Dual-Powertrain Rotary Actuator for Redundant Flight Control Torque
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Solution Overview
Problem
Existing actuators for flight control surfaces in aircrafts face challenges in providing efficient and reliable torque transmission and redundancy in case of motor failure, particularly in applications requiring precise movement and high torque.
Innovation Solution
A rotary actuator design incorporating two coaxial powertrains with series-arranged planetary gearsets driven by dual electric motors, allowing simultaneous operation and redundancy to ensure continuous functionality even if one motor fails, with sector gears providing reduced packaging and enhanced torque magnification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single electric motor and geartrain are used to drive the flight control surface, then the device complexity is reduced, but the reliability decreases due to lack of redundancy in case of motor failure
Solution Approach 1:
The actuator is segmented into two independent powertrains (first powertrain with first electric motor and first geartrain, second powertrain with second electric motor and second geartrain), each capable of independently driving the output shaft. This segmentation provides redundancy so that if one motor fails, the other can still operate the flight control surface, thereby improving reliability without requiring a completely redundant system.
Solution Approach 2:
The two independent powertrains are merged to share a common output shaft and housing space. Both powertrains are arranged coaxially within the same housing, with their drive gears engaging the same output shaft. This merging allows the system to maintain compact packaging while achieving redundancy, as the two motors can operate simultaneously or one can take over if the other fails.
2Reliability
If dual electric motors and geartrains are used to provide redundancy, then the reliability improves, but the volume increases due to additional components
Solution Approach 1:
The second powertrain is nested within the same housing as the first powertrain, with both powertrains arranged coaxially. The housing contains both electric motors, geartrains, and drive gears in a compact configuration where components are nested along the axial direction. This nesting allows the dual-powertrain system to occupy minimal volume while maintaining full redundancy capability.
Solution Approach 2:
Instead of placing the two powertrains side-by-side in the radial direction, they are arranged in the axial dimension, one after the other along the same axis. This dimensional arrangement allows both powertrains to share the same radial space, effectively reducing the overall volume requirement while maintaining redundancy.
3Power
If traditional gear arrangements are used, then the manufacturing is simpler, but the torque transmission efficiency decreases
Solution Approach 1:
Planetary gearsets are introduced as intermediary mechanisms between the electric motors and the output shaft. The planetary gearsets provide high torque multiplication in a compact configuration, efficiently transmitting power from the motors to the flight control surface. The planetary gears act as intermediaries that convert the high-speed, low-torque motor output into low-speed, high-torque actuation suitable for flight control surfaces.
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 dual powertrain design ensures reliable and efficient actuation of flight control surfaces with enhanced torque capability and redundancy, maintaining operation even in the event of motor failure, while minimizing space requirements.
Implementation Method 1
a first electric motor drivably connected to a first geartrain having at least two planetary gearsets arranged in series
Implementation Method 2
a first geartrain having at least two planetary gearsets arranged in series and a first drive gear driven by the first electric motor via the first geartrain
Data Source
AI summary
A rotary actuator for a flight control surface includes a first electric motor connected to a first geartrain having planetary gearsets in series and a first drive gear driven by the first electric motor via the first geartrain. The first geartrain and the first drive gear define a first powertrain. The rotary actuator also includes a second electric motor connected to a second geartrain having planetary gearsets in series. The second geartrain is separate from the first geartrain. The rotary actuator further includes a second drive gear driven by the second electric motor via the second geartrain. The second geartrain and the second drive gear define a second powertrain that is coaxial with the first powertrain. Additionally, the rotary actuator includes an output shaft parallel to the first and second powertrains. The output shaft is driven simultaneously via the first and second drive gears.