Variable Wobbler Segmented Design for Aerospace Weight Reduction
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Solution Overview
Problem
The existing hydraulic units in integrated drive generators for aerospace applications are heavy due to excess material in components like the variable wobbler, which needs to be redesigned to reduce weight while maintaining functionality.
Innovation Solution
A variable wobbler with a segmented exterior surface, 45-degree relief angles, trunnions, and a friction-reducing amorphous diamond-like carbon coating is designed to reduce weight and enhance performance, featuring a body with a central vertical axis and horizontal axes, and diametrically opposed projections to limit wobble rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If excess material is removed from the variable wobbler component, then weight is reduced, but structural integrity and mechanical performance may be compromised
Solution Approach 1:
The variable wobbler body is divided into multiple segments (first body segment, second body segment, third body segment) with distinct geometric features. Each segment serves specific functional purposes while allowing material optimization. The segmented design enables selective material placement to maintain strength where needed while reducing weight in non-critical areas.
Solution Approach 2:
Different regions of the variable wobbler have different material properties and geometric characteristics optimized for their specific functions. The first body segment has a conical outer peripheral edge for piston engagement, the second segment has a cylindrical outer peripheral edge for structural support, and the third segment has specific projections for rotational limiting. This local differentiation allows weight reduction while maintaining structural integrity in critical areas.
2Weight of moving object
If the variable wobbler is redesigned with reduced material, then manufacturing complexity increases, but weight reduction is achieved
Solution Approach 1:
The variable wobbler is designed as an integrated component with internally segmented geometry rather than multiple separate parts. The first, second, and third body segments are formed as a single monolithic structure, eliminating the need for complex assembly operations while achieving weight reduction through optimized material distribution within the integrated body.
Solution Approach 2:
The variable wobbler incorporates three-dimensional geometric features including conical and cylindrical outer peripheral edges, radial projections, and axial features that optimize material distribution in multiple dimensions. This 3D geometric optimization achieves weight reduction while maintaining manufacturability through conventional machining and forming processes.
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 redesigned variable wobbler achieves weight reduction while maintaining the necessary mechanical performance and stability, ensuring a constant rotational speed output to the generator, even with varying engine speeds.
Implementation Method 1
The annular inner contact surface has a friction-reducing coating thereon. Preferably, the friction-reducing coating is an amorphous diamond-like carbon coating.
Data Source
AI summary
A variable wobbler for a hydraulic unit is disclosed, which includes body defining a central vertical axis, a horizontal longitudinal axis and a horizontal transverse axis, and including an exterior surface having a segmented outer peripheral edge and a circular inner peripheral edge extending around the central vertical axis, wherein a datum point is located on a first lateral segment of the outer peripheral edge of the exterior surface, and wherein a 45 degree relief angle is formed between the outer peripheral edge of the first lateral segment and a datum line that extends through the datum point in a direction that is perpendicular to the horizontal longitudinal axis.