Power Take-Off Gear System for Missile Thrust Vectoring
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Solution Overview
Problem
Existing power take-off systems from control surface actuators in aerospace vehicles face challenges in efficiently enabling low-speed control and thrust vectoring, particularly in synchronizing the operation of rocket nozzle jet vanes, which requires a more direct and efficient mechanical connection between the actuator and the jet vane.
Innovation Solution
A power take-off system that includes a gear shaft engaging the actuator, a drive pinion on the gear shaft, a face gear sector, and a rotatable surface such as a jet vane, with a key mechanically coupling the bearing sleeve and face gear sector, allowing direct drive and rotation of the jet vane, and utilizing a cap and annular insulator for thermal protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a power take-off system uses a direct mechanical connection between the actuator and jet vane, then the thrust vectoring efficiency at low speeds is improved, but the system complexity and number of parts increases
Solution Approach 1:
The patent combines the actuator output shaft and the jet vane drive shaft into a single integrated shaft structure. The actuator directly drives the jet vane through this merged shaft, eliminating intermediate transmission components. This merging achieves direct mechanical connection for efficient thrust vectoring while reducing the overall number of parts and simplifying the system architecture.
Solution Approach 2:
The actuator is designed with multi-functionality, serving both as a control surface actuator and as a direct drive source for the jet vane power take-off. The single actuator performs dual functions: controlling aerodynamic surfaces and driving thrust vectoring vanes, thereby reducing the need for separate drive systems and minimizing system complexity while maintaining high efficiency.
2Reliability
If a power take-off system uses multiple intermediate components, then the system is more robust and reliable, but the connection between actuator and jet vane becomes less direct, reducing efficiency
Solution Approach 1:
By merging the actuator shaft and jet vane drive shaft into one integrated structure, the patent eliminates intermediate transmission components that would reduce efficiency. The direct connection ensures maximum power transfer efficiency for thrust vectoring while incorporating bearing supports and sealing mechanisms within the integrated design to maintain reliability without sacrificing directness.
Solution Approach 2:
The patent introduces bearing supports and sealing mechanisms as minimal intermediaries within the integrated shaft structure. These mediators provide necessary support and protection while maintaining the direct mechanical connection between actuator and jet vane, ensuring reliability without significantly increasing the number of external components or reducing efficiency.
3Device complexity
If the actuator directly drives the jet vane, then the number of parts is reduced, but thermal protection requirements increase due to direct exposure to exhaust heat
Solution Approach 1:
The patent merges the actuator and jet vane drive into a single integrated structure that is positioned within the nozzle assembly. This integration allows the actuator to be directly coupled to the jet vane while being protected by the nozzle structure itself, which serves as a thermal barrier against exhaust heat, thereby reducing the need for separate thermal protection components.
Solution Approach 2:
The nozzle structure and housing serve as thermal intermediaries between the exhaust gases and the actuator components. The housing and insulation layers act as protective barriers that shield the actuator from direct thermal exposure, allowing direct mechanical coupling without requiring additional active thermal management components.
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 system enables effective thrust vectoring at low speeds and control surface movement at high speeds, reducing the number of parts and being backward compatible, while providing a more direct connection between the control surface actuator and the thrust vectoring system, enhancing the steering capabilities of flight vehicles.
Implementation Method 1
a drive pinion on the gear shaft; a face gear sector that engages the drive pinion
Implementation Method 2
the system further including a key that mechanically couples the bearing sleeve and the face gear sector
Implementation Method 3
the drive pinion is press fit on the gear shaft
Implementation Method 4
the system further including an annular insulator engaged by the cap
Data Source
AI summary
A power take-off (PTO) system includes a spur pinion on a shaft, used to turn a sector face gear that is coupled to a surface to be turned, such as a jet vane in a rocket nozzle. These may be parts of a thrust vectoring system, with the PTO system used to connect to a control surface actuator for a control surface such as a fin. The mechanical coupling between the fin and the jet vane may enable steering of a flight vehicle such as a missile at both low speeds and high speeds, with the thrust vectoring by the jet vane effective at low airspeeds and the control surface movement used for steering at high airspeeds. The PTO system may be backward compatible with prior systems, while allowing a more direct connection between the control surface actuator and the thrust vectoring system, with a reduced number of parts.