Aircraft Electric Brake Actuator Module Segmentation
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Solution Overview
Problem
Existing aircraft electric brake systems require significant disassembly for maintenance and repair, leading to costly and time-consuming procedures, resulting in aircraft downtime and revenue loss due to complex integrated designs.
Innovation Solution
The electric brake actuator module design features a module housing with a reciprocating ram and electric motor, allowing for easy replacement and retraction without disassembling the overall brake assembly, utilizing a ball screw and nut assembly with a bi-stable holding brake for efficient braking and maintenance, and a cable conduit with module connectors for simplified electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex integrated brake assembly design is used, then the braking performance and reliability are improved, but the ease of repair and maintenance are worsened
Solution Approach 1:
The brake assembly is divided into modular components, with the actuator being a self-contained unit that can be independently removed and replaced. This segmentation allows the complex integrated brake to maintain high reliability while enabling easy maintenance by isolating the actuator as a separate serviceable module.
Solution Approach 2:
The actuator is designed as a removable module that can be extracted from the brake assembly without requiring disassembly of the entire brake system. This extraction capability resolves the contradiction by allowing the complex brake to maintain its integrated performance while enabling simple maintenance through module removal.
2Reliability
If a complex integrated brake assembly design is used, then the braking performance is improved, but the time required for maintenance and repair is increased
Solution Approach 1:
By segmenting the actuator as a separate module within the integrated brake assembly, maintenance time is reduced while preserving braking performance. The modular design allows quick removal and replacement of the actuator without time-consuming disassembly of the entire brake system.
Solution Approach 2:
The actuator module can be extracted from the brake assembly for maintenance or replacement without requiring teardown of the entire system. This extraction capability significantly reduces maintenance downtime while the actuator remains part of the integrated brake system during operation.
3Manufacturing precision
If a highly integrated design with complex machining and assembly procedures is used, then the precision and performance are improved, but the ease of manufacture is worsened
Solution Approach 1:
The actuator is manufactured as a separate module with pre-assembled components, reducing the complexity of the overall manufacturing process while maintaining precision. This segmentation allows specialized manufacturing of the actuator module independent of the brake assembly, simplifying production.
Solution Approach 2:
Multiple components (actuator ram, motor, ball screw, seals) are merged into a single integrated actuator module that is manufactured as one unit. This merging reduces the number of separate machining and assembly operations required for the overall brake system while maintaining the precision of individual components.
4Reliability
If a complex integrated brake assembly is used, then the braking reliability is improved, but the productivity of maintenance operations is reduced
Solution Approach 1:
The actuator is segmented as a removable module within the integrated brake assembly, allowing maintenance personnel to quickly remove and replace it without disassembling the entire brake system. This maintains brake reliability while significantly improving maintenance productivity.
Solution Approach 2:
The actuator module can be extracted from the brake assembly for maintenance or replacement without requiring teardown of the entire system. This extraction capability maintains the reliability benefits of an integrated design while dramatically improving maintenance efficiency by reducing disassembly time.
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
Enables quick and efficient replacement of actuator modules, reducing downtime and maintenance costs, allowing aircraft to remain in service with minimal disruption and facilitating faster periodic maintenance.
Implementation Method 1
utilizing a ball screw and nut assembly
Implementation Method 2
bi-stable holding brake
Data Source
AI summary
An electric brake comprises an actuator module including a module housing, a reciprocating ram, and an electric motor operatively connected to the reciprocating ram for selectively extending and retracting the reciprocating ram with respect to the module housing. The ram has an inner portion of non-circular cross-section and an outer portion of circular cross-sectional, and the housing has a guideway for the ram, which guideway has an inner portion of non-circular cross-section for interacting with the inner portion of the ram to prevent rotation of the inner portion of the ram, and an outer portion of circular cross-sectional. The actuator module can be equipped with a bi-stable holding brake having a first state permitting at least retraction of the ram and a second state preventing at least retraction of the ram.