Integrated Fly-By-Wire Servo Actuator With Redundant Differentials
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Solution Overview
Problem
Existing fly-by-wire (FBW) servo actuators for aircraft primary flight control often experience increased latency due to separate housings for dual servo actuators, which can lead to communication delays and reduced system reliability.
Innovation Solution
A single FBW servo actuator design featuring two differentials, each driven by two distinct motors, providing redundancy and eliminating the need for separate housings, thus reducing latency and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate servo actuators are used to provide redundancy, then system reliability is improved, but communication latency increases and device complexity increases
Solution Approach 1:
The patent combines two separate servo actuators into a single integrated actuator unit. The housing contains both differentials and their associated motors within one structure, eliminating the need for separate housings and reducing communication latency between actuators while maintaining redundancy through the dual-differential design
2Reliability
If two separate servo actuators are used to provide redundancy, then system reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges two servo actuators into one integrated unit with a common housing, reducing the number of separate components and simplifying installation while maintaining the redundancy benefits of having two differentials with four motors total
Solution Approach 2:
The single housing serves multiple functions: it houses both differentials, provides a unified mounting structure, and integrates the control system, thereby reducing overall system complexity despite maintaining redundant actuation paths
3Reliability
If four motors are used in the dual differential system, then redundancy and reliability are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent divides the actuator system into two independent differential units, each with its own motors and gear train. This segmentation allows for modular manufacturing and assembly, where each differential can be tested and assembled separately before integration into the final actuator unit
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 proposed solution enhances the reliability and efficiency of FBW servo actuators by eliminating single points of failure, reducing latency, and simplifying installation and maintenance through the use of a single housing.
Implementation Method 1
The differentials may comprise harmonic gears (also known as strain wave gears) in which a circular spline is driven by a first gear coupled to a motor, a wave generator is driven by a second gear coupled to a motor or by a direct drive motor, and a flex spline is the differential output.
Data Source
AI summary
A fly-by-wire (FBW) servo actuator may be used for primary flight control for an aircraft. The FBW servo actuator may have an inner output shaft coupled to an output arm that actuates a control surface of the aircraft. A first differential and a second differential may be coupled to the output shaft via a first outer shaft and a second outer shaft, respectively. Two inputs may be provided to each of the two differentials, and each input may be driven by a distinct motor. Thus, if one of the motors fails, the other motors may allow for uninterrupted operation of the servo actuator. The differentials may comprise harmonic gears driven by the two inputs. The inputs may be applied to a wave generator and a circular spline of the harmonic gear, and a flex spline of the harmonic gear may drive the outer shaft.