Mechanical Actuator Locking Mechanism With Reduced Part Count
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Solution Overview
Problem
Conventional aircraft actuators are complex, costly, and require lengthy servicing times due to their numerous components, which are often made from different metals and metal alloys, leading to high manufacturing and maintenance costs and extended downtime.
Innovation Solution
A mechanical actuator with an improved locking mechanism and reduced component count, featuring a cylinder with locking recesses and a piston assembly that moves between extended and retracted positions via fluid pressure, utilizing a lock that engages and disengages with these recesses to control movement, along with a monolithic castle nut for simplified construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional actuator designs are used with multiple parts made from different metals and metal alloys, then the actuator achieves reliable flight control functionality, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent combines multiple separate components into a single integrated actuator assembly. The piston, rod, seals, and housing are merged into one unified structure that can be manufactured as a single piece or pre-assembled unit, eliminating the need for multiple discrete parts made from different materials.
Solution Approach 2:
The actuator design integrates multiple functions into a single component structure. The housing simultaneously serves as structural support, fluid containment, and mounting interface, while the piston-rod assembly provides both actuation force and positional control, reducing the overall part count while maintaining reliability.
2Strength
If conventional actuators with numerous components are used, then the actuator provides sufficient structural strength, but the manufacturing and maintenance costs increase
Solution Approach 1:
By merging multiple components into a single integrated actuator, the patent reduces manufacturing steps, material joining operations, and quality control requirements. This single-piece or pre-assembled design significantly lowers manufacturing cost while maintaining the necessary structural strength through optimized material selection and structural design.
Solution Approach 2:
The patent optimizes material properties and structural parameters of the integrated actuator to achieve required strength levels. By carefully selecting materials and designing the internal geometry of the single-piece structure, the actuator attains sufficient structural strength without requiring multiple reinforced components, thereby reducing manufacturing complexity and cost.
3Reliability
If conventional actuators with many different parts are used, then the actuator achieves adequate performance, but the servicing time and turnaround period increase
Solution Approach 1:
The integrated actuator design reduces the number of parts that need to be inspected, disassembled, and reassembled during servicing. With fewer components and connection points, maintenance personnel can quickly diagnose and service the actuator, significantly reducing turnaround time while maintaining performance through built-in diagnostic features and modular serviceability.
Solution Approach 2:
The actuator incorporates self-diagnostic capabilities and self-lubricating features that reduce the need for extensive manual inspection and maintenance. Sensors and monitoring systems detect potential issues before they affect performance, allowing for predictive maintenance that minimizes servicing time and keeps the actuator operational.
4Reliability
If conventional actuators with multiple components are used, then the actuator provides necessary functionality, but the overall vehicle weight increases
Solution Approach 1:
By consolidating multiple components into a single integrated actuator, the patent eliminates the weight of fasteners, seals, gaskets, and connecting hardware that would be required to join multiple parts. The monolithic or pre-assembled structure reduces overall mass while maintaining the same actuation functionality through optimized material distribution and structural efficiency.
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 simplified design reduces manufacturing and maintenance costs, decreases servicing time, and lowers the overall weight of the vehicle by minimizing component parts, thereby enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
a piston assembly that moves between an extended position and a retracted position responsive to fluid pressure within the cylinder
Implementation Method 2
A lock is connected to the piston assembly and moves radially between a locked position and an unlocked position responsive to the fluid pressure within the cylinder. In the locked position, a biasing member radially biases the lock towards the locking recess such that the lock engages the locking recess
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
The present disclosure relates to a mechanical actuator (30) having a modified locking mechanism (140) and fewer components. The actuator has a cylinder (32), a locking recess (36) formed on an interior wall (38) of the cylinder, and a piston assembly (130) that moves between an extended position and a retracted position responsive to fluid pressure within the cylinder. A lock (60) is connected to the piston assembly and moves radially between a locked position and an unlocked position responsive to the fluid pressure within the cylinder.