Integral EHA Housing for Lower-Weight Actuator Assembly
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Solution Overview
Problem
Existing electro-hydrostatic actuator (EHA) assemblies are complex, heavy, and expensive due to the need for multiple separate parts, which increases manufacturing costs, assembly complexity, and weight.
Innovation Solution
The EHA assembly is redesigned with a single, integral housing that combines the hydraulic control block, motor-pump assembly, and power control module, using additive manufacturing to create a compact, topologically optimized structure that houses all necessary components, including a passage for the power line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate parts are used to assemble the actuator assembly, then manufacturing and assembly flexibility is improved, but the assembly becomes heavier, more complex, and more expensive
Solution Approach 1:
The patent combines multiple separate components (hydraulic block, motor-pump assembly housing, power control module housing, accumulator housing) into a single integrated housing structure. This merging eliminates the need for multiple suppliers and assembly operations, reducing assembly complexity and cost while maintaining manufacturing flexibility through the additive manufacturing process.
Solution Approach 2:
The integrated housing serves multiple functions simultaneously: it houses the hydraulic control block, contains the motor-pump assembly, accommodates the power control module, and provides structural support. This multi-functionality reduces the total number of parts needed while maintaining all necessary capabilities.
2Ease of manufacture
If multiple separate parts are used to assemble the actuator assembly, then ease of manufacture is improved, but production time and cost increase
Solution Approach 1:
The patent merges multiple manufacturing operations into a single additive manufacturing process. Instead of separately forging, machining, or casting multiple parts and then assembling them, the entire housing structure is produced in one additive manufacturing operation, significantly reducing production time and complexity.
Solution Approach 2:
The patent employs additive manufacturing technology, which represents a fundamental change in the manufacturing parameter from traditional subtractive or forming processes. This enables complex geometries to be produced directly without multiple assembly steps, reducing production time while maintaining manufacturing flexibility.
3Adaptability or versatility
If traditional multi-part assembly is used, then component availability is improved, but overall assembly weight increases
Solution Approach 1:
The patent combines multiple separate components into a single integrated housing, eliminating redundant materials and connection hardware (bolts, seals, flanges) between parts. This integration reduces the overall assembly weight while maintaining all necessary functional components within the unified structure.
Data Source
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AI summary
An electro-hydrostatic actuator, EHA, assembly comprising: a power line (200), and a one-piece, integral housing (100) housing a hydraulic control block, a power control module, PCM, and a motor-pump assembly, the integral housing (100) comprising a passage through which the power line (200) passes.