Direct-Drive Rotor Head Reducing Actuator Count and Transmission Losses
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Solution Overview
Problem
Current rotor head designs for helicopters and UAVs are complex and costly, especially when scaling up to carry higher payloads or increase endurance, due to increased size and inertia, making pitch, roll, and yaw control difficult and inefficient.
Innovation Solution
A novel rotor head design featuring a direct-drive motor system, swashplate synchronization mechanism, and a single-direction cyclic and collective rotor head configuration, reducing complexity, cost, and increasing reliability by minimizing the number of actuators and parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional gear- or belt-drive systems are used in rotor heads, then power transmission can be achieved, but the system complexity and transmission losses increase
Solution Approach 1:
The patent removes the intermediate transmission components (gearbox, belt drive) from the power transmission path, directly coupling the motor shaft to the rotor hub. This extraction of unnecessary components eliminates transmission losses and reduces system complexity while maintaining the essential power transmission function.
Solution Approach 2:
The patent replaces complex mechanical transmission systems (gears, belts) with a direct mechanical coupling system. The direct-drive configuration uses simple mechanical connection elements like keys, set screws, or splines to transmit power directly from the motor to the rotor, eliminating the need for complex mechanical transmission mechanisms.
2Adaptability or versatility
If multiple actuators are used for cyclic and collective control of the swashplate, then control functionality is complete, but the number of parts and system complexity increase
Solution Approach 1:
The patent combines the functions of multiple actuators into a single integrated actuator system. The swashplate mechanism is designed so that one actuator can simultaneously control both cyclic and collective pitch changes through its mechanical linkage geometry, reducing the total number of actuators from three to two while maintaining full control functionality.
Solution Approach 2:
The patent designs the actuator system to perform multiple functions. Each actuator is configured to control both cyclic and collective pitch movements through the swashplate mechanism, making the actuators universal in function rather than dedicated to a single control function. This multi-functionality reduces the total number of actuators required.
3Weight of moving object
If the aerial vehicle size and inertia are increased to carry higher payloads, then payload capacity improves, but pitch, roll and yaw control becomes much harder to accomplish
Solution Approach 1:
The patent replaces complex mechanical control systems with a direct-drive configuration that improves control responsiveness. By eliminating intermediate transmission components, the system achieves more direct and responsive control authority, which helps manage the increased inertia of larger, heavier vehicles carrying higher payloads.
Data Source
AI summary
A rotor system for aerial vehicles where two or more rotor systems are used in a coaxial or tandem arrangement on the aerial vehicle.