FASTDISC

Disconnect device for jam tolerant linear actuators

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 Obiettivo del progetto (Objective)

'One target of actual development activities for helicopter drives is the substitution of the conventional swash plate actuation based on hydraulic actuators by electro-mechanical actuators. In comparison to hydraulic actuators the jam of the electro-mechanical actuators has to be considered by a jam tolerant system design. A possible solution is a redundant system configuration with two identical actuators at the activating positions. In case of a jam the failed actuator has to be disconnected from the drive in very short time by a fast activating actuator. In regard to the requirements no state-of-the art disconnect device is applicable. The development of the disconnect device shall cover two different principles: - reversible system, preferred electro-mechanical - “single-shot” system, preferred pyrotechnical Therefore, the project work will be carried out by 4 cooperation partners: - The Institute of Engineering Design and Industrial Design of the University of Stuttgart (IKTD) has research experience in and expert knowledge on the development of fast operating connect/disconnect devices. - The Italian company Umbra (Umbra) is a highly competent manufacturer and supplier of components for the aerospace industry like ballscrews, actuators and EMA drives. - The German company PyroGlobe is a highly competent manufacturer and supplier of pyrotechnical components and will participate on the “single-shot” system. - The Swiss company phi Engineering has experience in methodical product development and will participate on a “single-shot” system beside pyrotechnics. During investigations performed by the IKTD a wide range of possible connect/disconnect principles were reviewed and concept studies were carried out in this context. This represents a promising basis for a continuative research work and a successful development may be expected. The experience of the industrial partners will ensure the realisation of the prototype considering the aerospace requirements.'

Introduzione (Teaser)

Helicopters rely on hydraulic actuation of the swash plate, the device that controls the rotor blades. Scientists are investigating options for electromechanical actuation to ensure that environmental and cost benefits do not come at the expense of safety.

Descrizione progetto (Article)

The European aerospace industry is moving toward more-electric and eventually all-electric aircraft aligned with specific benefits. Among these are decreased noise, weight, maintenance and emissions along with enhanced safety. Electromechanical actuators (EMA) for swash plates are on the drawing board, but certain technical issues remain to be addressed.

Four partners covering all aspects of the development have joined forces on the EU-funded project 'Disconnect device for jam tolerant linear actuators' (FASTDISC) to deliver a solution. One important consideration that is not applicable to well-proven and certified hydraulic actuators is mechanical jamming. This is because EMA operation relies on mechanical transmission components not certifiable as critical parts, since jamming is a relevant failure.

Redundancy (having a duplicate part available immediately) is a common solution to meet safety regulations. In order to make EMAs jam-tolerant, the failed actuator must be disconnected quickly by a fast-activating device. No such device is currently available for EMA applications.

The team is considering two different types of disconnect device, a reversible (preferably electromechanical) system and a single-shot (preferably pyrotechnical) one. Partner expertise covers academic and industrial development and manufacturing of fast connect/disconnect devices, pyrotechnical devices as well as aerospace components.

The partners used methodical product development tools to investigate concepts for disconnect mechanisms. Six reversible and six irreversible designs were selected and described in detail. The designs include various function structures and active structures. The most promising have been selected for further development in the upcoming project phases.