Hinge-Line Actuator Gearing for Compact High-Torque Wing Control
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Solution Overview
Problem
Hinge-line actuators for aircraft control surfaces face challenges in compact and lightweight design while maintaining high-torque, low-speed power transmission, particularly in thinly structured composite wings where spatial limitations and material durability are concerns.
Innovation Solution
A hinge-line actuator system featuring a drive shaft with contoured outer gear surfaces and a compound differential gearing mechanism, housed in a composite actuator housing with centering brackets and bearings, which allows for efficient torque transfer without damaging the composite structure, and includes gear seat extensions and stub shafts to accommodate rotational motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a hinge-line actuator uses compound differential gearing for high-torque, low-speed power transmission, then torque transmission capability is improved, but device size and weight increase
Solution Approach 1:
The patent implements nested gearing where the output gear is positioned between the first and second ground gears, with all gears sharing a common centerline. This nesting arrangement allows multiple gear stages to be compacted into a smaller volume, achieving high torque multiplication without proportionally increasing actuator size and weight.
Solution Approach 2:
The patent utilizes the axial dimension along the drive shaft to arrange the first and second ground gears spaced apart, while the output gear connects them radially. This three-dimensional arrangement optimizes space utilization and reduces the overall footprint of the actuator while maintaining the required gear ratios for high torque output.
2Volume of moving object
If the actuator is designed to be compact for thinly structured composite wings, then spatial efficiency is improved, but manufacturing precision and structural integrity become more difficult to maintain
Solution Approach 1:
The patent applies localized contouring to the gear seats, where each gear seat (first, second, and third) has a specific contoured outer surface that precisely matches the corresponding gear's outer gear surface. This localized precision fitting ensures accurate gear meshing and load distribution within the compact actuator volume, maintaining manufacturing precision despite the reduced overall size.
3Weight of stationary object
If the actuator housing is made from composite material to reduce weight, then weight is reduced, but durability and structural strength under high torque are compromised
Solution Approach 1:
The patent specifies that the actuator housing is formed from composite material, which provides a favorable strength-to-weight ratio. The housing includes integrated centering brackets and bearing supports that maintain structural integrity while minimizing weight, making it suitable for application in thinly structured composite wings where weight reduction is critical.
4Power
If the gear surfaces are contoured to improve torque transmission efficiency, then power transmission efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs contoured (curved) outer surfaces on the first, second, and third gears, with corresponding contoured gear seats in the housing. This curvature optimizes the contact pattern between mating gears, improving torque transmission efficiency and load distribution. The contoured surfaces are integrated into the gear and housing manufacturing processes, balancing performance improvement with manufacturing feasibility.
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
Enables high-torque, low-speed power transmission in a compact and lightweight form, suitable for thinly structured composite wings, ensuring durability and efficient operation by utilizing contoured gear surfaces and centering brackets to maintain structural integrity and facilitate relative motion.
Implementation Method 1
first and second ground gears spaced apart along the drive shaft, wherein the first and second output gears include first and second contoured outer gear surfaces; and an output gear disposed on the drive shaft and disposed between the first and second ground gears, wherein the output gear includes a third contoured outer gear surface
Implementation Method 2
contoured first, second and third gear seats that, respectively, seat the first, second and third outer gear surfaces
Implementation Method 3
first and second stub shafts that, respectively, extend outwardly from the first and second wheel flanges and surround the drive shaft
Data Source
AI summary
A hinge-line actuator has: a drive shaft; first and second ground gears spaced apart along the drive shaft, wherein the first and second output gears include first and second contoured outer gear surfaces; and an output gear disposed on the drive shaft and disposed between the first and second ground gears, wherein the output gear includes a third contoured outer gear surface; an actuator housing that includes: contoured first, second and third gear seats that, respectively, seat the first, second and third outer gear surfaces.