Magnetic Torque Couplers for Aircraft Wing Fold Gaps
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Solution Overview
Problem
Conventional couplers for torque transfer across an air gap, such as in aircraft wing folding mechanisms, are inefficient, costly, and complex, leading to issues like torsional vibration, weight addition, and limited folding ability due to mechanical gearboxes and linkages.
Innovation Solution
The implementation of magnetic torque couplers with tapered edges and magnetically coupled assemblies, allowing for efficient torque transfer across air gaps with improved engagement and disengagement capabilities, reduced size, and weight savings compared to conventional solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional mechanical couplers are used for torque transfer across an air gap, then torque transfer is achieved, but the system experiences increased weight, complexity, and torsional vibration
Solution Approach 1:
The patent replaces conventional mechanical couplers (gearboxes and linkages) with a magnetic coupling system that uses magnetic fields to transfer torque across an air gap. This substitution eliminates the need for direct mechanical contact, thereby reducing device complexity while maintaining torque transfer capability. The magnetic coupling system consists of magnetic assemblies on both the inboard and outboard flaps that interact magnetically across the gap, avoiding complex mechanical transmission mechanisms.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary medium to transfer torque between the inboard and outboard flaps across the air gap. Instead of direct mechanical contact, the magnetic field acts as the mediator that transmits rotational force. This intermediary approach allows torque transfer without physical connection, simplifying the overall system architecture and reducing the number of moving parts.
2Power
If conventional mechanical couplers are used for torque transfer, then torque transmission is achieved, but weight increases due to additional components
Solution Approach 1:
By replacing heavy mechanical components (gearboxes, linkages, shafts) with lightweight magnetic assemblies, the patent significantly reduces the weight of the coupling mechanism. The magnetic assemblies consist primarily of permanent magnets and magnetic materials, which are much lighter than equivalent mechanical torque transmission systems. This substitution maintains full torque transmission capability while minimizing weight penalty.
Solution Approach 2:
The patent extracts and removes unnecessary mechanical components from the torque transmission system. By eliminating the mechanical gearbox and linkage system, only the essential magnetic assemblies remain to perform the torque transfer function. This extraction of redundant components directly reduces the overall weight of the moving object while preserving the core functionality of torque transmission.
3Power
If conventional mechanical couplers are used across a wing fold gap, then torque transfer is possible, but the system becomes costly and less adaptable to folding configurations
Solution Approach 1:
The patent employs dynamic magnetic coupling that can adapt to changing spatial relationships between the inboard and outboard flaps during wing folding operations. The magnetic field interaction remains effective across varying gap distances and angles, allowing the system to dynamically adjust to different wing configurations. This dynamic capability enables full wing folding versatility while maintaining torque transfer, unlike rigid mechanical couplings that would constrain movement.
Solution Approach 2:
The magnetic field serves as a flexible intermediary that can transmit torque across the variable geometry of the wing fold gap. Unlike mechanical linkages that require precise alignment and fixed geometries, the magnetic field adapts naturally to the changing positions of the flaps during folding. This intermediary approach provides superior adaptability to the dynamic folding configurations required by modern aircraft wing designs.
4Device complexity
If magnetic torque couplers are used, then weight and complexity are reduced, but engagement and disengagement efficiency must be improved
Solution Approach 1:
The patent employs tapered frustoconical surfaces on the magnetic assemblies that guide engagement and disengagement through conical geometry. The tapered surfaces create a self-aligning effect that facilitates smooth engagement by guiding the assemblies into proper magnetic coupling alignment. During disengagement, the tapered geometry allows for controlled separation. This curved geometric approach simplifies the engagement/disengagement operation compared to flat-surfaced magnetic couplers that would require precise alignment mechanisms.
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
Magnetic torque couplers reduce torsional vibration, provide weight and cost savings, and enhance engagement/disengagement efficiency, enabling more effective torque transfer while maintaining structural integrity and flexibility in aircraft wing folding applications.
Implementation Method 1
The first plurality of magnets are operable to magnetically couple across a gap with the second plurality of magnets
Data Source
AI summary
In one embodiment, an aircraft includes a wing operable to fold along a wing fold gap. The wing comprises an inboard edge flap and an outboard edge flap, wherein the wing fold gap is between the inboard edge flap and the outboard edge flap. The aircraft further includes an input shaft operably coupled to the inboard edge flap, the input shaft mechanically coupled to a first magnetic torque coupler assembly at a first end of the input shaft. The wing further includes an output shaft operably coupled to the outboard edge flap, the output shaft mechanically coupled to a second magnetic torque coupler assembly at a first end of the output shaft. The first magnetic torque coupler assembly may magnetically couple to the second magnetic torque coupler assembly across the fold gap.