Mechanical Actuator Synchronization for Aircraft Jam Management
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Solution Overview
Problem
Distributed electromechanical actuation systems face challenges in maintaining absolute symmetry and effectively managing jam conditions due to induction motor slip differences and servo loop inaccuracies, particularly in systems requiring synchronous operation of multiple outputs like aircraft flaps and thrust reversers.
Innovation Solution
A mechanical synchronization system that includes a power module controller to output motor drive power synchronously to multiple actuators, along with mechanical synchronization devices such as flexible or rigid shafts, universal joints, and load limiting devices to transfer torque and maintain symmetry between actuators, and prevent motion or lock actuators when threshold torque is reached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electrical synchronization with individual motors at each drive station is used, then system complexity and weight are reduced, but absolute symmetry between actuators cannot be maintained due to motor slip differences and servo loop inaccuracies
Solution Approach 1:
A mechanical synchronization device is introduced as an intermediary component between individual electromechanical actuators. This device includes a first mechanical connection to a first actuator and a second mechanical connection to a second actuator, enabling torque transfer between actuators to maintain symmetry while preserving the benefits of distributed electrical actuation.
2Manufacturing precision
If mechanical synchronization devices are added to maintain actuator symmetry, then actuator synchronization is improved, but device complexity increases
Solution Approach 1:
The mechanical synchronization device provides localized torque transfer between specific actuators that require synchronization. The device is designed with specific mechanical connections tailored to the symmetry requirements of particular actuator pairs, rather than implementing a comprehensive mechanical linkage system across all actuators.
3Reliability
If load limiting devices are implemented to manage jam conditions, then system reliability is improved, but device complexity increases
Solution Approach 1:
A load limiting device is incorporated into the mechanical synchronization device to prevent excessive torque transfer between actuators during jam conditions. The load limiting device includes a yieldable element that allows controlled deformation or slipping when torque exceeds a predetermined threshold, protecting the actuators from damage before failure occurs.
Data Source
AI summary
A mechanical synchronization device for a distributed system. A plurality of actuators actuate movement of control surface components of an aircraft. Each actuator has a first end coupled to a structure of the aircraft and a second end coupled to a control surface component, and a drive path from a motion provider to the control surface component, the control surface component being configured to move along the respective drive path. A power module controller is operable to simultaneously output motor drive power from a power module through an electrical bus to at least two of the motion providers in a synchronous or nearly synchronous manner to actuate movement of control surface components. The mechanical synchronization device is between at least two of the actuators and transfers torque between the actuators to maintain symmetry between the actuators. A load limiting device may limit the power transferred through the mechanical synchronization device.