Aircraft Control Surface Actuation With Force-Summing Breakout Modules
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Solution Overview
Problem
Existing aircraft actuation systems face challenges with large actuators that hinder thin wing configurations, causing drag and reducing aerodynamic efficiency, and electromechanical actuators prone to jamming and failure, posing safety risks.
Innovation Solution
An aircraft control surface actuation system using multiple actuator modules configured to sum their output, with a breakout mechanism to disconnect failed modules and a force multiplier link, allowing smaller and lighter actuators to fit within thin wings while maintaining redundancy and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a single large actuator is used to deliver required performance to a control surface, then the actuator provides sufficient driving force, but the actuator is too large to fit within thin aircraft wings and causes drag
Solution Approach 1:
The patent divides a single large actuator into multiple smaller actuator modules (at least three modules) that work together to provide the required driving force. Each module is individually sized to be compatible with thin wing sections, eliminating the need for large blister housings and reducing drag while maintaining sufficient total force output through combined effort of all modules.
2Volume of moving object
If multiple actuator modules are used to reduce size, then the actuators can fit within thin wings, but the system complexity increases
Solution Approach 1:
The patent combines multiple actuator modules through a common rotary driver mechanism that integrates their outputs. The rotary driver receives input from all actuator modules and provides a unified rotational output to the control surface, effectively merging the functionality of multiple separate actuators into a coordinated system that achieves the desired motion while maintaining compact size.
3Extent of automation
If electromechanical linear actuators are used, then electronic control is achieved, but the actuators are prone to jamming and failure which can ground aircraft or be dangerous in flight
Solution Approach 1:
The patent incorporates a breakout mechanism that proactively prevents actuator failure from compromising the entire system. This mechanism is designed to disconnect individual actuator modules if they jam or fail, thereby cushioning the system against complete failure and maintaining safety during operation. The breakout mechanism allows the remaining functional modules to continue operating or the system to fail safely without grounding the aircraft.
4Reliability
If a breakout mechanism is added to disconnect failed modules, then reliability improves, but the device complexity increases
Solution Approach 1:
The breakout mechanism serves as an intermediary element between the actuator modules and the rotary driver. This intermediate component automatically engages or disengages the connection based on operational conditions, providing a simple yet effective way to isolate failed modules without requiring complex control systems or multiple disconnection points. The intermediary nature of the breakout mechanism allows for reliable failure isolation with minimal added complexity.
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 system enables smaller, lighter actuators to fit within thin aircraft wings, providing redundancy and safety by disconnecting failed modules, thus maintaining performance and reducing drag.
Implementation Method 1
electromechanical linear actuators
Implementation Method 2
a breakout mechanism configured to operably disconnect the actuator module from the rotary driver if a force exerted on the breakout mechanism exceeds a desired value
Implementation Method 3
A force multiplier link may be provided between each actuator module and the rotary driver
Data Source
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AI summary
An actuation system, for example an actuation system for an aircraft control surface (8), is provided. The actuation system may include a rotary driver (80) and three or more actuator modules (16), and each actuator module may be connected to the rotary driver such that the three or more actuator modules are configured to drive rotation of the rotary driver in combination.