Rotor Blade Control via Dovetail Housing and Linear-to-Rotary Drive

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing control systems for rotor blades in rotary-wing aircraft require structural modifications and increased weight, drag, noise, and maintenance due to the installation of mechanical and hydraulic connections, limiting their effectiveness and efficiency.

Innovation Solution

A rotor blade assembly with a housing secured via dovetail joints and a drive mechanism that translates linear motion into rotational motion using an actuator, rocker, and hinge rods, allowing for on-blade control without compromising the structural integrity or requiring additional penetration of the blade.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If mechanical and hydraulic connections are installed in rotor blades for control systems, then on-blade control capability is achieved, but structural integrity is compromised and weight increases

Engineering Contradiction:

Improveon-blade control capabilityVSAvoidstructural integrity

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The control system is divided into modular components: a control module containing the actuator, and a separate control surface. This segmentation allows the actuator to be mounted in a pocket within the blade spar without requiring through-blade penetrations, preserving structural integrity while enabling on-blade control capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control module is nested within an existing pocket structure in the rotor blade spar. The actuator and its mounting structure are contained within this pre-existing cavity, eliminating the need to drill holes through the blade and maintain the blade's structural continuity while accommodating the control system.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If mechanical and hydraulic connections are installed in rotor blades, then control functionality is achieved, but drag and noise increase

Engineering Contradiction:

Improvecontrol functionalityVSAvoiddrag and noise

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The mechanical connection points are extracted and relocated to the trailing edge of the blade where the control surface is mounted. This removes the need for internal mechanical linkages that would create drag and noise within the blade structure, while the control function is maintained through the external control surface actuation.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If control devices are installed on rotor blades, then on-blade control is enabled, but maintenance time and complexity increase

Engineering Contradiction:

Improveon-blade controlVSAvoidmaintenance time

Core Design Contradiction:

Adaptability or versatilityVSEase of repair

Solution Approach 1:

The control system is segmented into a removable control module and a control surface. This modular design allows the control surface to be accessed and serviced from the trailing edge without disassembling internal blade structures, significantly reducing maintenance time and complexity while preserving on-blade control functionality.

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If holes are cut in rotor blade spar for routing connections, then control system installation is enabled, but aerodynamic shape and structural properties are compromised

Engineering Contradiction:

Improvecontrol system installationVSAvoidaerodynamic shape

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The control module is nested within an existing pocket structure in the rotor blade spar that was designed for other purposes. This approach enables control system installation without cutting new holes through the blade, thereby preserving both the aerodynamic shape and structural properties of the blade while achieving ease of installation.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 enables efficient on-blade control with reduced structural compromise, noise, and maintenance requirements, while maintaining the aerodynamic shape and structural integrity of the rotor blade.

Implementation Method 1

The housing is secured to the rotor blade via one or more dovetail joints

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Implementation Method 2

The drive mechanism translates substantially linear motion of the actuator into rotational motion of the control surface about the control surface pivot

Methodology Applied

Scientific EffectMechanical motion transformation: Mechanical Advantage

Data Source

PatentUS9278755B2Modular integrated device for rotor blade control

Publication Date: 2016.03.08 SIKORSKY AIRCRAFT CORP

AI summary

A rotor blade assembly includes a rotor blade including one or more pockets and a housing located on the rotor blade within one or more pockets. The housing is secured to the rotor blade via one or more dovetail joints. A drive mechanism for a control surface of a rotor blade includes an actuator and a rocker operably connected to the actuator. At least one hinge rod is operably connected to the rocker and operably connected to a control surface at a control surface pivot. The drive mechanism translates substantially linear motion of the actuator into rotational motion of the control surface about the control surface pivot.