Linear Electric Motor Actuator for Aircraft Wing Leading Edge Flap

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Solution Overview

Problem

Existing aircraft wing designs with mobile leading edge flaps face challenges in reducing the mass, footprint, and reliability of the movement device, while also requiring complex mechanical transmission and suffering from acoustic nuisances and limited precision.

Innovation Solution

Integration of a linear electric motor with a primary assembly of fixed trucks and a mobile secondary assembly with a magnetic pathway on the drive rail, eliminating mechanical transmission elements and enabling electronic control for improved precision and flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional mechanical transmission means (drive shafts with pinions and racks) are used to move the mobile leading edge flap, then the movement function is achieved, but the mass and footprint of the movement device increase

Engineering Contradiction:

ImprovereliabilityVSAvoidmass of movement device

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent replaces the traditional mechanical transmission system (drive shafts, pinions, and racks) with a linear electric motor system. This substitution eliminates complex mechanical components, reducing the mass of the movement device while maintaining reliable flap movement functionality through electromagnetic actuation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention extracts and removes unnecessary mechanical transmission elements from the system. By eliminating drive shafts, pinions, and racks, the patent reduces the overall mass and complexity of the movement device while retaining the essential function of moving the leading edge flap.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If traditional mechanical transmission elements (pinions and racks) are used, then movement is achieved, but the device complexity increases

Engineering Contradiction:

ImprovereliabilityVSAvoidcomplexity of movement device

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the complex mechanical transmission system with a linear electric motor, significantly simplifying the movement device. This substitution reduces the number of moving parts and mechanical interfaces, thereby lowering device complexity while improving reliability through fewer failure points.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention merges the functions of multiple mechanical components (drive shaft, pinion, rack) into a single integrated linear electric motor system. This consolidation reduces device complexity by eliminating the need for separate transmission elements while maintaining the flap movement function.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If mechanical transmission elements are used, then movement is achieved, but acoustic nuisances are generated

Engineering Contradiction:

Improveservice lifeVSAvoidacoustic nuisances

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces mechanical transmission elements that generate acoustic noise during operation with a linear electric motor. This substitution eliminates gear meshing noise and mechanical friction sounds, reducing acoustic nuisances while extending service life through contactless electromagnetic actuation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If traditional mechanical transmission means are used, then the flap movement is achieved, but the precision is limited

Engineering Contradiction:

Improveservice lifeVSAvoidprecision of flap movement

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical transmission means with a linear electric motor, which provides superior precision in flap movement control. The electromagnetic actuation system enables more accurate positioning and smoother motion compared to mechanical pinion-rack systems, while maintaining durability through the absence of mechanical wear.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution reduces the mass and footprint of the movement device, enhances reliability and precision, and provides electronic control for dynamic operation during flight phases, improving aerodynamic performance and reducing maintenance needs.

Implementation Method 1

the movement device comprises a linear electric motor comprising: a primary assembly equipped with at least one fixed truck comprising coils, the primary assembly being rigidly connected to the fixed central body of the wing; and a mobile secondary assembly comprising a magnetic pathway arranged on the drive rail

Methodology Applied

Scientific EffectLinear electric motor: Linear Motor

Implementation Method 2

a mobile secondary assembly comprising a magnetic pathway arranged on the drive rail

Methodology Applied

Scientific EffectElectromagnetic propulsion: Electromagnetic Propulsion

Data Source

PatentUS11440641B2Aircraft wing comprising a mobile leading edge flap driven by a linear electric motor

Publication Date: 2022.09.13 SONACA SA

AI summary

The invention relates to an aircraft wing comprising a stationary central wing body as well as at least one mobile leading edge flap intended for being moved relative to the stationary central body between an extended position and a retracted position, the wing comprising a device for moving the mobile leading edge flap, the device being provided with at least one mobile drive rail including a front end connected to the mobile flap. According to the invention, the movement device comprises a linear electric motor including: a primary assembly provided with at least one stationary carriage comprising coils, the primary assembly being rigidly connected to the stationary central body of the wing; and a mobile secondary assembly including a magnetic track arranged on the drive rail.