Composite Actuator Fork for Rotor Blade Pitch Control
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Solution Overview
Problem
Conventional control systems for rotor blades in rotary-wing aircrafts are heavy, complex, prone to corrosion, and have high maintenance needs due to the use of metal components, with actuator forks and arms experiencing high fatigue and requiring complex mechanical designs to handle significant loads.
Innovation Solution
A new control system featuring an actuator fork and arm design made from composite materials with a U-shape and reinforcing elements, providing double support and high bending inertia to distribute loads effectively, reducing deformation and simplifying manufacturing, while using an overarching flange to minimize load on pivot bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal components are used in the control system, then the system can handle significant loads, but the system becomes heavy and prone to corrosion
Solution Approach 1:
The patent applies composite materials (specifically carbon fiber reinforced plastics) to manufacture the actuator fork and actuator arm, replacing traditional metal components. This resolves the contradiction by providing high strength-to-weight ratio, enabling the control system to handle significant loads while reducing overall weight and eliminating corrosion issues inherent to metal components.
2Strength
If complex mechanical designs are used to handle significant loads, then the system can support high forces, but the device complexity increases
Solution Approach 1:
The patent merges the actuator fork and actuator arm into a single integrated composite component, eliminating the need for separate metal parts and complex mechanical assemblies. This integration reduces device complexity while maintaining load handling capability through the inherent strength of composite materials.
Solution Approach 2:
The use of composite materials allows for simplified design geometry without compromising strength, as the materials themselves provide high strength-to-weight ratios and fatigue resistance, eliminating the need for complex reinforcement structures required in metal designs.
3Device complexity
If traditional actuator fork design is used, then the structure is simple, but the actuator fork experiences high fatigue and deformation under load
Solution Approach 1:
The patent employs composite materials with optimized fiber orientations (including ±45 degrees and 0 degrees) to enhance fatigue resistance and deformation resistance of the actuator fork while maintaining a relatively simple U-shaped structure. The composite construction provides superior fatigue performance compared to traditional metal designs.
Solution Approach 2:
The patent applies local quality enhancements through strategically placed reinforcing elements and optimized fiber orientations in specific regions of the actuator fork, providing enhanced strength and fatigue resistance exactly where needed under load without complicating the overall simple U-shaped design.
Data Source
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AI summary
The invention is related to a control system 10 for controlling the pitch of rotor blades 1b, 1c of a multi-blade rotor 1a in a rotary-wing aircraft 1, and, more particularly, to the actuator fork 20b, 100 and the actuator arms 20a, 200 of the control system 10 for controlling the pitch of rotor blades 1b, 1c. The control system 10 may include an actuator arm 20a, 200 and an actuator fork 20b, 100. The actuator arm 20a, 200 is mounted in a manner that allows rotation around an actuator arm rotation axis 125 on the actuator arm pivot bearing 30a, 300 between two attachment points. The actuator fork 20b, 100 provides two separate supports 110, 120 for the two attachment points. One of the supports 120 is located in an overarching flange 130 that at least partially encompasses the actuator arm 20a, 200.