Composite Gimbal Assembly With Integrated Pivots for Tight Space Envelopes
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Solution Overview
Problem
Actuator gimbals in thrust reverser actuation systems face space envelope constraints due to the need for mechanical fasteners and larger space accommodations for pivot pins and tools, making it challenging to reduce the overall size and weight of the gimbal assembly.
Innovation Solution
A gimbal assembly with a body featuring pivot bosses projecting radially outward, integrated into a carbon fibre-reinforced polymer matrix composite outer case, allowing direct pivotal coupling without mechanical fasteners, and manufactured using methods like carbon fibre winding, which reduces the size and weight by eliminating the need for separate pivot pins and fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional mechanical fasteners and pivot pins are used to assemble the gimbal, then the structural strength and reliability are improved, but the space envelope and weight increase
Solution Approach 1:
The outer case is formed as a monolithic integral structure that directly incorporates pivot bosses and receiving cavities, eliminating the need for separate mechanical fasteners and pivot pins. This merging of components reduces the space envelope while maintaining structural integrity through the continuous composite material structure.
Solution Approach 2:
The outer case is manufactured from carbon fibre-reinforced polymer matrix composite material, which provides high strength-to-weight ratio and torsional load capacity. This composite material enables the structure to maintain strength while reducing overall weight and envelope size compared to conventional metallic fastener systems.
2Reliability
If conventional mechanical fasteners and pivot pins are used to assemble the gimbal, then the structural reliability is improved, but the weight increases
Solution Approach 1:
By integrating the pivot bosses and receiving cavities directly into the monolithic outer case structure, the invention eliminates multiple separate components (fasteners, pivot pins, retaining straps) and their associated hardware, significantly reducing total weight while maintaining structural reliability through the integral design.
Solution Approach 2:
The carbon fibre-reinforced polymer matrix composite material provides exceptional strength-to-weight ratio, enabling the outer case to maintain high structural reliability and load-bearing capacity while dramatically reducing weight compared to conventional metallic assemblies with multiple fasteners and hardware components.
3Strength
If conventional mechanical fasteners are used, then the assembly strength is improved, but the device complexity and part count increase
Solution Approach 1:
The outer case is designed as a monolithic integral structure with pivot bosses and receiving cavities formed directly as part of the single component. This merging eliminates the need for separate fasteners, pivot pins, retaining straps, and associated hardware, dramatically reducing part count and assembly complexity while maintaining assembly strength through the continuous composite structure.
4Weight of moving object
If carbon fibre-reinforced polymer matrix composite material is used for the outer case, then the weight is reduced, but the manufacturing complexity increases
Solution Approach 1:
The outer case is manufactured as a monolithic integral structure using carbon fibre-reinforced polymer matrix composite material through processes such as autoclave curing or resin transfer molding. This preliminary formation of the complete outer case with integrated pivot bosses and cavities eliminates the need for subsequent assembly operations, reducing overall manufacturing complexity despite the advanced material processing required.
Data Source
AI summary
A gimbal assembly comprises a body, comprising at least one pivot boss projecting radially outwards along a first pivot axis (V) from an outer surface of the body; a gimbal, comprising an outer case surrounding the body and at least one hole projecting radially outwards along a second pivot axis (H) to receive a pivot pin to pivotally couple the gimbal to a fixed structure. The second pivot axis (H) is perpendicular to the first pivot axis (V) and the outer case is formed at least partially from carbon fibre-reinforced polymer matrix composite material. The outer case comprises at least one cavity on its inner surface in which the at least one pivot boss is located to pivotally couple the gimbal to the body.