Linear Motor Actuator with Segmented Stators for Jam-Free Operation
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Solution Overview
Problem
Conventional actuators in high-reliability applications like aerospace often require jam-free operation, which is challenging to achieve with existing electro-mechanical actuators, especially when integrating fly-by-wire electronic control systems with older mechanical systems.
Innovation Solution
A linear motor actuator design featuring multiple stators magnetically coupled to a translator rod, with redundant phase windings, position sensors, and controllers, allowing for independent control loops and automatic reconfiguration of stators to maintain operation even if one stator fails, ensuring continuous motion and low failure rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional actuators with gear trains and clutching are used, then jam-free operation is achieved, but device complexity increases
Solution Approach 1:
The patent replaces conventional mechanical actuation systems (gear trains, clutching mechanisms) with a linear motor system that uses electromagnetic fields to directly drive the translator rod. This substitution eliminates the need for mechanical transmission components, thereby achieving jam-free operation while reducing overall device complexity.
Solution Approach 2:
The linear motor is divided into multiple independent stators, each capable of operating autonomously. This segmentation allows the system to maintain functionality even if one stator fails, enhancing reliability without requiring complex mechanical backup systems.
2Reliability
If multiple redundant stators with independent control loops are implemented, then reliability improves to 1 in 10^9 hours, but device complexity increases
Solution Approach 1:
The system is segmented into multiple independent stator units, each with its own control loop and position sensor. This modular architecture enables redundancy without creating a monolithic complex system, as each segment can be independently managed and replaced if needed.
Solution Approach 2:
The control system dynamically adjusts operational parameters by designating master and slave stators. When a stator fails, the system changes its operational state by reconfiguring which stators are active, maintaining reliability through parameter adaptation rather than structural complexity.
3Duration of action of stationary object
If master-slave stator configuration with automatic reconfiguration is used, then continuity of operation is ensured, but control system complexity increases
Solution Approach 1:
The control system automatically detects stator failures and performs reconfiguration without external intervention. The system monitors the health of each stator and autonomously redesignates master and slave roles, ensuring continuous operation while minimizing the need for complex external control mechanisms.
Solution Approach 2:
Position sensors and control loops provide continuous feedback on stator performance. This feedback mechanism enables the system to detect failures and trigger automatic reconfiguration, maintaining continuous operation through real-time monitoring and adaptive control.
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
The solution provides a jam-free and highly reliable electro-mechanical actuator with a failure rate of less than 1 in 10^9 hours, ensuring continuous operation and eliminating uncommanded transients by coordinating the stators and position sensors.
Implementation Method 1
Each stator can include a plurality of phase windings configured to drive motion of the translator rod in a phased series of magnetic impulses from the phase windings
Implementation Method 2
The translator rod can include a plurality of permanent magnets stacked along the actuation axis, wherein the permanent magnets and the phase windings of each of the stators are magnetically coupled to drive motion of the translator rod
Data Source
AI summary
A linear motor actuator includes a plurality of stators mounted stationary relative to one another along a common actuation axis. A translator rod is mounted to the stators for linear motion relative to the stators along the actuation axis, wherein each stator is magnetically coupled to the translator rod to drive motion of the translator rod along the actuation axis.