U.S. patent application number 10/401458 was filed with the patent office on 2004-09-30 for thrust reverser system with sequential torque decoupler.
Invention is credited to Christensen, Donald J..
Application Number | 20040188211 10/401458 |
Document ID | / |
Family ID | 32927334 |
Filed Date | 2004-09-30 |
United States Patent
Application |
20040188211 |
Kind Code |
A1 |
Christensen, Donald J. |
September 30, 2004 |
THRUST REVERSER SYSTEM WITH SEQUENTIAL TORQUE DECOUPLER
Abstract
An aircraft thrust reverser system that includes a power drive
unit operable to supply a drive force. The power drive unit
includes a motor and a torque decoupler that sequentially decouples
the power drive unit from a plurality of loads. The torque
decoupler includes at least two output sections, each of which is
coupled to the motor, and are not coupled to one another under
normal operating circumstances. The output sections are each
operable to decouple the motor from associated thrust reverser
moveable components upon a torque magnitude being reached in the
output section. The torque decoupler is configured so that the
first and second output sections are coupled together a deadband
time period after the torque magnitude is reached in on of the
output sections.
Inventors: |
Christensen, Donald J.;
(Phoenix, AZ) |
Correspondence
Address: |
HONEYWELL INTERNATIONAL INC.
101 COLUMBIA ROAD
P O BOX 2245
MORRISTOWN
NJ
07962-2245
US
|
Family ID: |
32927334 |
Appl. No.: |
10/401458 |
Filed: |
March 28, 2003 |
Current U.S.
Class: |
192/3.51 |
Current CPC
Class: |
F02K 1/763 20130101 |
Class at
Publication: |
192/003.51 |
International
Class: |
B60K 041/22 |
Claims
I claim:
1. A thrust reverser control system, comprising: a motor having an
output shaft and operable to supply a drive force; at least two
drive mechanisms each coupled to receive the drive force; at least
two actuator assemblies, each actuator assembly coupled to at least
one of the drive mechanisms and operable to move, upon receipt of
the drive force, between a stowed position and a deployed position;
and a torque decoupler assembly coupled between the motor output
shaft and two of the drive mechanisms, whereby the drive force is
transmitted from the motor to the drive mechanisms, the torque
decoupler assembly including a first output section and a second
output section, wherein: the first output section is coupled to the
motor output shaft and is operable to (i) decouple the motor from
one of the drive mechanisms upon a first torque magnitude being
reached in the first output section and (ii) engage the second
output section a time period after the first torque magnitude is
reached, and the second output section is coupled to the motor
output shaft and is operable to (i) decouple the motor from the
other drive mechanism upon a second torque magnitude being reached
in the second output section and (ii) engage the first output
section a time period after the second torque magnitude is
reached.
2. The system of claim 1, further comprising: an engagement
mechanism on one of the first or second output sections; and a
contact mechanism on the other of the first or second output
sections, wherein the contact mechanism contacts the engagement
mechanism a time period after either the first or second torque
magnitudes is reached.
3. The system of claim 1, wherein the first and second output
sections each comprise: a plate including at least a peripheral
surface and an engagement surface; one or more shear pin
receptacles in the peripheral surface; and an engagement mechanism
and a contact mechanism each formed on the engagement surface.
4. The system of claim 3, further comprising: a drive ring coupled
to the motor output shaft and having at least two shear pin
receptacles formed in a surface thereof, at least one of the drive
ring shear pin receptacles substantially aligned with at least one
of the shear pin receptacles in the plate peripheral surface of
each of the first and second output sections; and two or more shear
pins, each inserted into one of the drive ring shear pin
receptacles and one of the shear pin receptacles in one of the
first and second plates
5. The system of claim 2, wherein the engagement mechanism and the
contact mechanism are spaced apart from one another and the spacing
thereof sets the time period.
6. The system of claim 1, further comprising: a quill shaft coupled
to the second output section and extending through the motor output
shaft, the quill shaft adapted to couple to one of the drive
mechanisms.
7. The system of claim 1, wherein the first and second output
sections are selectively coupled together upon the first or second
torque magnitudes being reached in either the first or second
output sections.
8. The system of claim 1, wherein the first and second torque
magnitudes are substantially equivalent.
9. A power drive unit, comprising: a motor having an output shaft
and operable to supply a drive force to at least a first load and a
second load; a first output section coupled to the motor output
shaft; and a second output section coupled to the motor output
shaft, wherein: the first output section is operable to (i)
decouple the motor from the first load upon a first torque
magnitude being reached in the first output section and (ii) engage
the second output section a time period after the first torque
magnitude is reached, and the second output section is operable to
(i) decouple the motor from the second load upon a second torque
magnitude being reached in the second output section and (ii)
engage the first output section a time period after the second
torque magnitude is reached.
10. The power drive unit of claim 9, further comprising: an
engagement mechanism on one of the first or second output sections;
and a contact mechanism on the other of the first or second output
sections, wherein the contact mechanism contacts the engagement
mechanism a time period after either the first or second torque
magnitudes is reached.
11. The power drive unit of claim 9, wherein the first and second
output sections each comprise: a plate including at least a
peripheral surface and an engagement surface; one or more shear pin
receptacles in the peripheral surface; and an engagement mechanism
and a contact mechanism each formed on the engagement surface.
12. The power drive unit of claim 11, further comprising: a drive
ring coupled to the motor output shaft and having at least two
shear pin receptacles formed in a surface thereof, at least one of
the drive ring shear pin receptacles substantially aligned with at
least one of the shear pin receptacles in the plate peripheral
surface of each of the first and second output sections; and two or
more shear pins, each inserted into one of the drive ring shear pin
receptacles and one of the shear pin receptacles in one of the
first and second plates
13. The power drive unit of claim 10, wherein the engagement
mechanism and the contact mechanism are spaced apart from one
another and the spacing thereof sets the time period.
14. The power drive unit of claim 9, further comprising: a quill
shaft coupled to the second output section and extending through
the motor output shaft, the quill shaft adapted to couple to at
least one drive mechanism.
15. The power drive unit of claim 9, wherein the first and second
output sections are selectively coupled together upon the first or
second torque magnitudes being reached in either the first or
second output sections.
16. The power drive unit of claim 9, wherein the first and second
torque magnitudes are substantially equivalent.
17. A torque decoupler assembly operable to decouple at least a
first and a second load from a single motor output shaft,
comprising: a first output section; and a second output section,
wherein: the first output section is adapted to couple to the motor
output shaft and operable to (i) decouple the motor output shaft
from the first load upon a first torque magnitude being reached in
the first output section and (ii) engage a second output section a
time period after the first torque magnitude is reached; and the
second output section is adapted to couple to the motor output
shaft and operable to (i) decouple the motor output shaft from the
second load upon a second torque magnitude being reached in the
second output section and (ii) engage the first output section a
time period after the second torque magnitude is reached.
18. The torque decoupler of claim 17, further comprising: an
engagement mechanism on one of the first or second output sections;
and a contact mechanism on the other of the first or second output
sections, wherein the contact mechanism contacts the engagement
mechanism a time period after either the first or second torque
magnitudes is reached.
19. The torque decoupler of claim 17, wherein the first and second
output sections each comprise: a plate including at least a
peripheral surface and an engagement surface; one or more shear pin
receptacles in the peripheral surface; and an engagement mechanism
and a contact mechanism each formed on the engagement surface.
20. The torque decoupler of claim 19, further comprising: a drive
ring adapted to couple to the motor output shaft and having at
least two shear pin receptacles formed in a surface thereof, at
least one of the drive ring shear pin receptacles substantially
aligned with at least one of the shear pin receptacles in the plate
peripheral surface of each of the first and second output sections;
and two or more shear pins, each inserted into one of the drive
ring shear pin receptacles and one of the shear pin receptacles in
one of the first and second plates.
21. The torque decoupler of claim 18, wherein the engagement
mechanism and the contact mechanism are spaced apart from one
another and the spacing thereof sets the time period.
22. The torque decoupler of claim 17, further comprising: a quill
shaft coupled to the second output section and extending through
the motor output shaft, the quill shaft adapted to couple to at
least one drive mechanism.
23. The torque decoupler of claim 17, wherein the first and second
output sections are selectively coupled together upon the first or
second torque magnitudes being reached in either the first or
second output sections.
24. The torque decoupler of claim 17, wherein the first and second
torque magnitudes are substantially equivalent.
25. A torque decoupler assembly operable to decouple at least a
first and a second load from a single motor output shaft,
comprising: a first output section adapted to couple to the motor
output shaft and operable to (i) decouple the motor from the first
load upon a first torque magnitude being reached in the first
output section and (ii) engage a second output section a time
period after the first torque magnitude is reached; and a second
output section adapted to couple to the motor output shaft and
operable to (i) decouple the motor from the second load upon a
second torque magnitude being reached in the second output section
and (ii) engage the first output section a time period after the
second torque magnitude is reached, wherein the first and second
output sections each comprise: a plate including at least a
peripheral surface and an engagement surface, one or more shear pin
receptacles in the peripheral surface, and an engagement mechanism
and a contact mechanism each formed on the engagement surface and
spaced apart from one another, the spacing thereof setting the time
period, wherein the contact mechanisms contact the engagement
mechanisms the time period after either the first or second torque
magnitudes is reached; a drive ring adapted to couple to the motor
output shaft and having at least two shear pin receptacles formed
in a surface thereof, at least one of the drive ring shear pin
receptacles substantially aligned with at least one of the shear
pin receptacles in the plate peripheral surface of each of the
first and second output sections; two or more shear pins, each
inserted into one of the drive ring shear pin receptacles and one
of the shear pin receptacles in one of the first and second plates;
and a quill shaft coupled to the second output section and
extending through the motor output shaft, the quill shaft adapted
to couple to at least one drive mechanism
Description
FIELD OF THE INVENTION
[0001] The present invention relates to aircraft engine thrust
reverser actuation systems and, more particularly, to a decoupler
that is used to limit the torque in an aircraft thrust reverser
drive train that is driven by a single power drive unit.
BACKGROUND OF THE INVENTION
[0002] When a jet-powered aircraft lands, the landing gear brakes
and aerodynamic drag (e.g., flaps, spoilers, etc.) of the aircraft
may not, in certain situations, be sufficient to slow the aircraft
down in the required amount of runway distance. Thus, jet engines
on most aircraft include thrust reversers to enhance the braking of
the aircraft. When deployed, a thrust reverser redirects the
rearward thrust of the jet engine to a generally or partially
forward direction to decelerate the aircraft. Because at least some
of the jet thrust is directed forward, the jet thrust also slows
down the aircraft upon landing.
[0003] Various thrust reverser designs are commonly known, and the
particular design utilized depends, at least in part, on the engine
manufacturer, the engine configuration, and the propulsion
technology being used. Thrust reverser designs used most
prominently with jet engines fall into three general categories:
(1) cascade-type thrust reversers; (2) target-type thrust
reversers; and (3) pivot door thrust reversers. Each of these
designs employs a different type of moveable thrust reverser
component to change the direction of the jet thrust.
[0004] Cascade-type thrust reversers are normally used on
high-bypass ratio jet engines. This type of thrust reverser is
located on the circumference of the engine's midsection and, when
deployed, exposes and redirects air flow through a plurality of
cascade vanes. The moveable thrust reverser components in the
cascade design includes several translating sleeves or cowls
("transcowls") that are deployed to expose the cascade vanes.
[0005] Target-type reversers, also referred to as clamshell
reversers, are typically used with low-bypass ratio jet engines.
Target-type thrust reversers use two doors as the moveable thrust
reverser components to block the entire jet thrust coming from the
rear of the engine. These doors are mounted on the aft portion of
the engine and may form the rear part of the engine nacelle.
[0006] Pivot door thrust reversers may utilize four doors on the
engine nacelle as the moveable thrust reverser components. In the
deployed position, these doors extend outwardly from the nacelle to
redirect the jet thrust.
[0007] The primary use of thrust reversers is, as noted above, to
enhance the braking of the aircraft, thereby shortening the
stopping distance during landing. Hence, thrust reversers are
usually deployed during the landing process to slow the aircraft.
Thereafter, when the thrust reversers are no longer needed, they
are returned to their original, or stowed, position. In the stowed
position, the thrust reversers do not redirect the jet engine's
thrust.
[0008] The moveable thrust reverser components in each of the
above-described designs are moved between the stowed and deployed
positions by actuators. Power to drive the actuators may come from
a dual output power drive unit (PDU), which may be electrically,
hydraulically, or pneumatically operated, depending on the system
design. A drive train that includes one or more drive mechanisms,
such as flexible rotating shafts, may interconnect the actuators
and the PDU to transmit the PDU's drive force to the moveable
thrust reverser components.
[0009] Each of the above-described thrust reverser system
configurations is robustly designed and is safe and reliable.
Nonetheless, analysis has shown that secondary damage to various
portions of the thrust reverser system may result under certain
postulated circumstances. For example, if one of the actuators
coupled to one of the PDU outputs becomes jammed, it is postulated
that all of the drive force supplied from the PDU would be
concentrated, via the synchronization mechanisms, on the jammed
actuator. This postulated condition may result in damage to the
actuator system components, including the PDU, actuators, drive
mechanisms, or the moveable thrust reversers components. Repairing
such damage can be costly and result in aircraft down time. One
solution is to use stronger components, but this increases the cost
and/or weight of the thrust reverser system. Another solution is to
include numerous, independently operated torque limiters or
decouplers in each drive train coupled to the PDU outputs. However,
this solution may also increase system cost and/or weight.
[0010] Accordingly, there is a need for a thrust reverser system
that improves upon one or more of the drawbacks identified above.
Namely, a system that reduces the likelihood of component damage if
the thrust reverser system fails, for example, by a jammed
actuator, without significantly increasing the cost and/or the
weight of the thrust reverser system components. The present
invention addresses one or more of these needs.
SUMMARY OF THE INVENTION
[0011] The present invention provides a system and method that
sequentially decouples a thrust reverser system power drive unit
from two or more loads that are coupled to a single output shaft in
the event a torque magnitude is reached between the power drive
unit and one of the loads.
[0012] In one embodiment, and by way of example only, a thrust
reverser control system includes a motor, at least two drive
mechanisms, at least two actuators, and a torque decoupler. The
motor has an output shaft and is operable to supply a drive force.
The drive mechanisms are each coupled to receive the drive force.
Each actuator assembly is coupled to at least one of the drive
mechanisms and is operable to move, upon receipt of the drive
force, between a stowed position and a deployed position. The
torque decoupler is coupled between the motor output shaft and two
of the drive mechanisms and includes a first output section and a
second output section. The first output section is coupled to the
motor output shaft and is operable to (i) decouple the motor from
one of the drive mechanisms upon a first torque magnitude being
reached in the first output section and (ii) engage the second
output section a time period after the first torque magnitude is
reached. The second output section is coupled to the motor output
shaft and is operable to (i) decouple the motor from the other
drive mechanism upon a second torque magnitude being reached in the
second output section and (ii) engage the first output section a
time period after the second torque magnitude is reached.
[0013] In another exemplary embodiment, a power drive unit includes
a motor, a first output section, and a second output section. The
motor has an output shaft and is operable to supply a drive force
to at least a first load and a second load. The first and second
output section are coupled to the motor output shaft. The first
output section is operable to (i) decouple the motor from the first
load upon a first torque magnitude being reached in the first
output section and (ii) engage the second output section a time
period after the first torque magnitude is reached. The second
output section is operable to (i) decouple the motor from the
second load upon a second torque magnitude being reached in the
second output section and (ii) engage the first output section a
time period after the second torque magnitude is reached.
[0014] In yet another exemplary embodiment, a torque decoupler
assembly operable to decouple at least a first and a second load
from a single motor output shaft includes a first output section
and a second output section. The first output section is adapted to
couple to the motor output shaft and is operable to (i) decouple
the motor from the first load upon a first torque magnitude being
reached in the first output section and (ii) engage the second
output section a time period after the first torque magnitude is
reached. The second output section is adapted to couple to the
motor output shaft and is operable to (i) decouple the motor from
the second load upon a second torque magnitude being reached in the
second output section and (ii) engage the first output section a
time period after the second torque magnitude is reached.
[0015] Other independent features and advantages of the preferred
thrust reverser system and torque decoupler will become apparent
from the following detailed description, taken in conjunction with
the accompanying drawings which illustrate, by way of example, the
principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of portions of an aircraft jet
engine fan case;
[0017] FIG. 2 is a simplified end view of a thrust reverser
actuation system according to an exemplary embodiment of the
present invention;
[0018] FIG. 3 is a simplified functional schematic diagram of a
power drive unit according to an exemplary embodiment of the
present invention that may be used in the system of FIG. 2;
[0019] FIG. 4 is a detailed cross section view of an exemplary
embodiment of the power drive unit of FIG. 3;
[0020] FIG. 5 is an exploded perspective view of an exemplary
torque decoupler that may be used with the power drive unit of FIG.
4; and
[0021] FIG. 6 is a partial cross section view of the exemplary
torque decoupler of FIG. 5.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0022] Before proceeding with the detailed description, it is to be
appreciated that the described embodiment is not limited to use in
conjunction with a specific thrust reverser system design. Thus,
although the description is explicitly directed toward an
embodiment that is implemented in a cascade-type thrust reverser
system, in which transcowls are used as the moveable thrust
reverser component, it should be appreciated that it can be
implemented in other thrust reverser actuation system designs,
including those described above and those known now or hereafter in
the art.
[0023] Turning now to the description, and with reference first to
FIG. 1, a perspective view of portions of an aircraft jet engine
fan case 100 that incorporates a cascade-type thrust reverser is
depicted. The engine fan case 100 includes a pair of semi-circular
transcowls 102 and 104 that are positioned circumferentially on the
outside of the fan case 100. The transcowls 102 and 104 cover a
plurality of non-illustrated cascade vanes. A mechanical link 202
(see FIG. 2), such as a pin or latch, may couple the transcowls 102
and 104 together to maintain the transcowls 102 and 104 in correct
alignment on non-illustrated guides on which the transcowls 102 and
104 translate. When the thrust reversers are commanded to deploy,
the transcowls 102 and 104 are translated aft. This, among other
things, exposes the cascade vanes, and causes at least a portion of
the air flowing through the engine fan case 100 to be redirected,
at least partially, in a forward direction. This re-direction of
air flow in a forward direction creates a reverse thrust, and thus
works to slow the airplane.
[0024] As shown more clearly in FIG. 2, a plurality of actuators
210 are individually coupled to the transcowls 102 and 104. In the
depicted embodiment, half of the actuators 210 are coupled to one
of the transcowls 102, and the other half are coupled to another
transcowl 104. While not critical to understand or enable the
present invention, it is noted that some or all of the actuators
210 may include locks, some or all of which may include position
sensors. In addition, the transcowls 102 and 104 may also, or
alternatively, each include locks. It is noted that the actuators
210 may be any one of numerous actuator designs presently known in
the art or hereafter designed. However, in this embodiment the
actuators 210 are ballscrew actuators. It is additionally noted
that the number and arrangement of actuators 210 is not limited to
what is depicted in FIG. 2, but could include other numbers of
actuators 210 as well. The number and arrangement of actuators is
selected to meet the specific design requirements of the
system.
[0025] The actuators 210 are interconnected via a plurality of
drive mechanisms 212, each of which, in the particular depicted
embodiment, is a flexible shaft. Using flexible shafts 212 in this
configuration ensures that the actuators 210 and the transcowls 102
and 104 move in a substantially synchronized manner. For example,
when one transcowl 102 is moved, the other transcowl 104 is moved a
like distance at substantially the same time. Other synchronization
mechanisms that may be used include electrical synchronization or
open loop synchronization, or any other mechanism or design that
transfers power between the actuators 210.
[0026] A power drive unit (PDU) assembly 220, which includes a
torque decoupler assembly 216, is coupled to the actuators 210 via
one or more flexible shafts 212. In the depicted embodiment, the
PDU assembly 220 includes a motor 214 that is coupled to the torque
decoupler assembly 216. The motor 214 may be any one of numerous
types of motors such as, for example, an electric (including any
one of the various DC or AC motor designs known in the art), a
hydraulic, or a pneumatic motor. The torque decoupler assembly 216
is coupled between an output of the motor 214 and two of the
flexible shafts 212. Moreover, though not explicitly depicted in
FIG. 2, the PDU assembly 220 may include a lock mechanism. In any
case, with the depicted arrangement, the rotation of the PDU
assembly 220 results in the synchronous operation of the actuators
210, via the flexible shafts 212, thereby causing the transcowls
102 and 104 to move at substantially the same rate.
[0027] The PDU assembly 220 is controlled by a control circuit 218.
The control circuit 218 receives commands from a non-illustrated
engine control system such as, for example, a FADEC (full authority
digital engine control) system, and provides appropriate activation
signals to the PDU assembly 220 in response to the received
commands. In turn, the PDU assembly 220 supplies a drive force to
the actuators 210 via the flexible shafts 212. As a result, the
actuators 210 cause the transcowls 102 and 104 to translate between
the stowed and deployed positions.
[0028] Turning now to FIGS. 3-7 a description of a particular
preferred embodiment of the PDU assembly 220 and its operation will
be provided. Beginning with FIG. 3, which depicts a functional
schematic representation of the PDU assembly 220, a general
description of the PDU assembly 220 and its operation will first be
provided. Thereafter, a more detailed description of the depicted
PDU assembly embodiment will be provided.
[0029] As shown in FIG. 3, the PDU assembly 220 includes the motor
214 and the torque decoupler assembly 216. The motor 214 includes
an output shaft 302, and the torque decoupler assembly 216 includes
two output sections, a first output section 304a and a second
output section 304b. Each of the output sections 304a and 304b is
coupled to the motor output shaft 302. In addition, each output
section 304a and 304b is adapted to couple to a load such as, for
example, the above-mentioned drive mechanisms 212 and to one or
more actuators 210.
[0030] As was noted above, the PDU assembly 220, when installed in
a thrust reverser actuation system, supplies a drive force to the
actuators 210. While the PDU assembly 220 is supplying the drive
force, if the torque in the first (or second) output section 304a
(or 304b) exceeds a magnitude due, for example, to a jammed
actuator 210, then the first (or second) output section 304a (or
304b) will decouple the motor output shaft 302 from the drive
mechanisms 212 and the jammed actuator 210. Thereafter, if the
motor 214 continues rotating, the output sections 304a and 304b
will rotate at unequal speeds, and relative rotation will exist
between the first and second output sections 304a and 304b. After a
deadband time period, the first 304a and second 304b output
sections are coupled together. When this occurs, the torque in the
second (or first) output section 304b (or 304a) will then exceed
the torque magnitude, and decouple the motor output shaft 302 from
the drive mechanisms 212. As a result, the PDU assembly 220 is
fully decoupled from the load.
[0031] Sequentially decoupling the motor output shaft 302 from the
respective drive mechanisms 212 when the torque magnitude in one of
the output sections 304a or 304b reaches the magnitude reduces the
likelihood of any additional component damage. If the motor output
shaft 302 were decoupled from only one output section 304a or 304b,
the motor 214 would continue supplying the drive force to its
respective drive mechanism 212. If the thrust reverser transcowl
halves 102 and 104 are linked by, for example, the mechanical link
202, the motor 214 would continue to drive, or attempt to drive,
the transcowl half 102 or 104 to which it is coupled. This could
result in additional damage. In addition, the motor 214 may need to
be more robustly designed to withstand higher torque limits, which
can increase system size, weight, and/or cost.
[0032] With reference now to FIGS. 4-6, a detailed description of a
particular embodiment of the PDU assembly 220 will be provided.
Referring first to FIG. 4, the depicted PDU assembly 220 includes a
housing 402, which may be constructed of one or more pieces. The
motor 214 and output shaft 302 are mounted within the housing 402.
The output shaft 302 is rotationally mounted within the housing 402
by first 404a and second 404b bearing assemblies. The torque
decoupler assembly 216, which houses the first 304a and second 304b
output sections, is coupled to one end of the housing 402, and a
lock assembly 406 is coupled to another end of the housing 402. A
particular preferred embodiment of the torque decoupler assembly
216 is described in more detail below. The lock assembly 406 may
include either, or both, a remotely operated lock and a manual
lock, and is preferably any one of numerous known lock assemblies.
A detailed understanding of the lock assembly 406 is not needed
and, as such, it will not be further described.
[0033] The torque decoupler assembly 216 and its connection to the
motor 214 are shown more clearly in FIGS. 5 and 6. As can be seen,
the first 304a and second 304b output sections are mounted in a
housing 501, and each include a substantially cylindrical plate 502
and a substantially cylindrical hub 504. Each of the cylindrical
plates 502 includes a peripheral surface 506 and an engagement
surface 508. Two or more shear pin receptacles 510 are formed on
the peripheral surface 506 of each plate 502. The purpose of these
receptacles 510 is described more fully below. In the depicted
embodiment, the engagement surface 508 on each of the output
sections 304a, 304b includes at least one engagement mechanism 512
and at least one contact mechanism 514. It will be appreciated that
each engagement surface 508 need not include both the engagement
mechanism 512 and the contact mechanism 514. For example, one of
the output sections 304a (or 304b) could include one or more of the
engagement mechanisms 512 and no contact mechanisms 514, while the
other output section 304b (or 304a) includes one or more of the
contact mechanisms 514 and no engagement mechanisms 512.
Preferably, however, each engagement mechanism 512 on one
engagement surface 508 is collocated with each contact mechanism
514 on the other engagement surface 508.
[0034] In the depicted embodiment, the engagement mechanisms 512
are configured as protrusions that extend substantially
perpendicular away from the engagement surface 508, and the contact
mechanisms 514 are configured as depressions that extend
substantially perpendicular into the engagement surface 508. As
will be described more fully below, the engagement mechanisms 512
and the contact mechanisms 514 are not engaged with one another
during normal PDU assembly operations, but engage one another only
after the above-described torque magnitude is reached in either the
first 304a or second 304b output sections, and after the deadband
time period.
[0035] Each of the hubs 504 includes an opening 516 that has a
splined inner surface that is configured to engage one of the drive
mechanisms 212. The hub 504 of the first output section 304a is
rotationally mounted with a bearing assembly 505 With reference
back to FIG. 4, it is seen that the first output section 304a may
be directly coupled to one of the drive mechanisms 212, whereas the
second output section 304b may be coupled to one of the drive
mechanisms 212 via a quill shaft 408 and an extension 410. The
quill shaft 408 is coupled at one end to the hub 504 of the second
output section 304b, extends through the motor output shaft 302,
which is hollow, and is coupled at its other end to one end of the
extension 410. The extension 410 extends through the lock assembly
406, and its other end includes a splined inner surface that is
configured to couple to one of the drive mechanisms 212. It will be
appreciated that using a quill shaft is merely exemplary of a
particular preferred embodiment, and that other mechanisms for
splitting the output torque from the motor 214 may be used
including, but not limited to, a 90-degree gearbox, and a
differential gear.
[0036] Returning now to FIGS. 5 and 6, the motor output shaft 302
is coupled to the decoupler assembly 216 via a drive ring 518. The
drive ring 518 includes a shaft mating section 520 and a decoupler
mating section 522. In the depicted embodiment, the shaft mating
section 520 includes at least two slots 524, and is configured to
slide over a portion of the motor output shaft 302. Each of the
slots 524 mates with a protrusion 526 that is formed on the same
portion of the output shaft 302 that the shaft mating section 520
slides over. Thus, when the motor output shaft 302 rotates, it
causes the drive ring 518 to rotate. The decoupler mating section
522 includes a plurality of orifices 528, and is configured to
slide over the decoupler assembly 216. The orifices 528 are
collocated with at least one of the shear pin receptacles 510 on
each of the first 304a and second 304b output sections. A shear pin
530 extends through selected ones, or all, of the orifices 528 and
into the collocated shear pin receptacle 510, and is held in place
via a pin containment ring 532. Thus, when the motor output shaft
302 rotates the drive ring 518, the decoupler assembly 216 also
rotates. The shear pins 530 are designed to shear, thereby
disengaging the drive ring 518 from the associated output section
304a or 304b, upon a particular torque magnitude being reached in
the associated output section 304a or 304b.
[0037] During normal operations of the PDU assembly 220, the
engagement mechanisms 512 and contact mechanisms 514 do not contact
one another, and the decoupler assembly output sections 304a and
304b are rotated in unison with one another. If, however, the load
on the PDU assembly 220 causes the torque in, for example, the
first output section 304a to reach or exceed a first magnitude,
then each shear pin 530 that couples the first output section 304a
and the drive ring 518 together will shear. This will cause the
first output section 304a to decouple from the drive ring 518 and
the motor output shaft 302, and will cease rotating in unison with
the second output section 304b. As a result, after some deadband
time period, one or more of the engagement mechanisms 512 and one
or more of the contact mechanisms 514 on the first 304a and second
304b output sections will come into contact with one another,
coupling the first 304a and second 304b output sections together.
With the first 304a and second 304b output sections coupled
together, the torque in the second output section 304b will then
reach or exceed a torque magnitude, shearing each shear pin 530
that couples the second output section 304b to the drive ring 518.
This will cause the second output section 304b to decouple from the
drive ring 518 and motor output shaft 302. At this time, the PDU
assembly 220 is completely unloaded. It will be appreciated that
the time it takes for the engagement mechanisms 512 and the contact
mechanisms 514 to contact one another following a shear of the
shear pins 510 (e.g., the deadband time period) may be adjusted by,
for example, adjusting the amount of angular displacement between
the contact surfaces of the engagement mechanisms 512 and the
contact mechanisms 514.
[0038] The above-described PDU assembly 220 sequentially decouples
two or more loads, such as in a thrust reverser system, that are
coupled to a single output shaft in the event a torque magnitude is
reached between the power drive unit and one of the loads. Thus,
for example, the drive mechanisms can be sized to withstand only
half of the PDU assembly output torque, and will be decoupled from
the motor in the event of a jam. As a result, the cost and/or the
weight of the thrust reverser system and/or the system components
can be reduced relative to other designs.
[0039] While the invention has been described with reference to a
preferred embodiment, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt to a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended
claims.
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