Axially translating and radially tilting fan nozzle segments with combined actuation and position sensing

Abstract

An aircraft engine variable area fan nozzle structure disposed abaft a thrust reverser, including a sleeve translatable over a cascade array, comprises two semi cylindrical segments that can be axially translated and radially tilted to enlarge the fan duct exhaust area in order to optimize exhaust pressure and associated noise in high thrust circumstances such as on take-off, and to constrict that area under lower thrust conditions such as cruise. The segments are moved by actuators anchored to the fixed engine framework and independently of the thrust reverser translating sleeve. Each actuator incorporates a linear variable differential transformer acting as a fan nozzle position sensor. The tilting movement is imposed by the pivoting links of each segment to carriages that ride in a non-linear trackway secured to a thrust reverser translating sleeve slider. In an alternate embodiment of the invention, the thrust reverser sleeve actuator and the variable area fan nozzle actuator are coaxially mounted in a compact assembly anchored to stationary components of the nacelle.

Claims

1. In an aircraft gas turbine nacelle assembly having a fore-and-aft central axis, a stationary structure, including an annular torque box girder, at least two longitudinal beams and a transversal crosstie ring, said assembly further including a thrust reverser cascade array between said girder and said ring, a movable sleeve having axial sliders shaped and dimensioned to translate said sleeve across and close said array, and a plurality of movable fan nozzle segments abaft said sleeve, an improvement which comprises: at least one of said segments being slidingly and rockingly connected to at least two of said sliders, whereby said nozzle can be axially translated and radially varied; wherein said sleeve and said one of said segments are axially translated by first and second actuators both anchored to said stationary structure; wherein said first and second actuators are coaxially mounted in an assembly anchored to said stationary structure; wherein said assembly comprises: a translatable first ballnut attached to said sleeve; and a non-translatable tubular first ballscrew engaging said first ballnut; and, wherein said assembly further comprises: a translatable second ballnut; a torque tube coaxially mounted within said first ballscrew and secured to said second ballnut; and a translatable second ballscrew engaging said second ballnut and having a distal end attached to said segment.

2. The improvement of claim 1, which further comprises a gear box including: a rotatable input shaft; a first output shaft rotatively driving said first ballscrew; and a second output shaft rotatively driving said torque tube.

3. The improvement of claim 2, wherein said gear box comprises: a clutch mechanism and a rotation reverser mechanism between said input shaft and each of said output shafts.

4. In an aircraft gas turbine nacelle assembly having a fore-and-aft central axis, a stationary structure, including an annular torque box girder, at least two longitudinal beams and a transversal crosstie ring, said assembly further including a thrust reverser cascade array between said girder and said ring, a movable sleeve having axial sliders shaped and dimensioned to translate said sleeve across and close said array, and a plurality of movable fan nozzle segments abaft said sleeve, an improvement which comprises: at least one of said segments being slidingly and rockingly connected to at least two of said sliders, whereby said nozzle can be axially translated and radially varied; wherein said sleeve and said one of said segments are axially translated by first and second actuators both anchored to said stationary structure; wherein said first and second actuators are coaxially mounted in an assembly anchored to said stationary structure; wherein said assembly comprises: a translatable first ballnut attached to said sleeve; and a non-translatable tubular first ballscrew engaging said first ballnut; and, wherein said assembly further comprises: a slide tube coaxially surrounding said first ballscrew; and, a bearing attached to one of said beams and slidingly supporting said slide tube.

5. The improvement of claim 4, wherein said assembly further comprises: an arm extending axially from said second ballscrew distally outside said bearing; and a bracket connecting said arm to said segment.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a perspective view of a nacelle housing an aircraft gas turbine engine.

(2) FIG. 2 is a schematic of the VAFN control and actuation system.

(3) FIG. 3 is a perspective view of a left portion of a VAFN.

(4) FIG. 4 is a cross-sectional view of a carriage to trackway attachment in the un-translated and un-tilted position of the VAFN segment.

(5) FIG. 5 is a similar view in the translated and tilted position.

(6) FIG. 6 is a perspective partial view of the carriage to trackway attachment in the un-translated and un-tilted position of the VAFN segment.

(7) FIG. 7 is a similar view in the translated and tilted position.

(8) FIG. 8 is a cross-sectional view taken along line 8-8 of FIG. 5 and FIG. 6.

(9) FIG. 9 is partial inside perspective view of the fan duct flow blocker assembly from the outside of the fan duct.

(10) FIG. 10 is a similar inside view.

(11) FIG. 11 is a diagrammatical view of the movement of a VAFN segment.

(12) FIG. 12 is a diagrammatical view of the upper fairing split.

(13) FIG. 13 is a diametrical view of the lower fairing split.

(14) FIG. 14a is a side view of a segment actuator in a withdrawn position.

(15) FIG. 14b is a view thereof in a partial (VAFN only) extended position.

(16) FIG. 14c is a view thereof in the fully (VAFN and T/R sleeve) extended position.

(17) FIG. 15 is a cross-sectional view taken along line 15-15 of FIG. 14 when the VAFN segment is fully open and tilted and the T/R closed.

(18) FIG. 16 is a cross-sectional view taken along line 16-16 of FIG. 15 when the VAFN segment is fully open and tilted, and the T/R open.

(19) FIG. 17 is a cross-sectional view of the position sensor and gearbox.

(20) FIG. 18 is a perspective view of the actuator attachments.

(21) FIG. 19 is a perspective view of a dual actuator.

(22) FIG. 20 is a perspective view of the dual actuator connected to a T/R sleeve and a VAFN segment showing the TR in the open position and the VAFN in the closed position.

(23) FIG. 21 is a side view of the dual actuator.

(24) FIG. 22 is a cross-sectional view taken along line 17-17 of FIG. 21.

(25) FIG. 23 is diagram of the torque control and switching module.

(26) FIG. 24 is a diagram of the T/R sleeve and VAFN segment control and actuation system.

DETAILED DESCRIPTION

(27) Referring now to the drawing, there is shown in FIG. 1 the nacelle 10 of an aircraft gas turbine engine 11 supported by a pylon 12 integrating a trust reverser (T/R) 17 including a stationary frame including an annular torque box girder 13, fore-to-aft upper beam 14 and lower beam 15 and a transversal crosstie ring 16. Between the girder and the ring, the T/R further includes a cascade array 21. A semi-circular translatable sleeve 22 enshrouds the cascade array inwardly and outwardly. The sleeve can be shifted aftward by actuators 23 to open the T/R. Abaft of the sleeve is a variable area fan nozzle (VAFN) 18 divided into a left half portion 19 and a right half portion 20 by the upper and lower beams. Each half portion has a frusto-conical segment 24 that can be axially translated and tilted to increase or decrease the fan exhaust area 25 by actuators 26.

(28) It should be noted that both sets of actuators 23, 26 are anchored on components of a stationary structure, namely the torque box girder 13, and one actuator 26 is also anchored to a longitudinal beam. Each one of the segment actuators 26 incorporates a position sensor 27 as will be further described below.

(29) The schematic of FIG. 2, illustrates the control elements of one half portion 19 in the preferred two actuator configuration.

(30) The control system described below is intended to control both segment half portions 19, 20 simultaneously and synchronously. A motor 28 drives both VAFN portions 19,20. In practice the control system can either control one motor with splitting outputs to a plurality of actuators acting on both VAFN half portions, or the control system can send signals to a plurality of motors which are coordinated to move both VAFN halves in unison. The outputs 29 of the sensors are fed to a control unit 30 which can be integral with the engine controller which also receives engine and aircraft data 31, and generates control signals 32 for the motor that in turn drives the actuators. The placement of the actuators 26 adjacent to T/R fixed upper and lower beams 15, 16 allows actuators to be located within the upper and lower T/R slider track fairings. This in turn results in negligible enlargement of aforementioned fairings depending on nacelle shape.

(31) An alternate configuration illustrated in FIG. 3, positions two actuators in the midspan area equally spaced circumferentially about the VAFN segment centerplane and attached to both the girder 13 and the transversal crosstie ring 16. This allows the actuators to apply load to the VAFN close to the VAFN center of pressure. Also, in this configuration the segment actuators may be co-located with the T/R sleeve actuators 23 and reduces the amount of interruption to the cascade array 21. This also has a benefit of allowing common access panels (not shown) for the T/R sleeve mechanism and for the VAFN mechanism as well, reducing overall weight. As compared with prior art actuation systems, the fairing size required to house actuators away from the longitudinal beams is relatively small.

(32) It should be noted that in FIG. 1, the VAFN portions are shown in their withdrawn, that is closed, minimum exhaust area position; while in FIG. 3 the segment 24 is fully deployed, that is in an open, maximum exhaust position effected by a relatively short stroke of the actuators 26.

(33) A second alternate configuration (not illustrated) employs three actuators with two actuators located as per the preferred configuration and a third actuator evenly spaced circumferentially between the two at the VAFN segment midspan. This is beneficial on large aircraft engines where the large VAFN segment panel may be relatively soft. As compared with prior art designs, the fairing size required to house the actuator in a midspan mount configuration is relatively small.

(34) As illustrated in FIGS. 4-8, each circumferential edge 32 of the VAFN segment is rotatively connected to a pair of spaced-apart double-roller carriages 33 by pins 34. The rollers 35 of the carriages are captured by and run along a trackway 36 which is attached to one of the sliders.

(35) The trackway follows a non-linear path substantially located within the plane of the axial edge 32 of the VAFN segment. More specifically, the trackway has an outwardly bent trailing portion 38 that, when the segment approaches its most extended position, as illustrated in FIG. 7, causes the most rearwardly positioned carriage to force the rear of the segment to tilt radially outward and broaden the exhaust area 25.

(36) The upper and lower trackways 36 are disposed parallel to one another about the horizontal midplane of the VAFN segment structure. The upper and lower pins 34 are coaxial at both forward and aft locations. Their pivot axes are normal to the trackway center planes. The trackways may be lined with a sacrificial material (not shown). Their cross section may accommodate crowned rollers to allow for roller/track self-alignment and VAFN segment flex. The trackway path may be customized to engine requirements. The trackway 36 may be designed in such a way that the forward roller link translates inward to improve the T/R sleeve clearance or allow the VAFN segment to pivot outward at an earlier stroke extension or both. Further, the trackway path can be customized to suit nozzle area versus stroke requirements.

(37) Each roller linkage features rollers that can contact either the inboard or outboard side of the trackway in order to accommodate reversing structural loads. Attachments of the roller linkage to VAFN may be of a failsafe or waiting failsafe design. The roller attachment to roller linkages can be designed in such a way that a failure to one roller lug or roller pin will not cause the carriage to become disengaged from the trackway. There can be means (not shown) to prevent the rollers from wedging down into the trackway when the VAFN structure is not loaded against the inboard or outboard trackway surfaces such as when the engine is not operating. This may be accomplished by a protrusion in the roller pin or a boss at the bottom of the trackway or both or some other equivalent means.

(38) As shown in FIGS. 9 and 10, the angle of tilt A is usually in the range of several degrees. The gap between the beam 14, 15 and the VAFN segment 24 in the tilted position is covered by a blocker plate extension 39 of the sleeve in order to prevent premature duct leakage upstream of the nozzle exit plane.

(39) Recesses 46 in VAFN segments allow for structural features on thrust reverser translating sleeve to prevent fan duct leakage upstream of the nozzle exit plane. In practice, flow blockers 39 as shown in FIGS. 9 and 10, and/or seals shall accompany these structures in order to minimize fan duct airflow losses.

(40) The enlarging of the fan exhaust area 25 can be varied by adjusting the tilting movement 63 and/or translating movement 64 of the segment 24 relative to the conical fixed structure 11 as illustrated in the diagram of FIG. 11. A compressible seal 40 between the rear transversal edge 41 of the sleeve and the leading edge 42 of the segment prevents any premature escape of the fan duct airflow.

(41) It should be understood that the VAFN structure may be of any of the currently known configurations: ported, non-ported or sleeved. In the case of non-ported or sleeved VAFN configurations, the seal 40 shall accommodate the marginally-increased gap developed when the VAFN segments are tilted.

(42) As illustrated in FIGS. 12 and 13, upper and lower fairing splits 44 are disposed primarily perpendicular to the segment tilting axis 45 in order to prevent interference between them.

(43) Having each VAFN mechanical actuator 26 and a position sensor combined in one integral unit anchored on the fixed torque box girder 13 and longitudinal beam 14, 15 simplifies installation and maintenance, reduces weight, and locates the actuator in a low vibration environment compared with anchoring it to the T/R sleeve.

(44) The VAFN actuator 26 is illustrated in greater detail in FIGS. 14-18. The actuator comprises a ballscrew/ballnut coupling also called a jackscrew. At the aft end 43 an eyelet is provided at the extremity of the translating arm for attachment to a bracket 59 on the VAFN segment 24. The front end of the main body 47 houses a linear variable differential transformer 48, as shown in FIG. 17, which senses the position of the associated VAFN segment, and generates the signal 29 sent to the control unit 30. Behind the sensor, a gearbox 49, which may be a variety of configurations, is attached to the torque box girder 13. The gearbox can accept the rotating force 50 of the motor 28 and apply it through gears 51 to an output shaft 60. The output shaft is slidingly and rotationally connected to a torque tube 52 by way of a sliding spline 61, or other equivalent means. The torque tube houses a ballnut 55 fixedly journalled into the torque tube which captures and extends a ballscrew 54. The ballscrew is linked to the pushing arm 56 of the actuator. The torque tube is slaved to the T/R sleeve by a gimbaled linkage 57 with sufficient degrees of freedom and clearance to the torque tube to accommodate relative motion between the actuator and translating sleeve. A bearing 58 secured to one of the beams 14, 15 and slidingly and rotatively connected to the torque tube holds the aft end of the actuator. The output shaft 60 houses a sensor shaft 53 connected to the ballscrew 54 for relaying the position of the VAFN segment via sensor element 62 to the linear variable differential transformer sensor 48.

(45) Given the fact that each VAFN actuator has two external thrust linkages as seen in FIG. 18; first by a pushing rod 56 to a bracket 59 connected to a VAFN segment, and second by a gimbaled linkage 57 to the T/R sleeve 22, it has two motions. First, it delivers the translating force to move the VAFN segment to any axial location within the range of the actuator in relation to the T/R sleeve. The second motion is the slidably-free ability to position the segment at any location within that range while being axially coupled to the moving T/R sleeve 22 allowing the two structures to move in unison under the sleeve actuation mechanism. Accordingly, the segment 24 can be axially translated independently of the sleeve 22 by its actuator 26, but the sleeve actuators 23 can also act on the segment.

(46) Though the gimbaled linkage 57 is depicted in FIG. 15-16 as containing a pair of bearings in front and a gimbal in back, many equivalent configurations are possible that incorporate such components, such as thrust bearings, roller bearings, spherical bearings, spherical roller bearings or any combination thereof and other means known in the art. Similarly, though the gearbox 49 and aft support 58 are shown rigidly fixed to the torque box girder 13 and beams 14,15 respectively, these attachments may include components to allow supplemental degrees of freedom such as gimbals or other structures commonly known in the art to accommodate structural deflections.

(47) The aft end configuration of the actuator translating arm link 43, 59 obviates the need for exaggerated fairings to house the VAFN actuation mechanism.

(48) Compared with previous designs this actuator embodiment can be used as a midspan actuator away from the upper/lower fixed structure beams either as a center actuator in a group of 3 or as a dual actuator system with actuators co-located with the thrust reverser actuators thereby reducing obstruction of the thrust reverser cascade array.

(49) The disadvantages mentioned earlier in the Background associated with prior art attempts to integrate the VAFN and T/R actuators in one unit can be largely overcome by the alternate design described below.

(50) Referring now to FIGS. 19-24, there is illustrated combined dual actuators 98 adapted to control the translations of both the T/R sleeve and the VAFN. The T/R sleeve actuator 63 comprises a hollow first ballscrew, referred to as the T/R ballscrew 64 engaged by a first ballnut, referred to as the T/R ballnut 65 attached by a gimbaled linkage 66 to the T/R sleeve 67. While the gimbaled linkage 57 of the previously described embodiments was intended to transmit the movement supplied by the actuator of the T/R sleeve to the VAFN actuator assembly, the instant linkage transmits the translating movement of the T/R ballscrew 64 to the sleeve and synchronized movement to the VAFN.

(51) The VAFN segment actuator 68 comprises a second ballscrew, referred to as the VAFN ballscrew 69 engaging a second ballnut, referred to as the VAFN ballnut 70 fixedly journalled into a torque tube 71 which is slidably and rotatively connected to the VAFN gearbox output shaft 96 by way of a sliding spline 97. The VAFN gearbox output shaft 96 is rotatively supported by bearings 100 to the gearbox 79 and to the T/R ballscrew 64.

(52) The segment actuator further comprises a slide tube 72 which coaxially surrounds the first ballscrew, and the torque tube. The distal portion of the torque tube which fixedly mounts the second ballnut is supported within the slide tube by bearings 73. The bearings allow rotation of the torque tube within the rotationally fixed slide tube which is fixedly linked to the first non-rotating ballnut in order to accommodate the VAFN segment following the translating movement of the sleeve actuator. A key 93 running along the slide tube attaches the rotation of the slide tube to the first ball nut 65 in order to generate axial motion when the slide tube and first ballnut are acted upon by the first ballscrew 64.

(53) The VAFN ballscrew 69 driven by the rotation of the torque tube 71 and second ballnut 70 extends into the distal section 74 of the slide tube and is linked to a pushing arm 75 which connects to a bracket 76 mounted on the VAFN segment 19. The distal section of the slide tube is supported by a bearing 77 secured to one of the longitudinal beams 14, 15.

(54) Accordingly, the translation of the T/R sleeve results from the rotation of the first ballscrew 64, and the movement of the VAFN segment follows the rotation of the VAFN ballnut 70 in conjunction with or independently from the first ballscrew 64. These rotational movements are driven and controlled by a gearbox 79 secured to the torque box girder 13, a stationary structure with respect to the assembly, at the proximal end of the actuator. As described in the previous embodiments, though the gearbox 79 and bearing 77 are shown rigidly fixed to the structure, these attachments may contain components commonly known in the art to allow supplemental degrees of freedom.

(55) As shown in FIGS. 22 and 23, the gearbox accept a rotational force from a motor 80 on its input shaft 81 and transmits the rotation to a T/R shaft 82 and to a VAFN shaft 83. These shafts penetrate a torque control and switching module 84 that contains clutches 85, and various mechanisms 86, that may include locking mechanisms, lock sensors, load/torque limiters, anti-backdrive devices, manual drive units, rotation sensors, and other sensing and conditioning mechanisms common in the art. A T/R output shaft 87 is geared to the first ballscrew 64, and a VAFN output shaft 88 is geared to the VAFN output shaft 96. As in the previously described embodiments, a linear variable differential transformer 90 can sense the axial position of the VAFN via a sensor element 89 mounted upon the proximal end of a sensing shaft 91 connected to the back of the second ballscrew 69.

(56) Torque output shafts 92 are provided out of the gearbox to drive auxiliary independent or combined T/R and VAFN actuators operating on other parts of the T/R and VAFN via flexshafts. The output shafts and flexshafts are thus synchronized to the movements of the T/R output shaft 87 VAFN output shaft 88.

(57) FIG. 24 illustrates the overall operating system for the T/R sleeve and of the VAFN. The master actuator control unit 84 incorporates a plurality of drivers and sensors used in managing the operation of both the T/R actuation system (TRAS) and the VAFN actuation system. Each respective TRAS and VAFN actuation system lock/unlock supplies positive locking to their respective system when the motive force is not provided by the drive system or in case of failure of the input torque transmission flexshaft. As illustrated in FIG. 24, if the output flexshaft fails, the system will result in a top/bottom skew of the VAFN segment due to aerodynamic loads and because the slave actuator lacks a controlled locking mechanism. This skew may be mitigated by adding another locking mechanism into the slave actuator. The TRAS and VAFN lock/unlock sensors provide an indication to the controller that the T/R sleeve lock or the VAFN lock is engaged. The TRAS and VAFN position sensors relay the positions of the sleeve and segment and compare the output from all actuators to ensure that no skew condition exists. The motive force switch comprises an electromechanical device that shuttles motive force from the dual use input 81 between the TRAS and VAFN drive channels.

(58) While the preferred embodiment has been described and alternate arrangements have been suggested, other embodiments and modification may be devised without departing from the spirit of the invention and the scope of the appended claims.