Rotary Actuator Redundant Load Paths for Failure-Tolerant Mounting
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Solution Overview
Problem
Conventional rotary hydraulic actuators for aircraft flight control often present single points of failure, leading to potential loss of control surface control and aircraft control due to mechanical failures such as stress fractures or complex load reaction paths.
Innovation Solution
The implementation of rotary hydraulic actuators with redundant load paths, featuring multiple parallel mechanical connections between the load and the connected object, which are integrated into the core design to reduce weight and cost while enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional single load path actuators are used, then device complexity is reduced, but reliability deteriorates due to single points of failure
Solution Approach 1:
The actuator is divided into multiple independent mounting brackets (first mounting bracket, second mounting bracket, third mounting bracket, fourth mounting bracket) that form separate load paths. Each bracket is independently attachable to the housing and external mounting surface, creating segmented redundant connections that eliminate single points of failure while maintaining manageable device complexity through modular design
Solution Approach 2:
The patent implements redundant mounting brackets as a form of prior cushioning against potential failures. By pre-configuring multiple independent load paths before any failure can occur, the system ensures that if one bracket fails, the remaining brackets continue to support the actuator, preventing catastrophic failure and maintaining aircraft safety
2Ease of operation
If actuators are mounted between wing ribs, then ease of operation is improved, but harmful factors increase due to torque moments causing bending and stress fractures
Solution Approach 1:
The mounting system is segmented into multiple brackets distributed across different locations on the housing and external mounting surface. This segmentation distributes the load paths and reduces concentrated torque moments at any single mounting point, thereby reducing bending stresses and the risk of stress fractures in the airframe structure
Solution Approach 2:
Multiple mounting brackets are combined to work together as an integrated redundant system. The first and second mounting brackets connect to the first external mounting connector, while the third and fourth mounting brackets connect to the second external mounting connector, creating merged load paths that share the mechanical burden and reduce harmful torque moments on the airframe
Data Source
AI summary
The subject matter of this specification can be embodied in, among other things, a rotary actuator having a housing with a first mounting assembly, a first mounting bracket adapted for attachment to the first mounting assembly and attachment to a first external mounting connector of a first mounting surface, a second mounting bracket adapted for attachment to the first mounting assembly and attachment to the first external mounting connector, a rotor assembly rotatably journaled in said housing and having a rotary output shaft having a second mounting assembly, a third mounting bracket adapted for attachment to the rotary output shaft and adapted for attachment to a second external mounting connector of a second mounting surface, and a fourth mounting bracket adapted for attachment to the rotary output shaft and adapted for attachment to the second external mounting connector.