EP-4735332-A2 - ROTOR ASSEMBLY DEPLOYMENT MECHANISM AND AIRCRAFT USING SAME

EP4735332A2EP 4735332 A2EP4735332 A2EP 4735332A2EP-4735332-A2

Abstract

A rotor assembly deployment mechanism configured to deploy a rotor assembly of a vertical take-off and landing aircraft from a horizontal, forward thrust, position to a vertical, hover, position. The rotor assembly deployment mechanism is configured to deploy an electric motor and propeller together. The deployment mechanism provides significant stiffness and strength with the use of torsion box constructions. The deployment mechanism may utilize bar linkages wherein the primary linkage pivot is of a large diameter relative to the span of the pivot in order to provide significant stiffness. The deployment mechanism may utilize rotary actuators to drive the deployment and stowing of the rotor assembly.

Inventors

THODAL, Robert
JULE, Florian
PEI, Baixi
GRENESTEDT, Joachim, L.
GISCHLER, Jordin

Assignees

Joby Aero, Inc.

Dates

Publication Date: 20260506
Application Date: 20240621

Claims (18)

1. A rotor assembly deployment mechanism, said deployment mechanism comprising: a first main mounting bracket; a first rotary actuator fixedly mounted to said first main mounting bracket; a second main mounting bracket; a second rotary actuator fixedly mounted to said second main mounting bracket; a top mounting bracket, said top mounting bracket coupled to an upper forward portion of said first main mounting bracket at a first location; said top mounting bracket coupled to an upper forward portion of said second main mounting bracket at a second location; a main idler box pivotally coupled to said first main mounting bracket and said second main mounting bracket; a first drive link pivotally coupled to an output of said first rotary actuator at a first end of said first drive link; a second drive link pivotally coupled to an output of said second rotary actuator at a first end of said second drive link; a first main drive link pivotally coupled to a second end of said first drive link; a second main drive link pivotally coupled to a second end of said second drive link; wherein said first main drive link and said second main drive link are pivotally coupled to said main idler box at an intermediate portion of said first main drive link and said second main drive link and said main idler box; an outboard idler box, said outboard idler box pivotally coupled to a second end of said main idler box at a first end of said outboard idler box; and an outboard mounting bracket, said outboard mounting bracket pivotally coupled to a second end of said outboard idler box and to a second end of said first main drive link and said second main drive link.
2. The rotor assembly deployment mechanism of claim 1 wherein said top mounting bracket defines a top mounting bracket plane, and wherein said outboard mounting bracket is configured to deploy from a stowed position predominantly below said top mounting bracket plane to a deployed position predominantly above said top mounting bracket plane.
3. The rotor assembly deployment mechanism of claim 1 wherein said top mounting bracket defines a top mounting bracket plane, and wherein said outboard mounting bracket is configured to deploy from a stowed position predominantly below said top mounting bracket plane to a deployed position completely above said top mounting bracket plane.
4. The rotor assembly deployment mechanism of claim 1 wherein said outboard mounting bracket is configured to deploy from a stowed position to a deployed position wherein all of said outboard mounting bracket is higher in the deployed position than the position of the any of said outboard mounting bracket in the stowed position.
5. The rotor assembly deployment mechanism of claim 2 wherein said outboard mounting bracket is configured to deploy from a stowed position to a deployed position wherein all of said outboard mounting bracket is higher in the deployed position than the position of the any of said outboard mounting bracket in the stowed position.
6. The rotor assembly deployment mechanism of claim 3 wherein said outboard mounting bracket is configured to deploy from a stowed position to a deployed position wherein all of said outboard mounting bracket is higher in the deployed position than the position of the any of said outboard mounting bracket in the stowed position.
7. The rotor assembly deployment mechanism of claim 1 wherein said first main drive link is pivotally coupled to said main idler box with a bearing of a first diameter, and wherein said second main drive link is pivotally coupled to said main idler box with a bearing of said first diameter, and wherein said first drive link and said second main drive link are separated by a minimum distance of a first distance, and wherein the ration of said first diameter to said first distance is greater than 0.2.
8. The rotor assembly deployment mechanism of claim 2 wherein said first main drive link is pivotally coupled to said main idler box with a bearing of a first diameter, and wherein said second main drive link is pivotally coupled to said main idler box with a bearing of said first diameter, and wherein said first drive link and said second main drive link are separated by a minimum distance of a first distance, and wherein the ration of said first diameter to said first distance is greater than 0.2.
9. The rotor assembly deployment mechanism of claim 5 wherein said first main drive link is pivotally coupled to said main idler box with a bearing of a first diameter, and wherein said second main drive link is pivotally coupled to said main idler box with a bearing of said first diameter, and wherein said first drive link and said second main drive link are separated by a minimum distance of a first distance, and wherein the ration of said first diameter to said first distance is greater than 0.2.
10. The rotor assembly deployment mechanism of claim 6 wherein said first main drive link is pivotally coupled to said main idler box with a bearing of a first diameter, and wherein said second main drive link is pivotally coupled to said main idler box with a bearing of said first diameter, and wherein said first drive link and said second main drive link are separated by a minimum distance of a first distance, and wherein the ration of said first diameter to said first distance is greater than 0.2.
11. The rotor assembly deployment mechanism of claim 1 wherein said first main drive link is pivotally coupled to said main idler box with a bearing of a first diameter, and wherein said second main drive link is pivotally coupled to said main idler box with a bearing of said first diameter, and wherein said first drive link and said second main drive link are separated by a minimum distance of a first distance, and wherein the ration of said first diameter to said first distance is greater than 0.3.
12. The rotor assembly deployment mechanism of claim 2 wherein said first main drive link is pivotally coupled to said main idler box with a bearing of a first diameter, and wherein said second main drive link is pivotally coupled to said main idler box with a bearing of said first diameter, and wherein said first drive link and said second main drive link are separated by a minimum distance of a first distance, and wherein the ration of said first diameter to said first distance is greater than 0.3.
13. The rotor assembly deployment mechanism of claim 5 wherein said first main drive link is pivotally coupled to said main idler box with a bearing of a first diameter, and wherein said second main drive link is pivotally coupled to said main idler box with a bearing of said first diameter, and wherein said first drive link and said second main drive link are separated by a minimum distance of a first distance, and wherein the ration of said first diameter to said first distance is greater than 0.3.
14. The rotor assembly deployment mechanism of claim 6 wherein said first main drive link is pivotally coupled to said main idler box with a bearing of a first diameter, and wherein said second main drive link is pivotally coupled to said main idler box with a bearing of said first diameter, and wherein said first drive link and said second main drive link are separated by a minimum distance of a first distance, and wherein the ration of said first diameter to said first distance is greater than 0.3.
15. The rotor assembly deployment mechanism of claim 1 wherein said first rotary actuator and said second rotary actuator are low profile actuators comprising a harmonic drive and a drive motor, and wherein said drive motor resides within the cup of said harmonic drive.
16. The rotor assembly deployment mechanism of claim 2 wherein said first rotary actuator and said second rotary actuator are low profile actuators comprising a harmonic drive and a drive motor, and wherein said drive motor resides within the cup of said harmonic drive.
17. The rotor assembly deployment mechanism of claim 5 wherein said first rotary actuator and said second rotary actuator are low profile actuators comprising a harmonic drive and a drive motor, and wherein said drive motor resides within the cup of said harmonic drive.
18. The rotor assembly deployment mechanism of claim 6 wherein said first rotary actuator and said second rotary actuator are low profile actuators comprising a harmonic drive and a drive motor, and wherein said drive motor resides within the cup of said harmonic drive.

Description

ROTOR ASSEMBLY DEPLOYMENT MECHANISM AND AIRCRAFT USING SAME [0001 ] CROSS-REFERENCE TO RELATED APPLICATIONS [0002] This application claims priority to U.S. Patent Application No. 63/523,795 to Thodal et al., filed 06/28/2023, which is hereby incorporated by reference in its entirety. [0003] Field of the Invention [0004] This invention relates to the aviation field, namely a rotor assembly deployment mechanism used on aerial vehicles. [0005] BRIEF DESCRIPTION OF THE DRAWINGS [0006] Figure 1A is a vertical take-off and landing aircraft in a take-off configuration according to some embodiments of the present invention. [0007] Figure IB is a vertical take-off and landing aircraft in a forward flight configuration according to some embodiments of the present invention. [0008] Figure 2 is a view of a nacelle and rotor according to some embodiments of the present invention. [0009] Figures 3A-B are partial cutaway views of a nacelle, rotor, and deployment mechanism according to some embodiments of the present invention. [0010] Figures 4A-C are views of a rotor assembly deployment mechanism in a stowed configuration according to some embodiments of the present invention. [0011] Figures 5A-C are views of a rotor assembly deployment mechanism in a partially deployed configuration according to some embodiments of the present invention. [0012] Figures 6A-C are views of a rotor assembly deployment mechanism in a deployed configuration according to some embodiments of the present invention. [0013] Figure 7 is a side view of a mounting bracket with motor according to some embodiments of the present invention. [0014] Figure 8 is partial view of a rotor assembly according to some embodiments of the present invention. [0015] SUMMARY [0016] A rotor assembly deployment mechanism configured to deploy a rotor assembly of a vertical take-off and landing aircraft from a horizontal, forward thrust, position to a vertical, hover, position. The rotor assembly deployment mechanism is configured to deploy an electric motor and propeller together. The deployment mechanism provides significant stiffness and strength with the use of torsion box constructions. The deployment mechanism may utilize bar linkages wherein the primary linkage pivot is of a large diameter relative to the span of the pivot in order to provide significant stiffness. The deployment mechanism may utilize rotary actuators to drive the deployment and stowing of the rotor assembly. [0017] DETAILED DESCRIPTION [0018] In some embodiments of the present invention, a rotor assembly deployment mechanism provides a compact, stiff, and reliable device adapted to control and alter the thrust angle of a rotor assembly of an aircraft. In some aspects, the rotor assembly deployment mechanism is configured to deploy an electric motor, a propeller hub, a propeller, and a spinner. In some aspects, the electric motor is outboard of the primary mounting plane of the rotor assembly mounting bracket of the rotor assembly deployment mechanism. In some aspects, the rotor assembly deployment mechanism utilizes torsion box construction to lend stiffness the assembly. In some aspects, the primary central pivot is of an enlarged diameter to lend strength and stiffness to the assembly. In some aspects, rotary actuators utilizing harmonic drives are utilized to deploy the rotor assemblies affixes to the rotor assembly deployment mechanism. [0019] In some aspects, a representative aircraft propulsion system includes a rotor assembly, a nacelle, a propeller hub, and a drive motor with an external rotor. The rotor includes a propeller with a set of blades coupled to the propeller hub and may include a cowling, or spinner. The nacelle defines an outer surface. The drive motor includes a rotary portion rigidly coupled to the propeller hub, and a fixed portion coupled to the nacelle, or otherwise to the aircraft structure. The system can include a tilt mechanism housed at least partially in the lumen of the nacelle, a power supply, and any other suitable components. The aircraft propulsion system can be used in conjunction with a rotorcraft. The rotorcraft is preferably a tiltrotor aircraft with a plurality of aircraft propulsion systems (e.g., rotor assemblies, rotor systems, etc.), operable between a forward arrangement and a hover arrangement. The rotorcraft can alternatively be a fixed wing aircraft with one or more rotor assemblies, and/or any other suitable rotorcraft or vehicle propelled by rotors. The rotorcraft preferably includes an all-electric powertrain (e.g., battery or hydrogen fuel cell powered electric motors) to drive the one or more rotor assemblies, but can additionally or alternatively include a hybrid powertrain (e.g., a gas-electric hybrid including an internal-combustion generator), an internal -combustion powertrain (e.g., including a gas-turbine engine, a turboprop engine, etc.), and any other suitable powertrain. [0020] The term “rotor” as utilized herein, in relation