Flap Actuator Housing Integrating Hydraulic Channels
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Solution Overview
Problem
Existing servo/spoiler actuators for aircraft have unfavorable flow transitions and increased complexity due to drilling methods, leading to large construction height and weight, and the sealing with press plugs further complicates the hydraulic circuits.
Innovation Solution
The actuator housing integrates all fluid-conducting channels and components, eliminating the need for a valve block by using generative processes like selective laser melting, which allows for a layer-wise structure and direct integration of hydraulic and electrical lines, reducing size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If drilling methods are used to create flow channels in the valve block, then the hydraulic circuits can be established, but unfavorable flow transitions and sharp edges result which are difficult to define with respect to strength and require complex rework
Solution Approach 1:
The patent replaces conventional mechanical drilling processes with laser technology to create flow channels. The laser beam melts and removes material along the desired channel path, eliminating sharp edges and creating smooth, continuous flow transitions without requiring subsequent rework or deburring operations.
Solution Approach 2:
The invention changes the manufacturing parameter from mechanical cutting to thermal processing. By using laser energy to melt and vaporize material, the process achieves superior surface quality and flow characteristics that cannot be obtained through traditional drilling, while also enabling complex three-dimensional channel geometries.
2Reliability
If press plugs are used to seal hydraulic circuits in the valve block, then closed hydraulic circuits are achieved, but the defect complexity increases and larger material cross-sections are required
Solution Approach 1:
The patent extracts and eliminates the press plugs from the system entirely. By using laser-generated channels with integrated sealing structures built directly into the housing, the separate sealing components are removed, reducing assembly complexity and potential failure points while maintaining reliable hydraulic circuit sealing.
Solution Approach 2:
The invention merges the sealing function into the housing structure itself. The laser-generated channels create integrated sealing features that are built-in rather than added through separate components, combining the structural and sealing functions into a single monolithic piece.
3Reliability
If the valve block is designed with sufficient material cross-sections for press plug press fits, then the sealing reliability is ensured, but the construction height and weight increase which are undesirable in aeronautic applications
Solution Approach 1:
The patent removes the press plugs and their associated large material cross-section requirements from the design. The laser-generated channels enable sealing through integrated features that require minimal material, dramatically reducing the valve block weight while maintaining sealing reliability through the precision of the laser-formed geometry.
4Reliability
If a valve block is used to connect the servo valve and actuator, then the hydraulic circuits are established, but the construction height and complexity increase
Solution Approach 1:
The patent merges the valve block functionality directly into the actuator housing. The laser-generated channels are built directly into the housing structure, eliminating the separate valve block component and reducing the overall construction height while maintaining all necessary hydraulic connection functions.
Solution Approach 2:
The actuator housing is designed to perform multiple functions: it serves as the structural housing, contains the laser-generated flow channels, provides sealing features, and mounts the servo valve. This multi-functional design eliminates the need for a separate valve block, reducing complexity and construction height.
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 results in a lighter, more compact flap actuator with optimized flow and reduced complexity, eliminating the need for press plugs and enabling the integration of multiple components within the actuator housing, thereby enhancing aerodynamic efficiency and reducing material usage.
Implementation Method 1
at least one electrohydraulic servo valve and at least one actuator which are hydraulically connected to one another
Implementation Method 2
the valve blocks are provided with connection bores and transverse bores for transferring the fluid from the servo valve to the actuator
Data Source
AI summary
The invention relates to a flap actuator, in particular to a servo/spoiler actuator, comprising at least one electrohydraulic servo valve and at least one actuator which are hydraulically connected to one another, wherein the actuator comprises at least one actuator housing in and/or at which the at least one channel is arranged by means of which one or more components, preferably likewise arranged in and/or at the actuator housing, are hydraulically connected and wherein no valve block is arranged between the actuator and the servo valve.