Compact Spring Load Test Stand for Actuating Systems
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Solution Overview
Problem
Existing load test benches for missile systems are costly and inflexible, requiring large climatic chambers and separate devices for multi-axis vibration tests, and struggle to apply defined lateral forces efficiently.
Innovation Solution
A compact, passive load test stand with a spring mechanism and adjustable flange, allowing independent alignment along multiple axes and application of defined lateral forces, coupled with a measuring system for precise measurements and inertial bodies for realistic simulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If almost linear torsion springs are used to cover a sufficiently large actuating angle range, then the verification range is improved, but the minimum length of the torsion bars increases leading to very large climatic chambers and structural-mechanical difficulties
Solution Approach 1:
The patent divides the single large torsion bar into multiple smaller torsion bars (first, second, third torsion bars) arranged in parallel. Each torsion bar has a shorter length and can be accommodated in smaller climatic chambers, while collectively they provide the same or greater actuating angle range through their combined torsional capacity.
Solution Approach 2:
The multiple torsion bars are arranged in a compact parallel configuration where they share common mounting points (first and second connection points) on the frame and the common axis. This nested-like arrangement allows the torsion bars to be closely packed, minimizing the overall volume required while maintaining the functional range.
2Volume of stationary object
If different offset angles when flange-mounting the torsion spring are used to reduce the required adjustment range, then the spring size is reduced, but re-clamping is required leading to multiplication of temperature cycles in climatic chambers
Solution Approach 1:
The patent introduces adjustable positioning elements that allow the connection points of the torsion bars to be dynamically repositioned along the frame structure. This adjustability enables the system to accommodate different test requirements without requiring physical re-clamping of the torsion bars themselves, thus reducing time loss while maintaining compact spring sizes.
Solution Approach 2:
The frame structure is designed with multiple predefined mounting positions and adjustable mechanisms that allow the same torsion bar assembly to be configured for different actuating angle ranges and test specifications. This multi-functional design eliminates the need for re-clamping when changing test parameters, as the adjustable positions provide universal adaptability.
3Adaptability or versatility
If large torsion bars are used to cover large actuating angle ranges, then the actuating angle verification is improved, but the load test bench requires enormously large and powerful climatic chambers unfavorable for three-axis clampability
Solution Approach 1:
The patent segments the load path by using multiple shorter torsion bars instead of one large torsion bar. Each bar carries a portion of the total torque, and their parallel arrangement provides the cumulative actuating angle range. This segmentation reduces the individual bar lengths and allows compact arrangement, simplifying the overall structural dimensions and improving three-axis clampability.
Solution Approach 2:
The patent transitions from a single-dimensional (one large bar) to a multi-dimensional arrangement by positioning multiple torsion bars in parallel along different spatial orientations. This dimensional change allows the system to achieve the required actuating angle range through spatial distribution rather than increasing the length of individual components, thereby reducing structural complexity.
4Ease of manufacture
If separate test devices are used for vibration tests, then the function test can be carried out separately, but only separate function test without application of torsional moments is possible
Solution Approach 1:
The patent merges the function test capability and vibration test capability into a single integrated load test bench. The frame structure is designed to be rigid enough to serve as a vibration test platform while the torsion bar mechanism provides the necessary torsional moments for function testing. This combination allows both types of tests to be performed on the same apparatus, either separately or simultaneously, eliminating the need for separate test devices.
Solution Approach 2:
The load test bench is designed with universal functionality to perform multiple test types: function testing with torsional moments, vibration testing, and combined testing. The frame and mounting structure are engineered to accommodate both static torsion loading and dynamic vibration excitation, making the device adaptable to various test requirements without needing separate specialized equipment.
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
Enables quick, reliable, and flexible testing of actuating systems with reduced re-clamping efforts and temperature compensation, accommodating multi-axis vibration tests within compact climatic chambers.
Implementation Method 1
A passive load test stand 2 is described, in particular for simulating load cycles. The spring mechanism stores energy when deformed and releases it during recoil, creating realistic load cycles without active control systems.
Implementation Method 2
The spring mechanism has a preferred symmetrical arrangement of at least four spring elements and includes frame points connecting to the frame and pivot points connecting to the flange, generating restoring forces that simulate realistic load profiles on the output shaft.
Data Source
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AI summary
The stand (1) has a spring mechanism mounted on a frame (13) and comprising four spring elements, frame points connecting the spring mechanism and the frame, and articulation points connecting the spring mechanism and a flange. The flange is coupleable to an output shaft of a servo system (4) to be tested by an adapter. The frame points are mounted in a substructure. The substructure and the spring mechanism form an adjustable or calibratable independent module (7), where the module is arranged on the frame by a universal interface.