The design of a hingeline electro-mechanical actuator

Aircraft control mechanisms, such as those that operate the flaps, ailerons, rudders, etc., are almost exclusively driven by hydraulic-based systems. Their popularity in flight control systems is not unfounded; hydraulic actuators are quite torque-dense and benefit from decades of development bringing operating performance to a high level. On the other hand the infrastructure to support this system increases weight, adds system development complexity, and reduces aircraft maintainability [Jensen et al, 2000]. Based on recent Electro-Mechanical Actuator (EMA) development and design efforts at the Robotics Research Group (RRG), a new opportunity exists to replace current hydraulic flight control systems with those powered by electricity through a national program [Tesar, 2005]. A literature review of the topic found a 30 year old effort by AiResearch to develop a similarly powered hingeline actuator with given traditional performance goals (torque capacity, redundancy, output speed, reliability). In this report,a thorough analysis is performed on each major component group to quantitatively evaluate this baseline device. Using component technologies developed at RRG, this report proposes a dual torque-summing electromechanical actuator, each with a star compound / hypocyclic combined gear train, designed to exceed the performance of the original (1976) AiResearch project. This preliminary design exercise includes a layout of the entire actuator along with an appropriate analysis of major components including bearings, gear train, motor, housing, and release mechanism. The performance of this gear train is critical to overall actuator success and fundamental analytics have already been developed in this area [Park and Tesar, 2005]. Finite Element Analysis on the gear train and housing provide early design feedback and verification of actuator performance characteristics. In particular, simulation results show the gear stiffness, load sharing, and torque capacities exceed analytical estimates. Finally, four different comparisons are presented that evaluate configuration variations of the two designs based on applicable performance criteria. Results show the RRG fault-tolerant actuator has a marked improvement over the baseline in average stiffness (14.2x), reflected inertia (3.2x) and nominal torque density (3.4x). The chapter next lists actuator test methods and aircraft qualification standards. Finally, a summary of future work is detailed in a ten step outline to bring this EMA technology to a level of early deployment in a large range of aircraft systems.Mechanical Engineerin