Hybrid Actuator Assembly for Independent Flight Surface Control
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Solution Overview
Problem
Current aircraft actuator systems rely heavily on hydraulic systems, which can be unreliable in failure scenarios, lacking a robust backup mechanism for independent control of flight control surfaces.
Innovation Solution
A dual-independent hybrid actuator system that combines hydraulic and electric motor control, using an electrohydraulic servo valve and an electric motor with a threaded axle to provide independent control of a hydraulic piston assembly, allowing for coordinated hydraulic and mechanical force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic actuator system is used to control flight control surfaces, then the system can provide sufficient control force, but the system lacks reliability when hydraulic failure occurs
Solution Approach 1:
The patent combines hydraulic actuation and electric motor actuation into a single hybrid actuator system. The electric motor is mechanically coupled to the hydraulic piston assembly via a threaded axle, allowing both hydraulic and electric forces to act on the same piston rod. This merging enables the system to provide sufficient control force through hydraulic pressure while simultaneously gaining backup control capability through the electric motor, thus improving reliability without sacrificing adaptability.
2Reliability
If a backup system is added to the hydraulic actuator, then reliability is improved, but device complexity increases
Solution Approach 1:
Instead of adding a separate backup actuator system, the patent integrates the electric motor directly into the hydraulic actuator structure. The electric motor shares the same actuator body, piston rod, and control linkage as the hydraulic system. This merging approach provides backup control capability while minimizing additional complexity by reusing existing structural components rather than adding entirely separate systems.
Solution Approach 2:
The hybrid actuator system is designed to perform multiple functions: it can operate in hydraulic-only mode, electric-only mode, or combined mode. The electric motor serves both as a backup actuator and as a means to reduce hydraulic pressure requirements. This multi-functionality reduces the need for separate dedicated backup systems, thereby improving reliability while controlling device complexity.
3Force
If hydraulic pressure is increased to ensure sufficient control force, then control capability is improved, but energy consumption increases
Solution Approach 1:
The electric motor in the hybrid system serves multiple functions: it can act as a backup actuator and simultaneously function as a force assistant to reduce the hydraulic pressure needed to achieve the required control force. By sharing the load between electric and hydraulic systems, the hydraulic pressure can be reduced while maintaining sufficient total control force, thereby reducing hydraulic energy consumption while preserving control capability.
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 reliable and independent control of flight control surfaces by leveraging both hydraulic and electric motor forces, enhancing system reliability and dynamics, particularly in cases where hydraulic pressure is insufficient.
Implementation Method 1
a threaded axle mechanically coupled to a motor shaft of the electric motor. The threaded axle passes through the first hydraulic sub-chamber and engages with a threaded port formed in the hydraulic piston assembly
Implementation Method 2
controlling operation of an electrohydraulic servo valve of a hydraulic system to generate a first hydraulic pressure differential between opposing sides of a hydraulic piston that urges a piston rod mounted to the hydraulic piston to move
Data Source
AI summary
A dual-independent hybrid actuator system includes an actuator body defining a hydraulic chamber. The actuator system includes a hydraulic piston assembly, including a hydraulic piston disposed within the hydraulic chamber and dividing the hydraulic chamber into a first hydraulic sub-chamber in fluid communication with a first hydraulic fluid passage and a second hydraulic sub-chamber in fluid communication with a second hydraulic fluid passage. The actuator system further includes a piston rod mounted to the hydraulic piston that passes through the second hydraulic sub-chamber with a distal end that projects outward from the actuator body. The actuator system further includes an electric motor mounted to the actuator body, and a threaded axle mechanically coupled to a motor shaft of the electric motor. The threaded axle passes through the first hydraulic sub-chamber and engages with a threaded port formed in the hydraulic piston assembly.