Failure detector and indicator for aircraft flap actuation system

Claim 5

A method of detecting and indicating the failure of the primary drive train of an aircraft flap actuator system as claimed in claim 2 wherein two free motion zones are formed, one of said free motion zones being associated with one of said two wings of said aircraft and the other being associated with the other of said two wings of said aircraft and wherein the crossing of either of said two free motion zones is sensed.

Claim 6

A method of detecting and indicating the failure of the primary drive train of an aircraft flap actuator system as claimed in claim 3 wherein said step of providing an indication of the crossing of either of said two free motion zone includes the substep of providing an indication of which one of said two wings is associated with said failure of said primary drive train.

Claim 7

Apparatus for detecting and indicating the failure of the primary drive train of an actuator system that includes a primary and secondary drive train, said secondary drive train including a coupling system for coupling power between a driven torque tube, and at least one secondary torque tube, said apparatus comprising: at least one free motion zone formed in said coupling system; at least one detecting means for detecting the crossing of said at least one free motion zone; and, an indicating means coupled to said at least one detecting means for providing an indication of the crossing of said at least one free motion zone.

Claim 8

Apparatus for detecting and indicating the failure of the primary drive train of an actuator system that includes a primary and secondary drive train, said secondary drive train including a coupling system for coupling power between a driven torque tube, and at least one secondary torque tube, said apparatus comprising: at least one free motion zone formed in said coupling system; at least one detecting means for detecting the crossing of said at least one free motion zone; and, an indicating means coupled to said at least one detecting means for providing an indication of the crossing of said at least one free motion zone.

Claim 9

Apparatus for detecting and indicating the failure of the primary drive train of an actuator system as claimed in claim 5 wherein said free motion zone is formed between said driven torque tube and said coupling system.

Claim 10

Apparatus for detecting and indicating the failure of the primary drive train of an actuator system as claimed in claim 5 wherein said coupling system is adapted to couple power between said driven torque tube and two secondary torque tubes, and wherein two free motion zones are formed in said coupling system, one of said free motion zone formed between said coupling unit and one of said two secondary torque tubes and the other of said free motion zones formed between said coupling unit and the other of said two secondary torque tubes.

Claim 11

Apparatus for detecting and indicating the failure of the primary drive train of an actuator system as claimed in claim 5 wherein said detecting means comprises a mechanically movable element adapted to change position when said free motion zone is crossed.

Claim 12

Apparatus for detecting and indicating the failure of the primary drive train of an actuator system as claimed in claim 5 wherein said indicating means is a switch whose state is changed when said detecting means detects the crossing of said free motion zone.

Claim 13

Apparatus for detecting and indicating the failure of the primary drive train of an actuator system as claimed in claim 5 wherein said free motion zone is formed in said coupling system by: keys associated with one of: (a) said coupling system and (b) said driven torque tube or said at least one secondary torque tube; and keyways associated with the other of: (a) said coupling system; and, (b) said driven torque tube or said at least one secondary torque tube, said keys being mounted in said keyways in a manner such that relative movement can occur between said keys and said keyways.

Claim 14

A coupling unit for connecting a drive torque tube to at least one driven torque tube, including means for providing an indication of the application of driving power from said drive torque tube to said at least one driven torque tube, said coupling unit comprising: a first gear affixed to the end of said drive torque tube; a second gear affixed to the end of said at least one driven torque tube and arrayed so as to mesh with said first gear; a free motion zone formed between one of said first gear and said drive torque tube and said at least one driven torque tube and said second gear; detecting means mounted so as to detect the crossing of said free motion zone; and, indicating means coupled to said detecting means for providing an indication when said detecting means detects that said free motion zone has been crossed.

Claim 15

A coupling unit for connecting a drive torque tube to at least one driven torque tube, including means for providing an indication of the application of driving power from said drive torque tube to said at least one driven torque tube, said coupling unit comprising: a first gear affixed to the end of said drive torque tube; a second gear affixed to the end of said at least one driven torque tube and arrayed so as to mesh with said first gear; a free motion zone formed between one of said first gear and said drive torque tube and said at least one driven torque tube and said second gear; detecting means mounted so as to detect the crossing of said free motion zone; and, indicating means coupled to said detecting means for providing an indication when said detecting means detects that said free motion zone has been crossed.

Claim 16

A coupling unit as claimed in claim 11, wherein said free motion zone is formed between said drive torque tube and said first gear.

Claim 17

A coupling unit as claimed in claim 12 wherein said free motion zone is formed by keys associated with one of said first gear and said drive torque tube, and keyways associated with the other of said first gear and said drive torque tube, said keys being substantially narrower in arcuate width than said keyways, and lying in said keyways.

Claim 18

A coupling unit as claimed in claim 13, wherein said detecting means comprises: at least one transverse aperture formed in said drive torque tube; at least one pin lying in said at least one transverse aperture formed in said drive torque tube and projecting outwardly; an aperture formed in said first gear and positioned such that the outer tip of said pin lies in said aperture when said keys lie substantially in the center of said keyways; and, a coupling mechanism coupled to the inner end of said pin, said coupling mechanism adapted to move when said pin is moved out of said aperture in said first gear, said movement occurring when said free motion zone is crossed.

Claim 19

A coupling unit as claimed in claim 14, wherein said indicating means comprises an electrical switch operatively connected to said coupling mechanism so as to be changed in state when said coupling mechanism is moved by said pin moving out of said aperture in said first gear.

Claim 20

A coupling unit as claimed in claim 13, wherein said detecting means comprises: a plurality of indentations formed in the outer periphery of said drive shaft; a first collar affixed to said first gear so as to surround said plurality of indentations, said collar including a plurality of apertures equal in number to said plurality of indentations and aligned therewith when said keys are centered in said keyways; a plurality of pins equal in number to said plurality of apertures and lying in said plurality of apertures; a second collar surrounding said first collar and affixed to said first gear, and including a plurality of apertures equal in number to said plurality of pins and aligned with said apertures in said first collar; a plurality of springs equal in number to said number of pins and associated therewith on a one-to-one basis, said springs mounted between said pins and said second collar so as to force said pins into said indentations when said keys lie in the center of said keyways; and, a split ring affixed to the outer ends of said pins and movable between an inner position and an outer position, said split ring moved between said inner and said outer positions when the inner tips of said pins are moved from said indentations, said inner tips of said pins moving from said indentations when said free motion zone is crossed.

Claim 21

A coupling unit as claimed in claim 16, wherein said indicating means comprises: a roller adapted to ride on the outer surface of said split ring; and, a switch mechanically connected to said roller so as to sense when said split ring moves from its inner position to its outer position.

Claim 22

A coupling unit as claimed in claim 11, wherein said free motion zone is formed between said second gear and said at least one driven torque tube.

Claim 23

A coupling unit as claimed in claim 18, wherein said free motion zone is formed by keys associated with one of said at least one driven torque tube and said second gear, and keyways associated with the other of said at least one driven torque tube and said second gear, said keys being substantially narrower in arcuate width than said keyways, and lying in said keyways.

Claim 24

A coupling unit as claimed in claim 19, wherein said first gear is a worm gear and wherein said second gear is a worm wheel mounted so as to mesh with said worm gear.

Claim 25

A coupling unit as claimed in claim 20, wherein said detecting means comprises: a boss extending outwardly from said worm wheel about its axis of rotation; peripheral threads formed on said boss; and a nut threaded onto said peripheral threads and affixed to said at least one driven torque tube so as to be movable longitudinally with respect thereto, but not rotationally, said longitudinal movement occurring when said free motion zone is crossed.

Claim 26

A coupling unit as claimed in claim 21, wherein said indicator means comprises a switch including a switch arm, said switch arm mounted so as to be moved by said nut when said nut is moved longitudinally, movement of said switch arm by said nut causing said switch to change states.

Claim 27

A coupling unit as claimed in claim 19, wherein said detecting means comprises a cam affixed to said at least one driven torque tube so as to change relative positions when said free motion zone is crossed, and a cam follower operatively connected between said cam and said indicating means.

Claim 28

A coupling unit as claimed in claim 18, wherein said coupling unit connects a driving torque tube to first and second driven torque tubes and includes means for providing an indication of the application of driving power from said driving torque tube to either of said driven torque tubes and wherein said second gear is affixed to the end of said first driven torque tube, said coupling unit including a third gear affixed to the end of said second driven torque tube so as to mesh with said first gear, a second free motion zone being formed between said third gear and said second driven torque tube.

Claim 29

A coupling system as claimed in claim 18 wherein said first free motion zone is formed by keys associated with one of said first driven torque tubes and said second gear, and keyways associated with the other of said first driven torque tubes and said second gear and said second free motion zone is formed by keys associated with one of said second driven torque tubes and said third gear, and keyways associated with the other of said second driven torque tubes and said third gear, said keys being substantially narrower in arcuate width than said keyways, and lying in said keyways.

Claim 30

A coupling unit as claimed in claim 25, including a first cam affixed in a nonrotatable manner to said first driven torque tube so as to be movable in a rotational manner with respect to said second gear when said first free motion zone is crossed and a second cam affixed to said second driven torque tube so as to be moved in a rotational manner with respect to said third gear when said second free motion zone is crossed.

Claim 31

A coupling unit as claimed in claim 26, wherein said indicating means comprises: first and second switches mechanically connected to said first and second cams, respectively, so as to be in states determined by the rotational positions of said cams; and, an asymmetry detector connected to said first and second switches, said cams being oriented such that said first and second switches change states in a symmetrical manner as long as neither of said first and second free motion zones are crossed.

Claim 32

A coupling unit as claimed in claim 19 including: a flange plate non-rotatably affixed to said at least one driven torque tube so as to be facing said second gear; and, pressing means for pressing said flange plate against said second gear in a manner such that said flange plate can rotate with respect to said second gear when said free motion zone is crossed, said rotation causing said flange plate to move away from said second gear against the force created by said pressing means.

Claim 33

A coupling system as claimed in claim 28, wherein said indicating means comprises a switch mechanically coupled to said flange plate so as to sense the movement of said flange plate away from said second gear when said free motion zone is crossed, said movement causing said switch to change states.