Helicopter Fly-By-Wire Electro-Mechanical Interface for Weight Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current primary flight controls for helicopters face challenges in weight reduction, safety, and processing power, particularly due to their mechanical nature, which makes them less suitable for modern helicopter operations with high sensitivity and instability requirements, and existing electric systems are complex and costly to implement.
Innovation Solution
The implementation of Fly-By-Wire and Fly-by-light primary flight controls using hydraulic servo actuators with direct drive electro motors and a smart electro-mechanical interface, which reduces weight, complexity, and cost while providing reliable and flexible control, allowing for retrofitting of existing mechanical systems and integration with hydraulic servo actuators, and enabling real-time monitoring and feedback mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical primary flight controls are used in helicopters, then structural strength and load-bearing capacity are ensured, but weight increases and operational complexity increases
Solution Approach 1:
The patent replaces traditional mechanical push-pull rods and cables with an electro-mechanical interface consisting of electric motors, reduction gears, and mechanical linkages. This substitution maintains the necessary mechanical strength and load-bearing capacity while reducing overall system weight by eliminating extensive mechanical transmission components.
Solution Approach 2:
The control system is segmented into independent electro-mechanical modules, each with its own motor and linkage. This segmentation allows for localized strength requirements rather than requiring the entire mechanical system to handle maximum loads, thereby reducing overall weight while maintaining necessary strength at each control point.
2Strength
If mechanical primary flight controls are used in helicopters, then load distribution is achieved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical load distribution systems with independent electro-mechanical modules. Each module independently handles its own load through electric motors and reduction gears, eliminating the need for complex mechanical load-sharing mechanisms while maintaining proper load distribution across the control system.
Solution Approach 2:
The electro-mechanical interface modules are designed to be universal and multi-functional, capable of handling various control functions through a standardized architecture. This universality reduces overall system complexity by using identical modular components rather than specialized mechanical mechanisms for each control function.
3Weight of moving object
If electric primary flight controls are implemented in helicopters, then weight is reduced, but reliability decreases due to susceptibility to malfunctions
Solution Approach 1:
The patent introduces hydraulic servo actuators as intermediaries between the electro-mechanical interface and the control surfaces. These actuators provide a robust mechanical final stage that is highly reliable and less susceptible to malfunctions, while the electro-mechanical interface handles the lighter-weight signal transmission and control functions.
Solution Approach 2:
The system incorporates redundancy and fail-safe mechanisms in the electro-mechanical interface, including backup motors and protective circuitry, to cushion against potential malfunctions before they occur. This beforehand cushioning maintains reliability while allowing the use of lighter electric components.
4Productivity
If digital computers are used for high processing power in helicopter controls, then stability control is improved, but susceptibility to malfunctions increases
Solution Approach 1:
The patent positions digital computers as intermediaries that process control signals and provide stability enhancement, but separates them from the critical flight control path. The computers operate in parallel, processing data and providing guidance signals to the electro-mechanical interface, while the primary control reliability is maintained through the independent electro-hydraulic control channels.
Solution Approach 2:
The system applies partial automation through digital computers for non-critical functions such as stability augmentation and data processing, while maintaining manual or electro-mechanical control for critical flight functions. This partial action approach provides the benefits of high processing power for stability without exposing the entire control system to computer susceptibility.
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 solution provides a modern, high-performance flight control system that is lightweight, reliable, and adaptable, capable of handling high-frequency vibrations and aeroelastic instabilities, while reducing the risk of jamming and allowing for condition-based maintenance, thus enhancing safety and operational efficiency.
Implementation Method 1
at least one direct drive electric motor (5) without mechanical gears, the armature (12) of which is mechanically connected to the control valve (29) as a mechanical input of the hydraulic servo actuator (8)
Implementation Method 2
hydraulic servo actuators (8) of the main and/ or tail rotor controls (4)
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to primary flight controls (10) for main and/or tail rotors (4) of helicopters with an electro-mechanical interface between any of Fly-By-Wire and/or of Fly-by-light controls and hydraulic servo actuators (8) for control force amplification towards said main and/or tail rotor controls (4). For each of the main and/or tail rotor controls (4) there is provided but one of the hydraulic servo actuators (8), connected by one mechanical linkage (7) to one electro motor (5), said one hydraulic servo actuator (8) being of the type having the one mechanical linkage (7) connected to its input (29) and its output (30) and the one electro motor (5) being of the direct drive type, the position of said electro motor (5) having a reference to said one mechanical linkage (7) and the torque delivered by said electro motor (5) to the hydraulic servo actuator (8) being related to the power consumption of said electro motor (5).