator in that support linkage.

[0012] In the examples disclosed herein, each drive subsystem of the dual drive system includes a coupler that provides a selective operative connection between the actuator and the corresponding flap support connection. The exemplary coupler disclosed herein includes a cam having a plurality of teeth and an output shaft having a corresponding plurality of teeth. The output shaft is operatively connected to one of the flap support linkages via a drive linkage. For example, during operation of the actuator of the first drive subsystem of the dual drive system, a drive ring engages the teeth of the cam with the teeth of the output shaft. The connection between the cam and the output shaft operatively connects the actuator to the drive linkage and thus to the flap support linkage. The actuator of the first drive subsystem can be used to drive the movement of the flap via the drive linkage and the support linkage (to which the drive linkage is connected).

[0013] For example, if a malfunction occurs in the actuator of the first drive subsystem, the drive ring of the coupler will not be driven by the malfunctioning actuator. As a result, the cam teeth of the coupler will no longer engage with the teeth of the output shaft. Therefore, the exemplary coupler disclosed herein prevents an operational connection between the malfunctioning actuator of the first drive subsystem and the drive linkage of the first drive subsystem connected to the flap support linkage. In such an example, the actuator of the second drive subsystem of the dual drive system can be used to control the movement of the flap via the support linkage without being affected by the malfunctioning actuator of the first drive subsystem. Specifically, the drive linkage associated with the first drive subsystem can be controlled by the actuator of the second drive subsystem. This is because the drive linkage is no longer operably connected to the malfunctioning actuator. Therefore, the asymmetry associated with the drive linkage in a dual drive system including a malfunctioning actuator is reduced. Further, in the example disclosed herein, since the actuator of the second drive subsystem can control the movement of the flap via the corresponding support linkage, each support linkage of the flap is continuously controlled via the actuator, and thus distortion in the flap is prevented. Therefore, in the example disclosed herein, the influence of the malfunctioning actuator is isolated by the dual drive system that provides continuous control of the movement of the flap.

[0014] FIG. 1 shows an exemplary aircraft 100 in which the examples disclosed in this document may be implemented. In this illustrated example, the aircraft 100 includes a plurality of stabilizer plates 102 and a plurality of wings 104 connected to the fuselage 106. Each of the wings 104 defines an upper surface and a lower surface 103, 105 (e.g., upper and lower surfaces, upper and lower aerodynamic surfaces, etc.). The wings 104 of the aircraft 100 have a plurality of control surfaces 108 disposed along the leading edge and / or trailing edge of the wings 104. The control surfaces 108 can be displaced or adjusted (e.g., tilted) to provide lift during takeoff, landing, and / or flight control. In some examples, the control surfaces 108 are operated (i.e., displaced) independently of each other. The control surfaces 108 include a leading edge flap 110, a leading edge slat 112, an upper spoiler 114 (e.g., flight spoiler, ground spoiler, upper surface spoiler, etc.), and a trailing edge flap (e.g., rotatable flap) 116. The illustrated example of the control surfaces 108 also includes auxiliary wings 118 and flaperons 120. In this example, the stabilizer plates 102 include an elevator 122 and a rudder 124.

[0015] The upper spoiler 114 in the illustrated example changes the lift and drag of the aircraft 100 to control the flight of the aircraft 100. The flap 116 changes the lift of the aircraft 100. The illustrated example of the auxiliary wings 118 and flaperons 120 change the roll of the aircraft 100. In this example, the leading edge slat 112 changes the lift of the aircraft 100. The illustrated example of the control surfaces 108 also serves to control the speed of the aircraft 100. For example, the upper spoiler 114 can be used to apply the brakes of the aircraft 100. Any of the illustrated example of the control surfaces 108 can be moved independently (e.g., deflected) to direct the movement of the aircraft 100 by controlling the distribution of loads in various directions across each of the wings 104.

[0016] The examples described in this book can be applied to any control surface associated with the stabilizer 102, wing 104, and / or any other optional external structure or externally mounted structure (e.g., horizontal stabilizer, wing strut, engine strut, tail stabilizer, slat, etc.) of the aircraft 100. Specifically, the wing 104 and / or stabilizer 102 can have a control surface 108 that can be adjusted, for example, to control the aircraft 100 and / or to control the speed of the aircraft 100. Additionally or alternatively, in some examples, the fuselage 106 has a control surface that can be twisted to change the flight control characteristics during cruise and / or takeoff of the aircraft 100. Therefore, the description of the examples disclosed in this book in relation to flaps is for illustrative purposes only and does not limit these examples to use related to flaps.

[0017] FIG. 2 shows an exemplary flap actuation system 200 according to the teachings of this disclosure. The exemplary flap actuation system 200 controls the movement of the flap 202 between an extended position for increasing the lift of a wing (e.g., wing 104 of FIG. 1) including the flap 202 and a retracted position for reducing drag. The exemplary flap actuation system 200 includes a first dual drive system 204 and a second dual drive system 206. The first dual drive system 204 is operably coupled to the flap 202 via a first flap support linkage 208. The second dual drive system 206 is operably coupled to the flap 202 via a second flap support linkage 210. The exemplary flap actuation system 200 can include additional support linkage(s) and corresponding dual drive system(s) in addition to those shown in the example of FIG. 2. Also, the spacing between the flap support linkages 208 and 210 can be different from the example shown in FIG. 2.

[0018] The first dual drive system 204 in FIG. 2 includes a first drive subsystem 205 and a second drive subsystem 207. The first drive subsystem 205 includes a first actuator 212 (e.g., a servo motor). The first actuator 212 is operably connected to the first flap support linkage 208 via a first cycloidal drive 216, a first coupler 218, and a first drive linkage or a first drive arm 219. The second drive subsystem 207 includes a second actuator 220 (e.g., a servo motor). The second actuator 220 is operably connected to the first flap support linkage 208 via a second cycloidal drive 222, a second coupler 224, and a second drive arm 225.

[0019] Similarly, the second dual drive system 206 in FIG. 2 includes a third drive subsystem 209 and a fourth drive subsystem 213. The third drive subsystem 209 includes a third actuator 226 (e.g., a servo motor). The third actuator 226 is operably connected to the second flap support linkage 210 via a third cycloidal drive 228, a third coupler 230, and a third drive arm 231. The fourth drive subsystem 213 includes a fourth actuator 232 (e.g., a servo motor). The fourth actuator 232 is operably connected to the second flap support linkage 210 via a fourth cycloidal drive 234, a fourth coupler 236, and a fourth drive arm 237.

[0020] During operation, the power generated by actuators 212, 220, 226, 232 is used to drive the movement of the drive arms 219, 225, 231, 237 of the respective drive subsystems 205, 207, 209, 213, thereby causing the movement of the respective flap support linkages 208, 210 and thus the flap 202. In the example of FIG. 2, the operation of the actuators 212, 220, 226, 232 and thus the movement of the flap 202 are controlled by the control surface controller 238. The exemplary control surface controller 238 is coupled to communicate with the respective actuators 212, 220, 226, 232 via one or more wired or wireless communication protocols. As disclosed herein, the control surface controller 238 generates commands, which are transmitted to the actuators 212, 220, 226, 232 to control the movement of the flap 202 from a stowed position to one or more of an extended position or a drooped position. In some examples, the commands (if any) generated by the control surface controller 238 control, among other things, the speed at which the flap 202 moves and the period during which the flap 202 is in a particular position.

[0021] In the exemplary flap actuation system 200 of FIG. 2, since each flap support linkage flap 208, 210 is controlled by one of the dual drive systems 204, 206, redundancy in the control of the movement of the flap 202 is provided. As disclosed herein, the couplers 218, 224, 230, 236 of each of the respective drive subsystems 205, 207, 209, 213 of the dual drive systems 204, 206 can operatively isolate or separate the corresponding actuator 212, 220, 226, 232 from the flap 202 if there is a defect in one of the actuators 212, 220, 226, 232 of a particular drive subsystem 205, 207, 209, 213. For example, if a defect occurs in the first actuator 212 of the first drive subsystem 205, the first coupler 218 prevents the operative connection between the first drive arm 219 of the first drive subsystem 205 and the defective first actuator 212. In such an example, the movement of the flap 202 via the first flap support linkage 208 is controlled by the second actuator 220 of the second drive subsystem 207. Since the first drive arm 219 is not operatively connected to the defective first actuator 212, it can move in response to the movement of the second drive arm 225 by the second actuator 212 (i.e., by the connection of each drive arm 219, 225 to the first flap support linkage 208). Thus, the first drive arm and the second drive arm 219, 225 may be used to control the movement of the first flap support linkage 208, and the asymmetry in the first dual drive system 204 is prevented or substantially reduced. Further, due to the redundancy in the actuators 212, 220 of the first dual drive system 204, the first flap support linkage and the second flap support linkage 208, 210 can be continuously used to move the flap 202, so that flap distortion is prevented or substantially reduced despite the defect in the first actuator 212.

[0022] FIGS. 3 and 4 are exploded views of the first drive subsystem 205 of the exemplary first dual drive system 204 of FIG. 2. Although FIGS. 3 and 4 are described in connection with the exemplary first drive subsystem 205 of FIG. 2, the second drive subsystem 207 of the first dual drive system 204 of FIG. 2 includes the same or substantially the same components as the first drive subsystem 205 (e.g., the component(s) of the second drive subsystem are arranged as a reverse image of the components of the first drive subsystem 205). Also, the third drive subsystem 209 and the fourth drive subsystem 213 of the second dual drive system 206 may include the same or substantially the same components as the first drive subsystem 205 shown in FIGS. 3 and 4.

[0023] As shown in FIGS. 3 and 4, the output shaft 300 of the actuator 212 of the first drive subsystem 205 is coupled to the cycloid drive section 216. The output shaft 302 of the cycloid drive section 216 is received by the first coupler 218 so as to operably couple the actuator 212 to the first coupler 218. In the example of FIGS. 3 and 4, the substantially flat side shape of the cycloid drive section 216 serves to reduce the form factor of the first drive subsystem 205 and thus the form factor of the first dual drive system 204 as compared to the form factor that would result if a different type of gear (such as a planetary gear) were used. The reduction in the form factor of the first drive subsystem 205 can help offset the additional space consumption by using dual actuators in each of the flap support linkages 208, 210 (FIG. 2). In other examples, a planetary gear may be used instead of the cycloid drive section to provide gear reduction (if a planetary gear is not used, the gear reduction is provided by the cycloid drive section 216 of FIG. 2). Alternatively, in other examples, a more powerful actuator may be used to directly drive the first coupler 218 without using gear reduction.

[0024] As shown in FIG. 3, the output shaft 304 of the first coupler 218 extends through an opening 306 defined in a rib 308 so that the output shaft 304 can be coupled to the first drive arm 219. In an exemplary aircraft (e.g., aircraft 100 of FIG. 1), the rib 308 is one of a plurality of ribs that define the trailing edge of a wing (e.g., wing 104 of FIG. 1) that includes a flap 202 (FIG. 2). The rib(s) 308 support the trailing edge components of the wing (e.g., flap 202 and flap actuation system 200 of FIGS. 2-4).

[0025] In the example of FIGS. 3 and 4, the first drive arm 219 includes a brake 310. As disclosed herein, the operation of the brake 310 is controlled by the flight control surface controller 238 of FIG. 2. The brake 310 can operate to lock, for example, the first drive arm 219 and thus the flap 202, in a particular position (e.g., during extension of the flap 202). As disclosed herein, in some examples, the brake 310 operates to stiffen the first drive arm 219 and provide a degree of resistance or control over the movement of the first drive arm 219 via the second actuator 220 of the second drive subsystem 207 (FIG. 2) in the event of a malfunction in the first actuator 212.

[0026] FIGS. 5 and 6 are exploded views of the first coupler 218 of the first drive subsystem 205 of the exemplary first dual drive system 204 of FIGS. 2-4. FIGS. 5 and 6 illustrate the first coupler 218 of the first drive subsystem 205, but the second coupler, third coupler, and fourth couplers 224, 230, 236 of the respective second drive subsystem, third drive subsystem, and fourth drive subsystems 207, 209, 213 of FIG. 2 also include components that are the same as or substantially the same as those of the first coupler 218 shown in FIGS. 5 and 6.

[0027] The exemplary first coupler 218 of FIGS. 5 and 6 includes a housing 500, a bearing 502, a drive ring 504, a cam 506, a spring 507, and an output shaft 304. The housing 500 defines an opening 508 for receiving the output shaft 302 of the cycloid drive 216. The output shaft 302 of the cycloid drive 216 extends through the opening 508 of the housing 500 and engages the drive ring 504. In the examples of FIGS. 5 and 6, the teeth 510 of the output shaft 302 of the cycloid drive 216 engage corresponding teeth 512 of the drive ring 504 to enable rotational movement to be transmitted from the cycloid drive 216 to the drive ring 504. The bearing 502 reduces friction between the drive ring 504 and the housing 500 during rotation of the drive ring 504.

[0028] In the examples of FIGS. 5 and 6, the cam 506 is disposed between the drive ring 504 and the output shaft 304. As shown in FIGS. 5 and 6, the drive ring 504 includes a first protrusion 515 and a second protrusion 517 extending from the body of the drive ring 504. As disclosed herein, the protrusions 515, 517 of the drive ring 504 are in contact with the cam 506 to transmit motion from the drive ring 504 to the cam 506. The drive ring 504 may include more or fewer protrusions than the exemplary protrusions 515, 517 shown in FIGS. 5 and 6, and / or protrusions having a shape and / or size different from such exemplary protrusions 515, 517.

[0029] As shown in FIG. 5, the cam 506 includes a set of teeth 514, and the output shaft 304 includes a set of teeth 516. As shown in FIG. 6, the housing 500 includes a set of teeth 600 defined inside the housing 500. During operation, the cam 506 selectively moves between a first position where the teeth 514 of the cam 506 engage the teeth 600 of the housing 500 and a second position where the teeth 514 of the cam 506 engage the teeth 516 of the output shaft 304. Specifically, as disclosed herein, the rotational movement of the drive ring 504 translates the cam 506 from a first position where the teeth 514 of the cam 506 engage the teeth 600 of the housing 500 to a second position where the teeth 514 of the cam 506 engage the teeth 516 of the output shaft 304.

[0030] As shown in FIGS. 5 and 6, the spring 507 is disposed between the cam 506 and the output shaft 304. When the cam 506 is in a first position where the teeth 514 of the cam 506 engage the teeth 600 of the housing 500, the spring 507 is in an extended position. The spring 507 serves to maintain the engagement between the teeth 600 of the housing 500 and the teeth 514 of the cam 506 in order to maintain the position of the cam 506 within the housing 500. When the cam 506 moves to a second position where the teeth 514 of the cam 506 engage the teeth 516 of the output shaft 304, the spring 507 is compressed as a result of the translation of the cam 506.

[0031] FIGS. 7 and 8 illustrate the relationship between the drive ring 504, the cam 506, and the output shaft 304 of the exemplary first coupler 218 of FIGS. 5 and 6. For clarity, the housing 500 is not shown in FIGS. 7 and 8.

[0032] In FIG. 7, the cam 506 is in a first position where the tooth 514 engages with the tooth 600 (FIG. 6) of the housing 500. As shown in FIGS. 7 and 8, the cam 506 includes one or more ramps 702 (i.e., surfaces (plural) having a partial gradient) defined by the body of the cam 506. When the drive ring 504 rotates, the protrusion(s) (e.g., the first protrusion 515 shown in FIGS. 7 and 8) of the drive ring 504 move along the ramp 702 of the cam 506 as indicated by the arrow 704 in FIG. 7. The movement of the protrusion 515 of the drive ring 504 along the ramp 702 of the cam 506 causes a translation of the cam 506 with respect to the output shaft 304 as indicated by the arrow 800 in FIG. 8. As a result of the rotational movement of the drive ring 504 and the corresponding translation of the cam 506, the cam 506 moves from a first position where the tooth 514 of the cam 506 engages with the tooth 600 of the housing 500 to a second position where the tooth 514 of the cam 506 engages with the tooth 516 of the output shaft 304 (FIGS. 5 and 6).

[0033] As shown in FIGS. 7 and 8, the cam 506 includes one or more protrusions or stops 706 proximal to the ramp 702. When the protrusion 515 of the drive ring 504 (and / or the protrusion 517 shown in FIGS. 5 and 6) engages with one of the stops 706 of the cam 506, the rotational movement of the drive ring 504 is transmitted to the output shaft 304 through the connection between the drive ring 504, the cam 506, and the output shaft 304. The connection between the protrusions 515, 517 of the drive ring 504 and the stop(s) 706 of the cam 506 helps to maintain the engagement of the cam 506 with the output shaft 304 and enables the transmission of rotational movement between the drive ring 504 and the output shaft 304. The rotation of the output shaft 304 causes the movement (e.g., pivoting) of the first drive arm 219 (FIGS. 2 to 4) connected to the output shaft 304. Thus, the connection between the drive ring 504, the cam 506, and the output shaft 304 enables the actuator 212 of the first drive subsystem 205 to control the movement of the first drive arm 219 connected to the output shaft 304 (FIGS. 2 to 6).

[0034] FIG. 9 and FIG. 10 are cross-sectional views of an exemplary first drive subsystem 205 taken along line A-A of FIG. 4. In FIG. 9, the first drive subsystem 205 is in a first operating state in which the teeth 514 of the cam 506 engage the teeth 600 of the housing 500. As shown in FIG. 9, the spring 507 is in an uncompressed or extended position and serves to maintain the engagement between the teeth 514 of the cam 506 and the teeth 600 of the housing 500.

[0035] FIG. 10 shows an exemplary first drive subsystem 205 in a second operating state in which the teeth 514 of the cam 506 engage the teeth 516 of the output shaft 304. As described above, the rotation of the cycloid drive section 216, the rotation of the drive ring 504, and the operation of the first actuator 212 that causes the corresponding parallel movement of the cam 506 cause the teeth 514 of the cam 506 to move and engage the teeth 516 of the output shaft 304. As shown in FIG. 10, when the teeth 514 of the cam 506 engage the teeth 516 of the output shaft 304, the spring 507 is in a compressed position due to the parallel movement of the cam 506.

[0036] Referring generally to FIGS. 2 through 10, when the teeth 514 of the cam 506 of the exemplary first drive subsystem 205 of FIGS. 2 through 10 engage the teeth 516 of the output shaft 304, the first actuator 212 is operably coupled to the first drive arm 219 and thus to the first flap support linkage 208 of the flap 202. The first actuator 212 controls the movement of the first flap support linkage 208 via the rotation of the drive ring 504. The rotation of the drive ring 504 causes a corresponding rotation of the output shaft 304 by virtue of the connection between the drive ring 504, the cam 506, and the output shaft 304. The rotation of the output shaft 304 drives the movement of the first drive arm 219. Also, the second actuator 220 of the second drive subsystem 207 of the dual drive system 204 is operably coupled to the second drive arm 225 in substantially the same manner as described in connection with the first drive subsystem 205. The actuators 212, 220 drive the movement of the first flap support linkage 208 via the drive arms 219, 225 so as to move the flap 202 up and down (i.e., in concert with the movement of the second flap support linkage 210 controlled by the second dual drive system 206).

[0037] When the flap 202 is in the stowed position, the actuators 212, 220, 226, 232 do not generate power to move the flap 202 (e.g., based on commands (s) from the control surface controller 238). Thus, for example, the drive ring 504 of the first coupler 218 of the first drive subsystem 205 is not driven by the first actuator 212. Since the drive ring 504 does not rotate, the connection between the teeth 514 of the cam 506 and the teeth 516 of the output shaft 304 is not maintained. As a result, the spring 507 extends and presses on the cam 506, whereby the teeth 514 of the cam 506 disengage from the teeth 516 of the output shaft 304 and re-engage the teeth 600 of the housing 500. As a result, the first actuator 212 is no longer operably coupled to the first drive arm 219 and thus also not operably coupled to the first support linkage 208 of the flap 202.

[0038] The selective coupling between the cam 506 and the output shaft 304 may be used in the event of a failure of the first actuator 212 or the first cycloidal drive 216 of the first drive subsystem 205. In particular, when the first actuator 212 and / or the first cycloidal drive 216 are in a failed state, the flight control surface controller 238 commands the first actuator 212 to cease generating power. As a result, the first actuator 212 ceases to generate power. This power, if generated, would cause the drive ring 504 to facilitate coupling between the teeth 514 of the cam 506 and the teeth 516 of the output shaft 304. In such an example, the teeth 514 of the cam 506 are not engaged with the teeth 516 of the output shaft 304, and therefore the first drive arm 219 is not operatively coupled to the first actuator 212. The first drive arm 219 is therefore free to be controlled by the second actuator 220 of the second drive subsystem 207 of FIG. 2. In particular, the first drive arm 219 is free to pivot in conjunction with the pivoting of the second drive arm 225 controlled by the second actuator 220 of the second drive subsystem 207 (i.e., due to the connection between both drive arms 219, 225 and the first flap support linkage 208).

[0039] Therefore, when a problem occurs in the first actuator 212 and / or the first cycloid drive unit 216, the actuator 212 of the first drive subsystem 205 is operatively isolated or separated from the first drive arm 219 and does not interfere with the movement of the first flap support linkage 208. Since the movement of the first drive arm 219 is not obstructed by the malfunctioning actuator 212, the asymmetry in the first drive subsystem 205 caused by the malfunctioning actuator 212 and / or the malfunctioning cycloid drive 216 is minimized. Instead, since the teeth 514 of the cam 506 of the first coupler 218 do not engage with the teeth 516 of the output shaft 304, the first drive arm 219 is not operatively connected to the malfunctioning actuator 212. In some examples, when a problem occurs in the first actuator 212, the brake 310 (FIG. 3) of the first drive subsystem 205 may operate (e.g., in response to a command from the control surface controller 238) to provide a certain degree of resistance and improve the control of the movement of the first drive arm 219 through the corresponding movement of the second drive arm 225 of the second drive subsystem 207.

[0040] Furthermore, since the first flap support linkage 208 can be controlled by the second actuator 220 of the second drive subsystem 207 when a problem occurs in the first actuator 212 and / or the first cycloid drive unit 216 of the first drive subsystem 205, distortion in the flap 202 is prevented or substantially reduced as compared to the case where only one actuator for controlling the first flap support linkage 208 exists. In such a case, if a problem occurs in the single actuator, the first flap support linkage 208 will stop operating, and distortion will occur between the portion of the flap 202 connected to the first flap support linkage 208 and the portion of the flap 202 connected to the second flap support linkage 210 that is moved by an operable or problem-free actuator(s). However, in the examples disclosed herein, due to the redundancy of the actuators 212, 220, 226, 232 in each of the dual drive systems 204, 206, even if a problem occurs in one of the actuators 212, 220 of the first dual drive system 204 and / or one of the actuators 226, 232 of the second dual drive system 206, both the flap support linkages 208, 210 can be moved.

[0041] Figures 11 to 15 show exemplary operational relationships between the first drive subsystem 205 and the second drive subsystem 207 during the operation of the first actuator 212 (FIG. 2) of the first drive subsystem 205 and the second actuator 220 (FIG. 2) of the second drive subsystem 207. Although described in relation to the first drive subsystem 205 and the second drive subsystem 207 of the first dual drive system 204 for FIGS. 11 to 15, the operational relationship between the third drive subsystem 209 and the fourth drive subsystem 213 can be substantially the same as the relationship between the first drive subsystem 205 and the second drive subsystem 207 of the first dual drive system 204.

[0042] Also, for purposes of illustration, only the drive ring 504 and the cam 506 of the first drive subsystem 205 are shown in FIGS. 11 through 15. Also, for purposes of illustration, only the drive ring 1100 and the cam 1102 of the second drive subsystem 207 are shown in FIGS. 11 through 15. In the examples of FIGS. 11 through 15, the drive ring 1110 and the cam 1102 of the second drive subsystem 207 are substantially the same as the drive ring 504 and the cam 506 of the first drive subsystem 205.

[0043] FIG. 11 shows the first drive subsystem 205 and the second drive subsystem 207 in the first operating state shown in FIG. 9. In this disengaged state, the teeth of the respective cams 506, 1102 of the drive subsystems 205, 207 (e.g., the teeth 514 of the cam 506 in FIGS. 5 through 10) are not engaged with the teeth of the output shafts of the respective drive subsystems 205, 207 (e.g., the teeth 516 of the output shaft 304 in FIGS. 5 through 6). Rather, the first drive subsystem and the second drive subsystems 205, 207 are in the first operating state shown in the example of FIG. 9 (e.g., the teeth 514 of the cam 506 are engaged with the teeth 600 of the housing 500 and the spring 507 is in the extended position).

[0044] FIG. 12 shows each of the exemplary first drive subsystem and the second drive subsystem 205, 207 in the second operating state shown in FIG. 10. In this state, the teeth of the cams 506, 1102 of the respective drive subsystems 205, 207 are engaged with the teeth of the output shafts of the respective drive subsystems 205, 207 as shown in FIG. 10 (e.g., the spring 507 is in the compressed position).

[0045] FIG. 13 shows the operation of the first drive subsystem and the second drive subsystem during the extension of a flap (e.g., flap 202 of FIG. 2). The flap can extend, for example, during takeoff or landing. During operation, there can be a lag time between when the cycloid drives 216, 222 (FIG. 2) of each drive subsystem 205, 207 move their respective drive rings 504, 1100 and when the cams 506, 1102 of each drive subsystem engage the corresponding output shaft 304. During operation, due to the aerodynamic load on the flap (e.g., flap 202 of FIG. 2), the flap may be returned to the retracted position. The time difference in the movement of the cams means that if the actuators 212, 220 of the first dual drive system 204 are in the same rotational position during operation, the aerodynamic load on the flap could move the flap naturally. To prevent such an effect, the respective actuators 212, 220 of the first drive subsystem and the second drive subsystem 205, 207 perform alternating agonist / antagonist roles. For example, during the extension of the flap, the first actuator 212 is used to drive the movement of the first flap support linkage 208 (FIG. 2) and thus acts as an effector or prime mover for driving the movement of the flap. In this example, the second actuator 220 of the second drive subsystem acts as an antagonist by providing a reverse torque that helps control the movement of the flap via the first flap support linkage 208. As a result of this reverse rotation configuration of the actuators 212, 220, even if there is a tendency for the flap to move naturally due to the aerodynamic load, it is eliminated or substantially eliminated by the generation of the reverse torque. In another example, the second actuator 220 of the second drive subsystem acts as an effector or prime mover during the extension of the flap.

[0046] FIG. 14 shows the operations of the first drive subsystem and the second drive subsystem during flap retraction. The second actuator 220 of the second drive subsystem 207 serves as a prime mover or actuating force to drive the movement of the first flap support linkage 208 to move the flap from the extended position to the retracted position in order to reduce the fatigue load on the first actuator 212 of the first drive subsystem 205. In this example, the first actuator 212 of the first drive subsystem 205 serves as an antagonist by providing a reverse torque that controls the movement of the first flap support linkage 208 as described above. In other examples, the first actuator 212 of the first drive subsystem 205 acts as an effector or prime mover during flap retraction.

[0047] FIG. 15 shows the first drive subsystem and the second drive subsystems 205, 207 in a disengaged state, in which the teeth of the cams 506, 1102 are not engaged with the teeth of the output shafts of the respective first drive subsystem and second drive subsystems 205, 207. The first drive subsystem and the second drive subsystems 205, 207 return to the first operating state illustrated in the example of FIG. 9 (i.e., the state in which the teeth 514 of the cam 506 are engaged with the teeth 600 of the housing 500 and the spring 507 is in the extended position). The first drive subsystem and the second drive subsystems 205, 207 can return to the first operating state, for example, during the cruise phase of an aircraft.

[0048] As disclosed in this book, for example, when a malfunction occurs in the first actuator 212 of the first drive subsystem 205, the first actuator 212 stops generating power. Therefore, the cam 506 of the first drive subsystem 205 does not engage with the output shaft 304 of the first drive subsystem 205. In such an example, the second actuator 220 of the second drive subsystem 207 controls the operation of the flap during extension and / or retraction of the flap. Therefore, in the examples of FIGS. 11 to 15, the first drive subsystem 205 remains in the first operating state of FIG. 11. The second drive subsystem 207 moves to the second operating state shown in FIGS. 12 to 14, and extends and retracts the flap through the operating connection between the second actuator 220 and the second drive arm 225 of the second drive subsystem 207.

[0049] Conversely, when a malfunction occurs in the second actuator 220 of the second drive subsystem 207, the second actuator 220 stops generating power. Therefore, the cam 1102 of the second drive subsystem 207 does not engage with the output shaft of the second drive subsystem 207, and the second drive subsystem 207 remains in the first operating state of FIG. 11. In such an example, the first actuator 212 of the first drive subsystem 205 controls the operation of the flap during extension and / or retraction of the flap. The first drive subsystem 205 moves to the second operating state shown in FIGS. 12 to 14, and extends and retracts the flap through the operating connection between the actuator 212 and the second drive arm 225 of the second drive subsystem 207.

[0050] Regarding FIGS. 3 to 15, although mainly described in association with the first drive subsystem 205 of FIG. 2, the examples disclosed in this book can be applied to any of the second, third, and / or fourth drive subsystems 207, 209, 213 of the first dual drive system and / or the second dual drive systems 204, 206.

[0051] FIG. 16 is a block diagram of an exemplary implementation of the control surface controller 238 of FIG. 2. As described above, the control surface controller 238 is constructed to generate command(s) to be sent to the actuators 212, 220, 226, 232 of the drive subsystems 205, 207, 209, 213 of the exemplary dual drive systems 204, 206 of FIG. 2 to control the movement of the flap 202. In the example of FIG. 16, the control surface controller 238 is implemented by one or more processors (e.g., processors (s) mounted on an aircraft including the flap 202), and / or cloud-based device(s) (e.g., server(s), processor(s), and / or virtual machine(s)).

[0052] The exemplary control surface controller 238 includes an actuator controller 1600. The actuator controller 1600 of FIG. 16 provides means for controlling the operation of the actuators 212, 220, 226, 232 of the drive subsystems 205, 207, 209, 213 of the exemplary dual drive systems 204, 206 from FIGS. 2 to 15. For example, the actuator controller 1600 generates commands that cause the actuators to generate the power used to drive the movement of the flap 202 between the stowed position and the extended position. In some examples, the actuator controller 1600 commands the actuators 212, 220, 226, 232 to generate power based on user input(s) received in a flight control system(s) that communicates with the control surface controller 238. The user input(s) may include commands to move the flap 202 to a specific position. In some examples, the actuator controller 1600 commands the actuators 212, 220, 226, 232 to stop generating power, for example, when the flap 202 is in the stowed position. In some examples, the actuator controller 1600 of FIG. 16 controls the operation of the actuators 212, 220, 226, 232 with respect to the operation of the actuators 212, 220, 226, 232 as prime movers during the movement of the flap 202 and the operation of such actuators 212, 220, 226, 232 as counteracting devices in certain drive subsystems 205, 207, 209, 213.

[0053] The actuator controller 1600 of the exemplary control surface controller 238 of FIG. 16 controls the operation of the actuators 212, 220, 226, 232 based on one or more actuator operation rules 1602. The actuator operation rule(s) 1602 may be defined by one or more user inputs and stored in a database 1604. In some examples, the exemplary control surface controller 238 includes the database 1604. In other examples, the database 1604 is located external to the control surface controller 238, in a location accessible to the controller, as shown in FIG. 16.

[0054] The exemplary control surface controller 238 of FIG. 16 includes an actuator malfunction detector 1606. The actuator malfunction detector 1606 detects a malfunction condition in each of the actuators 212, 220, 226, 232 based on data generated, for example, by sensors of the actuators 212, 220, 226, 232. For example, if the output of a sensor of a particular actuator 212, 220, 226, 232 does not meet a threshold value, or if the output value of this sensor does not change during a threshold period, the actuator malfunction detector 1606 detects a malfunction condition in this actuator 212, 220, 226, 232. The actuator malfunction detector 1606 may identify that the actuators 212, 220, 226, 232 are in a malfunction state based on actuator operation rules 1602 stored in the database 1604. The actuator operation rules 1602 may define the predicted output(s) for the actuators 212, 220, 226, 232, and this predicted output(s) is used by the actuator malfunction detector 1606 to identify that the actuators 212, 220, 226, 232 are in a malfunction state (e.g., based on a comparison(s) between the actual output(s) and the predicted output(s) of the actuators 212, 220, 226, 232).

[0055] In the example of FIG. 16, when the actuator malfunction detector 1606 detects that one or more of the actuators 212, 220, 226, 232 have malfunctions, it communicates the malfunction status of the actuators 212, 220, 226, 232 to the actuator controller 1600. In response, the actuator controller 1600 prevents the malfunctioning actuators 212, 220, 226, 232 from generating power (for example, by instructing the malfunctioning actuators 212, 220, 226, 232 to power down, or by ensuring that the malfunctioning actuators 212, 220, 226, 232 do not operate if their power is already off, etc.). As a result, the malfunctioning actuators 212, 220, 226, 232 stop generating power, and thus the cams 506 of the first couplers 218 of the respective drive subsystems 205, 207, 209, 213 do not engage with the corresponding output shafts 304 of the drive subsystems 205, 207, 209, 213. Therefore, as disclosed in this document, the first drive arms 219 of the respective drive subsystems 205, 207, 209, 213 that include the malfunctioning actuators 212, 220, 226, 232 are freely moved via another (non-malfunctioning) actuator 212, 220, 226, 232 of the corresponding dual drive systems 204, 206.

[0056] The exemplary control surface controller 238 of FIG. 16 includes a cycloid drive unit malfunction detector 1607. The cycloid drive unit malfunction detector 1607 detects a malfunction state in one or more of the cycloid drive units 216, 222, 228, 234 based on, for example, one or more cycloid drive unit operation rules 1609 stored in the database 1604 and data generated by sensors associated with the cycloid drive units 216, 222, 228, 234 and / or sensors associated with the corresponding actuators 212, 220, 226, 232. The cycloid drive unit operation rule(s) 1609 may be defined by user input(s) and include the predicted speed and / or position of the operating cycloid drive units 216, 222, 228, 234.

[0057] In the example of FIG. 16, when the cycloid drive unit defect detector 1607 detects that one or more of the cycloid drive units 216, 222, 228, 234 have a defect, it communicates the defect state of the cycloid drive units 216, 222, 228, 234 to the actuator controller 1600. In response, the actuator controller 1600 prevents the actuators 212, 220, 226, 232 associated with the defective cycloid drive units 216, 222, 228, 234 from generating power (for example, by instructing the actuators 212, 220, 226, 232 to turn off the power supply, preventing the actuators 212, 220, 226, 232 from operating, etc.). As a result, since the actuators 212, 220, 226, 232 no longer generate power, the defective cycloid drive units 216, 222, 228, 234 do not rotate, and thus do not drive the movement of the drive ring 504. Therefore, the cams 506 of the first couplers 218 of the respective drive subsystems 205, 207, 209, 213 do not engage with the output shafts 304 of the drive subsystems 205, 207, 209, 213. Thus, as disclosed herein, the first drive arms 219 of the respective drive subsystems 205, 207, 209, 213 including the defective cycloid drive units 216, 222, 228, 234 are freely moved by another actuator 212, 220, 226, 232 of the corresponding dual drive system 204, 206.

[0058] The exemplary control surface controller 238 of FIG. 16 includes a brake actuator 1608. The brake actuator 1608 provides means for controlling the actuation or release of the brakes 310 of the respective drive subsystems 205, 207, 209, 213. In some examples, the brake actuator 1608 generates commands that move the brake 310 from the release position to the actuation position that supports the first drive arm 219 when the flap 202 is, for example, in the raised position, locking the first drive arm 219 and thus positioning the flap 202 at a specific position. In some examples, the brake actuator 1608 generates commands that move the brake 310 from the actuation position to the release position while the flap is moving, for example, from the raised position to the retracted or stowed position. The brake actuator 1608 controls the brake 310 based on one or more brake actuation rules 1610 defined by user input(s) and stored in the database 1604.

[0059] In some examples, when the actuator malfunction detector 1606 detects that one of the actuators 212, 220, 226, 232 of the drive subsystems 205, 207, 209, 213 has a malfunction and / or when the cycloid drive unit malfunction detector 1607 detects that one of the cycloid drive units 216, 222, 228, 234 has a malfunction, the brake actuator 1608 commands the brakes 310 of the specific drive subsystems 205, 207, 209, 213 to move from the release position to the actuation position. In such examples, actuating the brakes 310 of the drive subsystems 205, 207, 209, 213 includes providing a degree of resistance and control to the first drive arm 219 of the drive subsystems 205, 207, 209, 213 when the malfunctioning actuators 212, 220, 226, 232 and / or the malfunctioning cycloid drive units 216, 222, 228, 234 cause the first drive arm 219 to be moved via another actuator 212, 220, 226, 232 of the dual drive systems 204, 206.

[0060] FIG. 16 shows an exemplary manner of implementing the control surface controller 238 of FIG. 2, but one or more of the elements, processes, and / or devices shown in FIG. 16 may be combined, divided, reconfigured, omitted, eliminated, and / or implemented in any other way. Further, the exemplary actuator controller 1600, exemplary database 1604, exemplary actuator malfunction detector 1606, exemplary cycloid drive unit malfunction detector 1607, exemplary brake actuator 1608, and / or, more generally, the exemplary control surface controller 238 of FIG. 16 may be implemented by hardware, software, firmware, and / or any combination of hardware, software, and / or firmware. Thus, for example, any of the exemplary actuator controller 1600, exemplary database 1604, exemplary actuator malfunction detector 1606, exemplary cycloid drive unit malfunction detector 1607, exemplary brake actuator 1608, and / or, more generally, the exemplary control surface controller 238, can be implemented by one or more analog or digital circuits(s), logic circuits, programmable processor(s), programmable controller(s), graphics processing unit(s) (GPU), digital signal processor(s) (DSP), application specific integrated circuit(s) (ASIC), programmable logic device(s) (PLD), and / or field programmable logic device(s) (FPLD).If any of the claims of this patent for an apparatus or system are construed to cover only embodiments of pure software and / or firmware, then, by this document, at least one of the exemplary actuator controller 1600, exemplary database 1604, exemplary actuator fault detector 1606, exemplary cycloid drive fault detector 1607, and / or exemplary brake actuator 1608 is expressly defined to include a non-transitory computer-readable storage device or storage disk (such as a memory, digital versatile disk (DVD), compact disk (CD), Blu-ray disk, etc.) containing software and / or firmware. Further, the exemplary control surface controller 238 of FIG. 16 may include one or more elements, processes, and / or devices in addition to or in place of those shown in FIG. 16, and / or may include two or more of any or all of the elements, processes, and devices shown. As used herein, the phrase "in communication" includes direct and / or indirect communication through one or more intermediate components, including variations thereof, and does not require direct and physical (e.g., wired) communication, and / or constant communication, but rather additionally includes selectively communicating at periodic intervals, at predetermined intervals, at aperiodic intervals, and / or in one-time events.

[0061] FIG. 17 is a flow diagram of an exemplary method for assembling a drive subsystem (e.g., drive subsystems 205, 207, 209, 213 of FIG. 2) of a dual drive system (e.g., dual drive systems 204, 206 of FIG. 2) for moving a control surface (e.g., flap 202 of FIG. 2) of an aircraft vehicle in accordance with the teachings of this disclosure. The exemplary method 1700 begins by coupling an actuator to a cycloid drive (block 1702). For example, the actuator 212 of FIGS. 2-5 is coupled to the cycloid drive 216 via the output shaft 300 of the actuator 212.

[0062] Exemplary method 1700 includes coupling means for operably coupling an actuator to a drive arm of a drive subsystem to a cycloidal drive (block 1704). For example, the first coupler 218 of FIGS. 2-10 is coupled to the cycloidal drive 216 via the output shaft 302 of the cycloidal drive 216. In this example, the output shaft 302 of the cycloidal drive 216 extends through the opening 508 of the housing 500 of the first coupler 218. The output shaft 302 of the cycloidal drive 216 is coupled to the drive ring 504 of the first coupler 218. Specifically, the teeth of the output shaft 302 of the cycloidal drive 216 engage the teeth 512 of the drive ring 504 to operably couple the actuator 212 to the first coupler 218.

[0063] Exemplary method 1700 includes coupling the output shaft of the means for operable coupling with the drive arm of the drive subsystem (block 1706). For example, the output shaft 304 of the first coupler 218 is coupled to the first drive arm 219 of the exemplary drive subsystem 205 of FIG. 2. In some examples, the output shaft 304 extends through the opening 306 of the rib 308 of the first drive subsystem 205 and is coupled to the first drive arm 219.

[0064] Exemplary method 1700 includes coupling a brake to the drive arm (block 1708). For example, the brake 310 of FIGS. 3 and 4 is coupled to the first drive arm 219 to lock the first drive arm 219 in a particular position.

[0065] Although exemplary method 1700 has been described with reference to the flow diagram shown in FIG. 17, a number of other methods of assembling the drive subsystem of a dual drive system may alternatively be used. For example, the order in which the blocks are executed may be changed and / or some of the blocks described may be changed, eliminated, or combined. Similarly, the exemplary method of FIG. 17 may include additional operations before, between, or after the blocks shown in FIG. 17.

[0066] FIG. 18 shows a flow diagram representing exemplary hardware logic, machine-readable instructions, hardware-implemented state machines, and / or any combination thereof for implementing the control surface controller 238 of FIG. 2 and / or FIG. 17. The machine-readable instructions can be one or more executable programs, or portions (plurals) of executable programs, that are executed by a computer processor (e.g., the processor 1912 shown in the exemplary processor platform 1900 described below in connection with FIG. 19). The program can be embodied in software stored on a non-transitory computer-readable storage medium (e.g., a CD-ROM, floppy disk, hard drive, DVD, Blu-ray disk, or memory associated with the processor 1912), but alternatively, all and / or portions of the program can be executed by devices other than the processor 1912 and / or can be embodied in firmware or dedicated hardware. Further, although an exemplary program is described with reference to the flow diagram shown in FIG. 19, alternatively, a number of other different ways of implementing the exemplary control surface controller 238 can be used. For example, the order in which blocks are executed can be changed and / or some of the blocks described can be changed, deleted, or combined. Additionally or alternatively, all or any of the blocks can be implemented by one or more hardware circuits (e.g., discrete or integrated analog and / or digital circuitry, FPGA (field programmable gate array), ASIC, comparator, operational amplifier (op-amp), logic circuit, etc.) constructed to perform the corresponding operations without executing software or firmware.

[0067] The machine-readable instructions described in this book can be stored in one or more of a compressed form, an encoded form, a fragmented form, a compiled form, an executable form, a packaged form, etc. The machine-readable instructions described in this book can be stored as data (e.g., instruction portions, code, code representations, etc.) that can be used to create, generate, and / or produce machine-executable instructions. For example, the machine-readable instructions can be fragmented and stored in one or more storage devices and / or computing devices (e.g., servers). The machine-readable instructions may require one or more of installation, modification, adaptation, update, composition, supplementation, configuration, decoding, deployment, decompression, distribution, reassignment, compilation, etc. in order to be directly readable, interpretable, and / or executable by a computing device and / or other machines. For example, the machine-readable instructions may be stored as multiple parts, and such multiple parts may be individually compressed, encoded, and stored in separate computing devices. When such multiple parts are decoded, decompressed, and composed, they form a set of executable instructions that implement a program (such as those described in this book).

[0068] In another example, the machine-readable instructions can be stored in a computer-readable state, but may require the addition of a library (e.g., a dynamic link library (DLL)), a software development kit (SDK), an application programming interface (API), etc.) in order to execute the instructions on a specific computing device or other device. In another example, the machine-readable instructions may need to be configured (e.g., storage of settings, data input, recording of network addresses, etc.) before the machine-readable instructions and / or the corresponding program(s) can be executed in whole or in part. Therefore, the disclosed machine-readable instructions and / or the corresponding program(s) are intended to encompass such machine-readable instructions and / or program(s) regardless of the specific form or state of the machine-readable instructions and / or program(s) at the time of storage or (if not stored) at rest or during transmission.

[0069] The machine-readable instructions described in this book can be expressed in any past, present, or future instruction language, scripting language, programming language, and the like. For example, the machine instructions can be expressed using any of C, C++, Java, C#, Perl, Python, JavaScript, Hypertext Markup Language (HTML), Structured Query Language (SQL), Swift, and the like.

[0070] As described above, the exemplary process of FIG. 19 can be implemented using executable instructions (e.g., computer-readable instructions and / or machine-readable instructions) stored on a non-transitory computer-readable medium and / or machine-readable medium (e.g., a hard disk drive, flash memory, read-only memory, compact disk, digital versatile disk, cache, random access memory, and / or any other storage device or storage disk on which information is stored for any period of time (e.g., long term, permanently, short term, for temporary buffering, and / or for caching of information)). As used in this book, the term "non-transitory computer-readable medium" is explicitly defined to include any kind of computer-readable storage device and / or storage disk and to exclude propagation signals and transmission media.

[0071] "Including" and "comprising" (and all forms and tenses thereof) are used in this document as open-ended terms. Thus, in a claim, any form of "including" or "comprising" (e.g., comprises, includes, comprising, including, having, etc.) used as a preamble or in any type of claim recitation shall always be understood to mean that additional elements, terms, etc. may exist without falling outside the scope of the corresponding claim or recitation. As used in this document, the expression "at least" is open-ended in the same manner as the terms "comprising" and "including" when used as a transition term, e.g., in the preamble of a claim. The term "and / or" when used, for example, in the form A, B, and / or C, refers to any combination or subset of A, B, and C (e.g., (1) only A, (2) only B, (3) only C, (4) A and B, (5) A and C, (6) B and C, and (7) A, B, and C). The expression "at least one of A and B" when used in this document in the context of describing a structure, component, item, object, and / or thing refers to an implementation form that includes any one of (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. Similarly, the expression "at least one of A or B" when used in this document in the context of describing a structure, component, item, object, and / or thing refers to an implementation form that includes any one of (1) at least one A, (2) at least one B, and (3) at least one A and at least one B.The expression "at least one of A and B" when used herein in the context of describing the implementation and execution of a process, instruction, act, activity, and / or step refers to an implementation form that includes any one of (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. Similarly, the expression "at least one of A or B" when used herein in the context of describing the implementation and execution of a process, instruction, act, activity, and / or step refers to an implementation form that includes any one of (1) at least one A, (2) at least one B, and (3) at least one A and at least one B.

[0072] When used herein, references to the singular (e.g., "a / an", "first", "second", etc.) do not exclude the plural. When used herein, the term "a" entity refers to one or more such entities. The terms "a", "one or more", and "at least one" may be used interchangeably herein. Further, multiple means, elements, or method acts, although individually recited, may be implemented by, for example, a single unit or processor. Additionally, individual features may be included in various examples or claims, but such features may also be combined, and inclusion in various examples or claims does not imply that combinations of features are not feasible and / or not beneficial.

[0073] FIG. 18 is a flowchart of an exemplary method 1800 for controlling selective operative coupling of an actuator (e.g., actuators 212, 220, 226, 232 in FIG. 2) of a dual drive system (e.g., dual drive systems 204, 206 in FIG. 2) and a corresponding drive arm (e.g., drive arms 219, 225, 231, 237 in FIG. 2) to control operation of a control surface (e.g., flap 202) of an aerial vehicle. The exemplary method 1800 may be implemented by an exemplary control surface controller 238 of FIG. 2 and / or FIG. 16.

[0074] The exemplary method 1800 begins by identifying that a first actuator of the dual drive system and an associated first cycloid drive, and a second actuator of the dual drive system and an associated second cycloid drive, are in an operative state and that no fault condition exists (block 1802). For example, an actuator fault detector 1606 of the control surface controller 238 confirms that both the first actuator and the second actuators 212, 220 of the first drive subsystem 205 are operable based on data (e.g., sensor data) received from the actuators 212, 220 and actuator operation rule(s) 1602 stored in the database 1604. A cycloid drive fault detector 1607 of the control surface controller 238 confirms that both the first cycloid drive 216 associated with the first actuator 212 and the second cycloid drive 222 associated with the second actuator 220 are operable based on data received from the cycloid drives 216, 222 and / or the actuators 212, 220 and cycloid drive operation rule(s) 1609 stored in the database 1604.

[0075] When both actuators of the dual drive system and their corresponding cycloid drive units are in an operating state, the actuators are used to move the control wing surface of the aircraft via the corresponding drive arms (block 1804). For example, the actuator controller 1600 of the control wing surface controller 238 commands the actuators 212, 220 of the first dual drive subsystem 205 to generate power to move the drive arms 219, 225, and thus the flap 202, based on the actuator operation rule(s) 1602. When the first actuator 212 is operable, the power from the first actuator 212 drives the cam 506 of the first coupler 218 of the first drive subsystem 205 from a first position where the teeth 514 of the cam 506 engage with the teeth 600 of the housing 500 to a second position where the teeth 514 of the cam 506 engage with the teeth 516 of the output shaft 304 (e.g., via the movement of the cycloid drive unit 216 and the drive ring 504). As a result of the engagement between the teeth 514 of the cam 506 and the teeth 516 of the output shaft 304, the first actuator 212 is operably connected to the first drive arm 219. Similarly, the power generated by the second actuator 220 is used to drive the cam of the coupler 224 of the second drive subsystem 207 to engage with the output shaft of the second drive subsystem 207 so as to operably connect the second actuator 220 to the second drive arm 225. In some examples, the actuator operation rule(s) 1602 determines which of the actuators 212, 220 operates as the prime mover during the movement of the flap 202 and which of the actuators 212, 220 acts as the antagonist during the movement of the flap 202.

[0076] In some examples, the brake actuator 1608 actuates brakes (e.g., brake 310) respectively associated with the drive arms 219, 225 to lock the drive arms 219, 225, and thus the flap 202, in a particular position.

[0077] In some examples of method 1800, a fault condition is detected (block 1806) in (a) the first actuator or the first cycloidal drive of the first drive subsystem of a dual drive system, or (b) the second actuator or the second cycloidal drive of the second drive subsystem of a dual drive system. For example, the actuator fault detector 1606 of the exemplary control surface controller 238 of FIG. 16 can identify that the first actuator 212 of the first drive subsystem 205 or the second actuator 220 of the second drive subsystem 207 is in a fault state (e.g., based on the outputs received from the respective actuator(s)). In other examples, the cycloidal drive fault detector 1607 of the exemplary control surface controller 238 of FIG. 16 can identify that the first cycloidal drive 216 of the first drive subsystem 205 or the second cycloidal drive 222 of the second drive subsystem 207 is in a fault state (e.g., based on sensor data generated for the respective cycloidal drives 216, 222).

[0078] If a fault condition is detected in block 1806, exemplary method 1800 includes preventing an operational connection between an actuator of a drive subsystem associated with the fault condition and a corresponding drive arm associated with that drive subsystem. For example, if the fault condition is associated with a first actuator or a first cycloid drive unit of a first drive subsystem, exemplary method 1800 includes preventing power generation by the first actuator to prevent an operational connection between the first actuator and the first drive arm (block 1808). For example, an actuator controller 1600 of a control surface controller 238 prevents the first actuator 212 from generating power. As a result, the cycloid drive unit 216 stops driving the drive ring 504 of the first coupler 218. Therefore, the cam 506 remains in a first position where the teeth 514 of the cam 506 engage the teeth 600 of the housing 500 and does not engage the teeth 516 of the output shaft 304 driven by the drive ring 504. Thus, the first actuator 212 is not operably connected to the first drive arm 219.

[0079] In such an example, method 1800 includes actuating the first drive arm via a second actuator of a second drive subsystem (block 1810). For example, the second actuator 220 drives the movement of a second drive arm 225 connected to a first flap support linkage 208. Since the first drive arm 219 is not operably connected to the first actuator 212, the first drive arm 219 also moves as a result of the movement of the second drive arm 225 and the connection between the first drive arm 219 and the first flap support linkage 208.

[0080] In some such examples, method 1800 includes applying a brake associated with the first drive arm (block 1812). For example, a brake actuator 1608 actuates a brake 310 of the first drive arm 219 to facilitate control of the movement of the first drive arm 219 by the second actuator 220.

[0081] In the example of FIG. 18, when a malfunction is detected in the second actuator or the second cycloid drive unit of the second drive subsystem (block 1806), the exemplary method 1800 includes preventing power generation by the second actuator and preventing operational connection between the second actuator and the second drive arm. For example, the actuator controller 1600 prevents the second actuator 220 from generating power, and thus prevents the second actuator 220 from being operably connected to the second drive arm 225 via the second cycloid drive unit 222 and the first coupler 218 of the second drive subsystem 207 (block 1814).

[0082] In such an example, the method 1800 includes actuating the second drive arm via the first actuator of the first drive subsystem (block 1816). For example, when the first drive arm 219 is being moved by the first actuator 212, the second drive arm 225 pivots, resulting in movement of the first flap support linkage 208. In some such examples, the method 1800 includes applying a brake associated with the second drive arm (block 1818). For example, the brake actuator 1608 actuates the brake 310 of the second drive arm 225 to facilitate control of the movement of the second drive arm 225 by the first actuator 212.

[0083] The exemplary method 1800 of FIG. 18 ends when the control surface returns to its stowed position (block 1820).

[0084] FIG. 19 is a block diagram of an exemplary processor platform 1900 constructed to execute the instructions of FIG. 19 to implement the control surface controller 238 of FIGS. 2 and / or 16. The processor platform 1900 can be, for example, a server, a personal computer, a workstation, a self-learning machine (such as a neural network), a mobile device (such as a mobile phone, a smartphone, a tablet such as an iPad (trademark)), a personal digital assistant (PDA), an Internet appliance, or any other type of computing device.

[0085] The illustrated example of the processor platform 1900 includes a processor 1912. The illustrated example of the processor 1912 is hardware. For example, the processor 1912 can be implemented by one or more integrated circuits, logic circuits, microprocessors, GPUs, DSPs, or controllers by any desired company or manufacturer. The hardware processor can be a semiconductor-based (e.g., silicon-based) device. In this example, the processor implements an exemplary actuator controller 1600, an exemplary actuator fault detector 1606, an exemplary cycloid driver fault detector 1607, and an exemplary brake actuator 1608.

[0086] The illustrated example of the processor 1912 includes local memory 1913 (such as a cache). The illustrated example of the processor 1912 communicates with a main memory including volatile memory 1914 and non-volatile memory 1916 via a bus 1918. The volatile memory 1914 can be implemented by a synchronous dynamic random access memory (SDRAM), a dynamic random access memory (DRAM), a RAMBUS (registered trademark) dynamic random access memory (RDRAM (registered trademark)), and / or any other type of random access memory device. The non-volatile memory 1916 can be implemented by flash memory and / or any other desired type of memory device. Access to the main memories 1914, 1916 is controlled by a memory controller.

[0087] The illustrated example of the processor platform 1900 also includes an interface circuit 1920. The interface circuit 1920 can be implemented by any type of interface standard (e.g., Ethernet interface, Universal Serial Bus (USB), Bluetooth (registered trademark) interface, Near Field Communication (NFC) interface, and / or PCI (Peripheral Component Interconnect) Express interface).

[0088] In the illustrated example, one or more input devices 1922 are connected to the interface circuit 1920. The input device(s) 1922 allow a user to input data and / or commands to the processor 1912. The input device(s) can be implemented, for example, by a voice sensor, a microphone, a camera (still or video), a keyboard, buttons, a mouse, a touch screen, a track pad, a track ball, an isopoint, and / or a voice recognition system.

[0089] One or more output devices 1924 are also connected to the interface circuit 1920 of the illustrated example. The output device 1924 can be implemented, for example, by a display device (examples include a light-emitting diode (LED), an organic light-emitting diode (OLED), a liquid crystal display (LCD), a cathode ray tube display (CRT), an in-plane switching (IPS) display, a touch screen, etc.), a tactile output device, a printer, and / or a speaker. Thus, the interface circuit 1920 of the illustrated example typically includes a graphics driver card, a graphics driver chip, and / or a graphics driver processor.

[0090] The interface circuit 1920 of the illustrated example also includes a communication device (such as a transmitter, a receiver, a transceiver, a modem, a resident gateway, a wireless access point, and / or a network interface, etc.) to facilitate data exchange with an external machine (such as any type of computing device) via the network 1926. The communication can be via, for example, an Ethernet connection, a digital subscriber line (DSL) connection, a telephone line connection, a coaxial cable system, a satellite system, a line-of-site wireless system, a cellular phone system, etc.

[0091] The illustrated example processor platform 1900 also includes one or more mass storage devices 1928 for storing software and / or data. Examples of such mass storage devices 1928 include floppy disk drives, hard disk drives, compact disk drives, Blu-ray disk drives, RAID (redundant array of independent disk) systems, and digital versatile disk (DVD) drives.

[0092] The encoded instructions 1932 of FIG. 19 can be stored on the mass storage device 1928, in the volatile memory 1914, in the non-volatile memory 1916, and / or on a removable non-transitory computer-readable storage medium (e.g., a CD or a DVD).

[0093] From the above description, it will be appreciated that exemplary methods, apparatuses, and products are disclosed that provide a selective operative coupling between an actuator and a mechanical coupling of a dual drive system for moving a control surface of an aircraft vehicle. The exemplary dual drive systems disclosed herein provide redundancy in the event of a failure in one of the actuators of the drive system, allowing the control surface to be moved regardless of the failure condition and reducing distortion in the control surface. The examples disclosed herein include a coupler that selectively couples an actuator of the dual drive system to a corresponding drive arm of the dual drive system. In the event of a failure in the actuator, this coupler prevents the operative coupling between the actuator and the corresponding drive arm. As a result, the drive arm can be moved by the other actuator of the dual drive system. Thus, the examples disclosed herein prevent or substantially reduce asymmetry in the dual drive system in the event of a failure condition in the dual drive system.

[0094] In the following paragraphs, various exemplifications of the examples disclosed herein are provided.

[0095] Example 1 includes a flap actuation system that includes a first actuator, a second actuator, a first drive arm coupled to the first actuator and to the flap, a second drive arm coupled to the second actuator and to the flap, a first cam, and a first output shaft. The first cam is coupled to the first drive arm via the first output shaft during operation of the first actuator to enable the first actuator to move the flap via the first drive arm. The exemplary flap actuation system also includes a second cam and a second output shaft. The second cam is coupled to the second drive arm via the second output shaft during operation of the second actuator to enable the second actuator to move the flap via the second drive arm. The first cam is to be decoupled from the first drive arm in response to a malfunction of the first actuator. The second actuator is to move the flap via the first drive arm and the second drive arm in response to a malfunction of the first actuator.

[0096] Example 2 includes the flap actuation system described in Example 1 and further includes a cycloid drive disposed between the first actuator and the first cam, the cycloid drive being rotatable to enable the first cam to couple to the first drive arm.

[0097] Example 3 includes the flap actuation system described in Example 2, the first cam including a first set of teeth, the first output shaft including a second set of teeth, the flap actuation system further including a housing including a third set of teeth, the first cam being disposed between the housing and the first output shaft, the first cam being moved by the first actuator from a first position where the first set of teeth of the first cam engages the third set of teeth of the housing to a second position where the first set of teeth of the first cam engages the second set of teeth of the first output shaft.

[0098] Example 4 includes the flap actuation system described in Example 3, and this flap actuation system further includes a drive ring connected to the shaft of the cycloid drive unit, and the drive ring rotates to cause a translation between a first position and a second position of the first cam.

[0099] Example 5 includes the flap actuation system described in any one of Examples 1 to 4, and the first drive arm includes a brake, and the brake operates in response to a malfunction of the first actuator.

[0100] Example 6 includes the flap actuation system described in Example 1. During the operation of the first actuator and the second actuator, the first actuator will move the flap from the first position to the second position, and the second actuator will move the flap from the second position to the first position. When the first actuator moves the flap, the first cam is connected to the first drive arm, and when the second actuator moves the flap, the second cam is connected to the second drive arm, respectively.

[0101] Example 7 includes the flap actuation system described in Example 6, and the first position includes an extended position and the second position includes a retracted position.

[0102] Example 8 includes an aircraft, and this aircraft includes a flap, a first actuator, a second actuator, a first drive arm connected to the flap, a second drive arm connected to the flap, a first coupler for selectively connecting the first actuator to the flap via the first drive arm, and a second coupler for selectively connecting the second actuator to the flap via the second drive arm.

[0103] Example 9 includes the aircraft described in Example 8, and this aircraft further includes a cycloid drive unit disposed between the first actuator and the first coupler.

[0104] Example 10 includes the aircraft described in Example 9, and the first actuator is capable of rotating the cycloid drive unit to enable the first coupler to be connected to the first drive arm.

[0105] Example 11 includes the aircraft described in Example 10 and includes a first coupler that is a spring, the spring moving between an extended position and a compressed position in response to the first coupler selectively connecting a first actuator to a flap via a first drive arm.

[0106] Example 12 includes the aircraft described in any one of Examples 8 to 11, the first coupler including a housing, a cam disposed within the housing, and an output shaft, the output shaft being connected to a first drive arm, the cam moving between a first position in which teeth of the cam engage teeth of the housing and a second position in which teeth of the cam engage teeth of the output shaft to selectively connect a first actuator to a flap.

[0107] Example 13 includes the aircraft described in any one of Examples 8 to 11, a first drive arm and a second drive arm being connected to a first flap support, the aircraft further including a third actuator, a fourth actuator, a third drive arm connected to the flap, a fourth drive arm connected to the flap, a third coupler for selectively connecting the third actuator to the flap via the third drive arm, and a fourth coupler for selectively connecting the fourth actuator to the flap via the fourth drive arm.

[0108] Example 14 includes the aircraft described in Example 13, the aircraft further including a controller for (a) commanding one of the first actuator or the second actuator to move the flap between an extended position and a retracted position and (b) commanding one of the third actuator or the fourth actuator to move the flap between an extended position and a retracted position.

[0109] Example 15 includes a system that includes a first actuator, a second actuator, a drive arm coupled to a flap of a vehicle, and a coupler disposed between the first actuator and the drive arm. The coupler includes a cam. The cam is selectively coupled to the drive arm to operably couple the first actuator to the drive arm. This exemplary system includes a controller for controlling the operative coupling of the first actuator and the drive arm via the coupler. The controller commands the second actuator to drive the movement of the flap when the cam is decoupled from the drive arm.

[0110] Example 16 includes the system described in Example 15, and the controller commands the second actuator to drive the movement of the flap in response to a malfunction of the first actuator.

[0111] Example 17 includes the system described in Example 15 or Example 16, and this system further includes a cycloid drive unit, and the cam is coupled to the drive arm in response to the rotation of the cycloid drive unit.

[0112] Example 18 includes the system described in Example 17, the cam includes a first set of teeth, the coupler further includes a housing including a second set of teeth and an output shaft including a third set of teeth, and the cam moves from a first position where the first set of teeth of the cam engages the second set of teeth of the housing to a second position where the first set of teeth of the cam engages the third set of teeth of the output shaft.

[0113] Example 19 includes the system described in Example 18, and the shaft of the cycloid drive unit extends through the housing.

[0114] Example 20 includes the system described in any one of Examples 15 to 19, and this system further includes a brake coupled to the drive arm, and the controller actuates the brake in response to a malfunction of the first actuator.

[0115] Although this book has disclosed certain exemplary methods, apparatuses, and products, the scope of this patent application is not limited thereto. Rather, this patent application is directed to all methods, apparatuses, and products that fairly fall within the scope of the claims of this patent application.

[0116] The following claims are hereby incorporated by reference into this "Detailed Description" in this book, and each claim stands on its own as a separate example of the present disclosure.

Claims

1. A flap actuation system (200), comprising: a first actuator (212); a second actuator (220); a first drive arm (219) connected to the first actuator and to the flap (202); a second drive arm (225) connected to the second actuator and to the flap; a first cam (506, 1102); a first output shaft (304), wherein the first cam is connected to the first drive arm via the first output shaft during operation of the first actuator to enable the first actuator to move the flap via the first drive arm; a second cam (506, 1102); a second output shaft (304), wherein the second cam is connected to the second drive arm via the second output shaft during operation of the second actuator to enable the second actuator to move the flap via the second drive arm, wherein the first cam is disconnectably coupled from the first drive arm in response to a malfunction of the first actuator, and the second actuator moves the flap via the first drive arm and the second drive arm in response to the malfunction of the first actuator; wherein the first drive arm includes a brake (310), and the brake is operative in response to the malfunction of the first actuator; wherein the first cam is coupled to the first drive arm when the first actuator moves the flap, and the second cam is coupled to the second drive arm when the second actuator moves the flap; a flap actuation system.

2. The flap actuation system according to claim 1, further comprising a cycloid drive unit (216, 222, 228, 234) disposed between the first actuator and the first cam, the cycloid drive unit being rotatable to enable the first cam to be coupled to the first drive arm.

3. wherein the first cam includes a set of first teeth (514), the first output shaft includes a set of second teeth (516), and the flap actuation system The flap actuation system according to claim 2, further comprising a housing (500) including a set of third teeth (600), wherein the first cam is disposed between the housing and the first output shaft, and the first cam is moved by the first actuator from a first position where a first set of teeth of the first cam engages with the set of third teeth of the housing to a second position where the first set of teeth of the first cam engages with the set of second teeth of the first output shaft.

4. The flap actuation system according to claim 3, further comprising a drive ring (506, 1100) connected to a shaft (302) of the cycloid drive unit, wherein the drive ring rotates to cause a translation between the first position and the second position of the first cam.

5. The flap actuation system includes a controller (238), the controller is configured to control the connection between the first actuator and the first drive arm via the first cam, and to command the second actuator to drive the flap when the first cam is disconnected from the first drive arm, as claimed in claim 1 of the flap actuation system.

6. During operation of the first actuator and the second actuator, the first actuator moves the flap from a first position to a second position, and the second actuator moves the flap from the second position to the first position, as claimed in claim 1 of the flap actuation system.

7. An aircraft (100), a flap (202), a first actuator (212), a second actuator (220), a first drive arm (219) connected to the flap, a second drive arm (225) connected to the flap, a first coupler (218) for selectively connecting the first actuator to the flap via the first drive arm, a second coupler (224) for selectively connecting the second actuator to the flap via the second drive arm, wherein the first drive arm includes a brake (310), and the brake operates in response to a malfunction of the first actuator. When the first actuator moves the flap, the first coupler is connected to the first drive arm, and when the second actuator moves the flap, the second coupler is connected to the second drive arm, respectively. Aircraft.

8. The aircraft according to claim 7, further comprising a cycloid drive unit disposed between the first actuator and the first coupler.

9. The aircraft according to claim 8, wherein the first actuator rotates the cycloid drive unit so that the first coupler can be connected to the first drive arm.

10. The first coupler includes a spring (507), and the spring moves between an extended position and a compressed position in response to the first coupler selectively connecting the first actuator to the flap via the first drive arm. The aircraft according to claim 9.

11. The first coupler is a housing, a cam disposed within the housing, and an output shaft connected to the first drive arm. The cam moves between a first position where the teeth of the cam engage the teeth of the housing and a second position where the teeth of the cam engage the teeth of the output shaft to selectively connect the first actuator to the flap. The aircraft according to any one of claims 7 to 10.

12. The first drive arm and the second drive arm are connected to a first flap support portion, a third actuator, a fourth actuator, a third drive arm (231) connected to the flap, a fourth drive arm (237) connected to the flap, a third coupler (230) for selectively connecting the third actuator to the flap via the third drive arm, and a fourth coupler (236) for selectively connecting the fourth actuator to the flap via the fourth drive arm. The aircraft according to any one of claims 7 to 10.

13. The aircraft includes a controller (238), and the controller is configured to control the connection between the first actuator and the first drive arm via the first coupler, and to command the second actuator to drive the flap when the first coupler is disconnected from the first drive arm. The aircraft according to claim 7.

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