Control Surface Actuator Gust Lock With Zero-Hold Power Locking
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Solution Overview
Problem
There is a need for an automated, electrically operated gust lock for control surfaces in urban air mobility and light aircraft that is lightweight, small, and cost-effective, capable of preventing rotation during gust loads without continuous battery current draw.
Innovation Solution
The implementation of an actuator assembly with a gust lock that includes a lock shaft, lock rotor, lock motor, and linear actuator, which can move between locked and unlocked positions, using a lock drive screw and nut to engage or disengage the lock rotor, allowing for controlled prevention of rotation, and utilizing a controller to manage the lock's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a manual gust lock is used, then the device complexity is reduced, but the extent of automation is insufficient
Solution Approach 1:
The gust lock mechanism is integrated with the existing actuator system, allowing the same motor and control electronics to serve both actuator operation and gust lock functions. The lock shaft and engagement features are incorporated into the actuator housing structure, enabling a single system to perform multiple functions without proportionally increasing complexity
Solution Approach 2:
The gust lock system utilizes the actuator's own motor and control system to operate the lock mechanism. The lock motor is integrated with the actuator drive source, and the control system automatically manages lock engagement based on operational state, eliminating the need for separate manual operation while maintaining system simplicity
2Extent of automation
If the gust lock is electrically operated, then the extent of automation is improved, but the use of energy increases due to continuous current draw
Solution Approach 1:
The gust lock motor operates intermittently rather than continuously. The motor is activated only during lock engagement and disengagement transitions, while the lock holding function is maintained through mechanical engagement without continuous power input. The control system periodically checks and maintains lock status without continuous current draw
Solution Approach 2:
The gust lock is engaged automatically before aircraft operation begins and disengaged automatically before operation concludes. The lock mechanism is prepared and positioned in advance, and the control system anticipates operational transitions to manage lock state changes proactively, minimizing the duration of motor activation and energy consumption
3Reliability
If a robust gust lock mechanism is implemented, then the reliability is improved, but the weight of the moving object increases
Solution Approach 1:
The gust lock components are integrated with the actuator structure. The lock shaft is incorporated into the actuator housing, the engagement features are formed as part of the existing mechanical components, and the lock motor shares mounting and support structures with the actuator system. This merging approach provides robust lock functionality while avoiding the weight penalty of a completely separate mechanism
Solution Approach 2:
The gust lock mechanism is nested within the actuator assembly. The lock shaft and engagement features are positioned within the actuator housing, utilizing the existing structural space. The lock components are contained within and integrated with the actuator's mechanical structure, providing a compact configuration that minimizes additional weight while maintaining reliability
4Volume of moving object
If a compact gust lock is designed, then the volume of the moving object is reduced, but the device complexity may increase
Solution Approach 1:
The gust lock mechanism is divided into distinct functional segments: the lock shaft for rotation, the engagement features for locking, the lock motor for actuation, and the control system for management. Each segment is optimized independently for its specific function, allowing compact arrangement while maintaining simplicity within each component. The segmented design enables efficient space utilization without requiring overly complex integrated mechanisms
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a lightweight, cost-effective, and energy-efficient means to prevent control surface rotation during gust loads, ensuring aircraft stability without continuous power consumption, while allowing for controlled movement when needed.
Implementation Method 1
The lock motor is configured, upon being electrically energized, to supply a lock drive torque
Implementation Method 2
The linear actuator is coupled to receive the lock drive torque and is configured, upon receipt of the lock drive torque, to move between an engaged position and a disengaged position
Data Source
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AI summary
An actuator assembly includes an actuator drive source and a gust lock. The actuator drive source is operable to supply an actuator drive torque to drive a component. The gust lock is movable between a locked position, in which rotation of the drive source is prevented, and an unlocked position, in which rotation of the drive source is not prevented. The gust lock includes a lock shaft, a lock rotor, a lock motor, and a linear actuator. The lock shaft is rotatable with the drive source when the gust lock is in the unlocked position. The lock rotor is rotatable with the lock shaft. The lock motor is configured to supply a lock drive torque. The linear actuator is coupled to receive the lock drive torque and is configured, upon receipt of the lock drive torque, to move between an engaged position and a disengaged position.