Integrated Actuator Housing via Additive Manufacturing
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Solution Overview
Problem
Conventional electromechanical actuators and electronic control units have separate housings that result in increased weight, size, and complexity, with inadequate connection efficiency and thermal management, particularly in applications like aircraft primary flight control surfaces.
Innovation Solution
The integration of the electronic control unit and electromechanical actuator housings using additive layer manufacturing techniques, where heat exchanger components provide pathways for power and electronic connections, and structural rigidity, forming a single, balanced, and lightweight apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate housings are used for the electromechanical actuator and electronic control unit, then ease of manufacture is improved, but weight and size increase
Solution Approach 1:
The patent merges the actuator housing and electronic control unit housing into a single integrated housing structure. The electronic control unit is mounted directly on the actuator housing, eliminating the need for separate housings and reducing overall weight while maintaining manufacturing feasibility through modular assembly of the integrated structure.
2Ease of manufacture
If separate housings are used for the electromechanical actuator and electronic control unit, then ease of manufacture is improved, but size increases
Solution Approach 1:
The patent combines the electronic control unit housing with the actuator housing into a single integrated structure, reducing the overall footprint and size of the assembly while maintaining ease of manufacture through the use of standardized mounting interfaces and modular components.
3Device complexity
If separate housings are used, then device complexity is reduced, but connection efficiency deteriorates
Solution Approach 1:
The integration of housings creates direct mounting interfaces between the electronic control unit and actuator, improving connection efficiency through rigid mechanical attachment and optimized signal/electrical connections, while the modular design maintains manageable device complexity.
4Device complexity
If separate housings are used, then device complexity is reduced, but thermal management deteriorates
Solution Approach 1:
The integrated housing design enables direct thermal coupling between the electronic control unit and actuator housing, allowing heat dissipation pathways to be optimized through the shared structure. The housing serves dual purposes as both mechanical enclosure and thermal management component, improving temperature control without significantly increasing device complexity.
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 approach reduces the weight and size of the combined unit, improves connection efficiency, enhances thermal management, and reduces the risk of water ingress and vibration, while allowing for better segregation of power and control signals, leading to improved reliability and handling.
Implementation Method 1
an additive layer manufacturing process to deposit a material
Implementation Method 2
heat exchanger components (120) connect the side portions (112) to the central portion (114)
Data Source
Figure 1A~1B
Figure 1C
Figure 2A~2B
AI summary
There is provided a method of manufacturing a housing 110 configured to hold an actuator 150 and an electronic control unit for the actuator 150. The method comprises additively manufacturing the housing 110 as a single piece, wherein the housing 110 comprises a central portion 114 configured to house the actuator, and one or more side portions 112 configured to house components of the electronic control unit.