Actuator Piston Retaining Assembly for End Cap Failure Backup
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Solution Overview
Problem
Control systems in aircraft can become decoupled, leading to potential loss of control due to failures in components such as the end cap, which can result in catastrophic failures if the supporting member and sensor decouple.
Innovation Solution
A retaining device is integrated within the actuator piston to maintain the coupling between the end cap and the supporting member, using a clamping mechanism to prevent decoupling, even when the fastener fails, and to confine debris, ensuring continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fastener is used to couple the supporting member to the end cap, then the coupling is simple and easy to manufacture, but the coupling may fail and cause decoupling leading to loss of control
Solution Approach 1:
The retaining device is pre-installed within the end cap before the fastener is attached. This preliminary action ensures that if the fastener fails, the retaining device is already in position to immediately engage and prevent decoupling, thus maintaining reliability without complicating the manufacturing process
Solution Approach 2:
The retaining device acts as a backup safety mechanism that is prepared in advance within the end cap. It provides a cushioning effect against the potential harmful outcome of fastener failure by being ready to engage and maintain coupling, preventing the catastrophic failure mode
2Strength
If the end cap is designed to clamp the supporting member, then the coupling is strong and reliable, but the end cap failure results in complete loss of coupling
Solution Approach 1:
The retaining device is divided into two separate parts: a first part fixedly coupled to the end cap and a second part that can engage with the supporting member. This segmentation allows the retaining device to function as an independent backup mechanism that remains effective even when the end cap's clamping function fails
Solution Approach 2:
The retaining device serves as an intermediary backup mechanism between the end cap and the supporting member. When the primary clamping function fails, the retaining device mediates to maintain the coupling, preventing complete loss of connection
3Reliability
If a retaining device is added to maintain coupling when the end cap fails, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The retaining device is merged within the existing end cap structure rather than being a separate external component. The first part of the retaining device is fixedly coupled to the end cap, combining multiple functions into a single integrated assembly, which minimizes the increase in overall device complexity while maintaining improved reliability
Data Source
AI summary
A control system includes: an actuator piston having an end cap, the actuator piston being reversibly translatable; a supporting member coupled to the end cap, the supporting member being configured to couple the end cap to a sensor; and a retaining device configured to maintain the coupling between the end cap and the supporting member when the end cap fails.