Tilt-rotor torque limiting system for asymmetric gusts
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Solution Overview
Problem
Shaft-driven systems in tiltrotor aircraft, particularly those with multiple rotors, face excessive torque loads due to asymmetrical wind conditions, leading to increased maintenance needs such as inspection and replacement of gearbox and rotor components.
Innovation Solution
Implementing a torque limiting system that uses differential collective pitch, symmetrical pitch, and torque command regulation to balance torque differentials between mast torque transfer systems, employing sensors and a general-purpose processor to adjust control signals and reduce torque differentials through collective pitch adjustments and governor control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If multiple rotors are connected to a shared gearbox in tiltrotor aircraft, then power transmission efficiency is improved, but torque components are exposed to excessive torque loads from asymmetrical gusts requiring inspection and repair
Solution Approach 1:
The control system continuously monitors torque loads on each rotor and provides feedback to the flight control system. This enables real-time detection of torque differentials caused by asymmetrical gusts, allowing the system to respond by adjusting rotor pitch angles to balance the torque loads and prevent gearbox overload
Solution Approach 2:
The system dynamically changes operational parameters (specifically rotor blade pitch angles) in response to detected torque differentials. By adjusting the pitch angle of individual rotors, the system modifies the aerodynamic forces to equalize torque loads across the shared gearbox, preventing over-torque conditions while maintaining efficient power transmission
2Reliability
If rotor components are designed to withstand maximum torque loads, then reliability under asymmetrical gusts is improved, but device complexity and weight increase
Solution Approach 1:
The torque transfer system incorporates self-regulating characteristics through the control system that automatically detects and corrects torque imbalances. The system monitors its own operational state and autonomously adjusts rotor pitch angles to maintain balanced torque distribution, eliminating the need for oversized mechanical components designed for worst-case scenarios
3Reliability
If rotor components are designed to withstand maximum torque loads, then reliability under asymmetrical gusts is improved, but manufacturing cost and maintenance requirements increase
Solution Approach 1:
Instead of designing components for maximum static torque loads, the system uses dynamic parameter changes (real-time pitch angle adjustments) to prevent torque differentials from exceeding design limits. This allows for more economical component design that operates within normal parameters while the control system prevents excursions into overload conditions that would require expensive reinforcement
Data Source
AI summary
A system includes a first mast torque transfer system, a second mast torque transfer system coupled to the first mast torque transfer system, and a torque limiting system. The torque limiting system includes a first sensor configured to determine a torque of the first mast torque transfer system, a second sensor configured to determine a torque of the second mast torque transfer system, and a processor configured to determine a differential torque between the torque of the first mast torque transfer system and the torque of the second mast torque transfer system and configured to control at least one of a torque input and a torque output to at least one of the first and second mast torque transfer systems as a function of the determined differential torque.