Active Throttle Link Force Sensing Without Dynamic Wires
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Solution Overview
Problem
The transition from mechanical to electrical throttles in aircraft resulted in the loss of haptic feedback for pilots, necessitating the development of active throttles that provide accurate and reliable force sensing while maintaining system reliability and simplicity.
Innovation Solution
The active throttle assembly incorporates a motor body casing, gearbox, lever, trunnion bearings, and a link with a force sensor, eliminating dynamic wires and reducing part count, which improves reliability and manufacturing simplicity, and allows for retrofitting to non-fly-by-wire aircraft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If dynamic wires are used to connect the force sensor to moving parts, then the force sensing capability is achieved, but the system reliability deteriorates due to wire failures and connection issues
Solution Approach 1:
The patent extracts and eliminates the dynamic wire connection from the force sensing system. Instead of using wires to transmit force data from the sensor to the control system, the force sensor is integrated directly into the link structure, allowing wireless transmission of sensor data and eliminating the reliability issues associated with dynamic wire connections.
Solution Approach 2:
The force sensor is merged with the link structure itself. The link serves dual purposes: mechanical connection between the actuator assembly and chassis, and integration of the force sensor to measure link forces. This combination eliminates separate wiring harnesses and reduces connection points that could fail.
2Adaptability or versatility
If multiple separate components are used in the actuator assembly, then the functionality is comprehensive, but the manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functional components into integrated assemblies. The actuator assembly merges the motor body casing, gearbox, and force sensor into a unified structure. The link integrates mechanical connection and force sensing functions. This reduction in separate parts simplifies manufacturing while maintaining comprehensive functionality.
Solution Approach 2:
The link structure serves multiple functions: mechanical connection between actuator and chassis, force transmission, and integration of the force sensor. The actuator assembly provides both actuation and sensing capabilities in a single integrated unit, reducing the need for separate components.
3Ease of operation
If the force sensor is connected via dynamic wires to moving parts, then the sensing range is maintained, but the reliability deteriorates due to wire wear and connection failures
Solution Approach 1:
The patent removes the dynamic wire connection entirely from the force sensing system. The force sensor is integrated into the link structure, which moves with the actuator assembly, eliminating the need for wires to accommodate movement while maintaining full sensing capability throughout the range of motion.
Data Source
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AI summary
An assembly is described which may be an active stick or throttle assembly or may be connected to mechanical linkage within an aircraft. The assembly comprises an actuator assembly comprising a motor body casing, and a gearbox; and a lever connected, via a proximal end of the lever, to an output stage of the gearbox. The assembly further comprises trunnion bearings configured to mount the motor body casing to a chassis and a link configured to connect the motor body casing to the chassis, wherein the link comprises a force sensor.