Rotorcraft Driveshaft Coupling Misalignment Measurement
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Solution Overview
Problem
Current methods for measuring driveshaft misalignment in rotorcraft are cumbersome, prone to error, and require extensive and costly static testing, which can be detrimental under tight schedule constraints.
Innovation Solution
Direct measurement of driveshaft misalignment and chucking using precision sensors such as hall sensors, infrared sensors, and lasers installed on both sides of the driveshaft coupling, allowing for continuous monitoring and accurate determination of misalignment angles during flight or regular operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pylon pull test is used to measure driveshaft misalignment, then misalignment can be indirectly measured, but the testing process becomes cumbersome, time-consuming, and costly
Solution Approach 1:
The patent replaces the complex mechanical pylon pull test system with optical measurement devices (lasers, infrared sensors, hall sensors) that directly measure coupling misalignment. This substitution eliminates the need for elaborate mechanical testing setups and reduces testing time from weeks to minutes while maintaining or improving measurement precision.
Solution Approach 2:
The patent extracts the measurement function from the complex pylon pull test system by installing dedicated measurement devices directly on the driveshaft coupling. This allows misalignment to be measured independently without requiring the entire pylon pull test infrastructure, significantly reducing testing complexity and time.
2Measurement precision
If pylon pull test is used to measure driveshaft misalignment, then misalignment can be indirectly measured, but the cost of tools, equipment, and facilities increases
Solution Approach 1:
The patent replaces expensive mechanical testing equipment with optical and electromagnetic sensors that are more compact, require less infrastructure, and can be deployed more easily. The measurement devices (lasers, infrared sensors, hall sensors) eliminate the need for costly pylon pull test facilities while providing direct, accurate measurements.
Solution Approach 2:
The patent uses optical fields (laser beams, infrared radiation) as information carriers to create a measurement system that copies the functionality of mechanical measurement without requiring physical contact or complex mechanical linkages. This allows misalignment to be measured through field interactions rather than mechanical force applications.
3Measurement precision
If pylon pull test is used to measure driveshaft misalignment, then calibration equations can be derived, but the process requires extensive planning and execution time
Solution Approach 1:
The patent installs measurement devices directly on the driveshaft coupling during assembly, allowing misalignment to be measured immediately in the field without requiring preliminary calibration tests. This preliminary positioning of measurement equipment eliminates the need for time-consuming calibration equations and allows direct measurement during flight testing or regular operation.
Solution Approach 2:
The measurement system is designed to be self-contained and autonomous, with sensors that automatically measure coupling misalignment without requiring external calibration procedures. The system performs self-measurement during normal operation, eliminating the need for separate calibration activities and improving development program efficiency.
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
This approach provides more accurate and timely misalignment information, reducing the need for costly static testing and enabling safer rotorcraft design, testing, and operation by continuously monitoring driveshaft conditions.
Implementation Method 1
measurement devices may include hall sensor(s)/probe(s)
Implementation Method 2
infrared sensor(s)
Implementation Method 3
laser(s)
Data Source
AI summary
According to one embodiment, a system for measuring coupling misalignment of a rotorcraft drive shaft includes a reference device and a sensor. The sensor is configured to receive a signal from the reference device indicative of a distance between the reference device and the sensor. The reference device and the sensor are configured to be disposed on opposite sides of a flexible coupling coupled to the drive shaft and disposed between the engine and the pylon. The flexible coupling is configured to rotate with the drive shaft and comprises a flexure portion configured to flex in response to a difference in alignment between the engine and the pylon. A misalignment measurement system may be configured to generate a misalignment value in response to the signal.