A linear guide-based actuation concept for a novel morphing aileron

This paper deals with the actuation system design of a full-scale morphing aileron for regional aircraft. The aileron is allowed to smoothly change its geometrical configuration and perform the in-flight transition from a baseline shape to a set of optimal morphed ones pre-defined on the basis of aerodynamic requirements. The design of such innovative aileron is aimed not only at substituting the conventional aileron installed on a real aircraft but also to provide additional functionality. The aileron is free to rotate around its main hinge axis and it is also allowed to smoothly modify camber with two independent actuation systems. In such manner it can be used also during cruise with a symmetric deflection between the two half wings in order to reduce drag in off design condition. To accomplish variable aileron shape, a rigid-body mechanism was designed. The proposed aileron architecture is characterised by segmented adaptive ribs rigidly linked each other with spanwise reinforcements such as spars and stringers in a multi-box arrangement. Each rib is split into two movable plates connected by means of rotational hinges in a finger-like mechanism. The mechanism is driven by a load-bearing actuator by means of a kinematic chain opportunely tied based on the structural requirements in terms of shape to be matched and load to be withstood. The proposed device is an innovative arrangement of the quick-return mechanism composed of a beam leverage, commercial linear guides and a crank. The actuator shaft is directly inserted in the crank, which transmits the rotation to the linear guide that slide along a rail moving upward or downward the beam thus resulting in a camber variation. The entire aileron is moved by three leverages internally contained and distributed along the first two bays while the most external ribs are considered passive and their movement slaved. Two actuation layouts are analytically and numerically studied, the analytical theory is presented and validated by means of a multi-body simulation. Moreover, a linear static analysis was carried out under the hypothesis of glued contact between linear guides components simulating a jamming condition. This assumption has been formulated because it represents the most severe condition that envelop all the operative loads to which the actuation system is subjected. The analyses conducted are preliminarily aimed to verify that no failure occur under the imposed loads. In this first design loop, the vertical static force acting on the linear carriage exceeded allowable value and then a new configuration with double-sided linear guides was then investigated