Dual-Motor Actuator Drive with Cone Clutch Failover

The drive system is segmented into independent motor channels, each with its own overrunning clutch and drive gear, that can operate independently or in combination. This segmentation allows redundancy without requiring a complex integrated differential gearbox, as each channel can function autonomously or contribute torque to the common output shaft through its own clutch mechanism.

Overrunning clutches serve as intermediary elements between the motors and the output shaft, enabling selective engagement and disengagement of motor channels. These clutches mediate the torque transmission, allowing the system to achieve redundancy and torque combination capabilities without the complexity of a differential gearbox, as the clutches automatically manage power flow based on operational mode.

Each motor channel is designed with universal components that can serve multiple functions: the overrunning clutch and drive gear assembly can handle both active torque contribution and standby redundancy roles. This multi-functionality allows the same components to provide weight-efficient redundancy without requiring separate dedicated backup mechanisms, as the system can dynamically switch between active-active and active-standby modes using the same hardware.

The overrunning clutches enable the drive system to be self-managing during failure conditions, automatically transferring load to the standby motor channel without requiring complex control systems or additional actuators. This self-service capability reduces the weight of control electronics and actuation mechanisms needed to manage redundancy, as the mechanical clutch design inherently handles the failover process.

The overrunning clutches act as passive intermediaries that automatically manage torque combination from both motors without requiring active control intervention. In active-active mode, both clutches engage simultaneously, and their mechanical design inherently combines the torques on the common output shaft. This eliminates the need for complex control algorithms to synchronize the motors, as the mechanical clutch system naturally handles the torque superposition.

The drive system uses the self-service property of overrunning clutches to automatically manage the active-active operational mode. The clutches inherently respond to torque demands and motor speeds, automatically combining power from both motors when both are active, without requiring external control signals or complex coordination logic. This self-managing behavior reduces control complexity while maintaining the ability to double output torque.