Rotorcraft Pitch Housing Sensor Nesting for Blade Position Monitoring
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Solution Overview
Problem
Existing rotorcraft blade position monitoring systems require costly and time-consuming modifications to the rotor hub, exposing sensors to the elements and risking disconnection, which complicates accurate and reliable data collection during flight testing.
Innovation Solution
A sensor assembly is positioned within the internal volume of a pitch housing connected to the rotor hub, using a bearing pin and spherical bearing to sense angular displacements about both flap and feather axes, eliminating the need for external sensor placement and reducing exposure to environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are installed on the exterior surface of the rotor hub, then rotor blade position data can be collected, but the sensors are exposed to the elements requiring frequent repairs and risk disconnection
Solution Approach 1:
The sensor assembly is nested within the pitch housing, which is itself connected to the rotor hub. The sensor assembly includes a first position sensor and a second position sensor housed within the pitch housing's internal volume, protecting them from environmental exposure while maintaining measurement capability through operable connections to the bearing pin and pitch housing.
Solution Approach 2:
The pitch housing serves as an intermediary structure that houses the sensor assembly and provides protected mounting locations. The bearing pin acts as an intermediary mechanical element that transmits angular displacement information from the rotor hub to the sensors without requiring direct external sensor mounting.
2Measurement precision
If sensors are installed on the exterior surface of the rotor hub, then rotor blade position data can be collected, but unrepairable modifications (drilling and taping holes) are required to the rotor hub
Solution Approach 1:
The sensor assembly is nested within the pitch housing, eliminating the need for modifications to the rotor hub itself. The pitch housing provides an internal volume that accommodates the sensor assembly, allowing installation without drilling or taping holes into the rotor hub structure.
Solution Approach 2:
The pitch housing serves multiple functions: it connects the rotor blade to the rotor hub, provides structural support, and houses the sensor assembly. This multi-functionality eliminates the need for separate modification of the rotor hub for sensor installation.
3Measurement precision
If sensors are installed on the exterior surface of the rotor hub, then rotor blade position data can be collected, but the installation is time consuming and expensive
Solution Approach 1:
The sensor assembly is nested within the pitch housing, which is an existing component in the rotor system. This integration allows the sensors to be installed as part of the pitch housing assembly rather than requiring separate installation on the rotor hub, significantly reducing installation time and cost.
Solution Approach 2:
The sensor assembly is merged with the pitch housing structure, combining the sensing function with an existing mechanical component. This integration eliminates the need for separate sensor mounting operations and reduces the overall installation process to a single integrated assembly step.
Data Source
AI summary
A rotorcraft including a rotor hub, a pitch housing moveable relative to the rotor hub about at least a feather axis and a flap axis, the pitch housing defining an internal volume, a bearing pin, the inboard end portion of the bearing pin being fixedly connected to the rotor hub, wherein the bearing pin defines the feather axis, a spherical bearing connected to the inboard end portion of the pitch housing and defining the flap axis, wherein the bearing pin extends through the spherical bearing, a rotor blade connected to the outboard end portion of the pitch housing, and a sensor assembly positioned in the internal volume and operatively connected to both the pitch housing and the outboard end portion of the bearing pin.