Gyroplane Pneumatic Torque Coupling for Weight Reduction
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Solution Overview
Problem
Current gyrocopters face challenges in designing a lightweight torque transmission device that can withstand torque peaks during pre-rotation without being oversized, and existing solutions like hydraulically or electrically operated couplings are either heavy or unsuitable due to weight and efficiency issues.
Innovation Solution
A pneumatic coupling with a dry friction mechanism, featuring a coaxial input and output shaft arrangement, a compact pneumatic cylinder, and a release spring, which allows for controlled torque transmission and avoids overloading, ensuring the powertrain is not overworked and maintains operational reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a lightweight torque transmission device is designed, then the overall aircraft weight is reduced, but the device cannot withstand torque peaks during pre-rotation
Solution Approach 1:
A pneumatic coupling is introduced as an intermediary element between the motor and the rotor head. This coupling includes a pneumatic cylinder with a piston that can slide along the drive shaft, and a friction element that presses against the drive shaft when pneumatic pressure is applied. The friction element acts as a mediator that limits torque transmission to a predefined maximum value, preventing torque peaks from reaching the powertrain components while allowing the use of a lightweight torque transmission device.
Solution Approach 2:
The pneumatic coupling changes the operational parameters of the torque transmission system by introducing controlled friction through the friction element. The friction coefficient and contact pressure are adjusted via pneumatic pressure, allowing the system to dynamically control torque transmission. This parameter change enables the torque transmission device to withstand torque peaks without being oversized, as the friction element limits the maximum torque to a predefined safe value.
2Ease of operation
If a hydraulically operated coupling is used, then torque transmission can be controlled, but the pilot can engage the coupling too quickly causing torque peaks that overwork the powertrain
Solution Approach 1:
The pneumatic coupling serves as an intermediary that decouples the pilot's control input from the actual torque transmission. The pneumatic system with its cylinder and piston mechanism provides inherent damping and control, preventing sudden engagement even if the pilot acts quickly. The friction element gradually engages with the drive shaft, smoothing out rapid movements and protecting the powertrain from torque peaks.
3Reliability
If the torque transmission device is oversized to withstand torque peaks, then reliability is improved, but the device becomes heavier
Solution Approach 1:
The pneumatic coupling with its friction element acts as a protective intermediary that limits torque transmission to a predefined maximum. This allows the use of a lightweight torque transmission device, as the friction element prevents excessive torque from reaching the powertrain components. The system achieves reliability through active torque limiting rather than through oversized component design.
4Ease of operation
If a magnetic coupling is used, then torque transmission can be controlled, but the generator creates large additional weight
Solution Approach 1:
The patent employs a pneumatic coupling system instead of a magnetic coupling with generator. The pneumatic cylinder is supplied with compressed air from the aircraft's existing pneumatic system, and the pneumatic pressure controls the friction element's engagement with the drive shaft. This pneumatic approach provides torque transmission control without requiring an additional generator, thereby avoiding the large weight penalty associated with magnetic coupling systems.
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 pneumatic coupling effectively manages torque peaks, preventing overloading and damage, while maintaining a lightweight design, enhancing operational safety and reliability by allowing for controlled torque engagement and reducing wear, thus meeting the requirements for a sport aircraft.
Implementation Method 1
a pneumatic coupling (28) with a dry friction mechanism, featuring a coaxial input and output shaft arrangement, a compact pneumatic cylinder
Implementation Method 2
pneumatic coupling (28) with a dry friction mechanism
Data Source
AI summary
A gyrocopter includes a motor, a rotor head and a torque transmission device for transmitting torque of the motor to the rotor head. The torque transmission device includes a pneumatic coupling.