Abstract:
A vented EMA may have a vent that allows gas to pass from into and out of the vented EMA, while preventing liquid from passing into and out of the vented EMA. The vented EMA may have a desiccant material inside the vented EMA that absorbs condensation from within the vented EMA. A vented EMA may also have an air flow path that conducts gas into and out of the vent during operation. As a result, the pressure inside the vented EMA may equalize with the pressure outside the vented EMA, but the deleterious ingress of liquids may be ameliorated.

Description:
FIELD 
       [0001]    The present disclosure relates to braking systems and, more specifically, to an electric motor actuator that is vented. 
       BACKGROUND 
       [0002]    Typical electric motor actuators in aircraft and/or large vehicle (e.g., trains, commercial equipment, and/or the like) brake systems may employ an electric motor actuator. In response to the actuator being engaged, the actuator translates a force-exerting member into and out the housing. This translating causes pressure changes in the air volume within the actuator, contributing to moisture ingress, which degrades the actuator operational life and performance. 
       SUMMARY OF THE INVENTION 
       [0003]    A vented EMA is disclosed. The vented EMA may include a motor, a gear train, and a ball screw assembly having a free air volume bounded by the radially inner surface of the ball screw assembly. The motor may drive the gear train, and the gear train may translate the ball screw assembly. The vented EMA may also include a housing forming a structural support member of the vented EMA, a cover forming a cylindrical member into which a portion of the housing is inserted, and a liner having a cylinder section disposed annularly between the motor and the ball screw assembly. The vented EMA may also include a vent having a gas exchange apparatus including a gas permeable-liquid impermeable membrane whereby gas may be drawn into the vented EMA and whereby liquid may be prevented from being drawn into the vented EMA, and an air flow path, whereby the gas may be conducted between the free air volume and the vent. 
         [0004]    A method of operating a vented EMA is disclosed. The method of operating a vented EMA may include extending a ball screw assembly from the vented EMA, increasing a volume of a free air volume of the vented EMA in response to the extending, and drawing a gas including a first quantity of water vapor into a vent in response to the increasing. The method may also include absorbing, by a desiccant material, the first quantity of water vapor, evaporating, from the desiccant material, a second quantity of water vapor, and retracting the ball screw assembly into the vented EMA. Moreover, the method may include decreasing the volume of the free air volume of the vented EMA in response to the retracting, and expelling the gas including the second quantity of water vapor from the vent in response to the decreasing. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the Figures, where like reference numbers refer to similar elements throughout the Figures, and: 
           [0006]      FIG. 1  illustrates a cross-sectional view of an example vented EMA, in accordance with various embodiments; 
           [0007]      FIG. 2  illustrates various features of an example liner of a vented EMA, in accordance with various embodiments; 
           [0008]      FIG. 3  illustrates an air flow path of an example vented EMA, in accordance with various embodiments; and 
           [0009]      FIG. 4  illustrates an example method of operating a vented EMA, in accordance with various embodiments. 
       
    
    
     DETAILED DESCRIPTION 
       [0010]    The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration and their best mode. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the inventions, it should be understood that other embodiments may be realized and that logical, chemical and mechanical changes may be made without departing from the spirit and scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. 
         [0011]    Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. 
         [0012]    As used herein, phrases such as “make contact with,” “coupled to,” “touch,” “interface with” and “engage” may be used interchangeably. 
         [0013]    In various embodiments, a brake system may comprise an electric motor actuator (“EMA”). The EMA may be coupled to or otherwise operate a pressure generating device such as, for example, a ball screw, a ram, and/or the like. In operation, the EMA may cause the pressure generating device to move and/or exert a force on other brake system structures such as, for example, a brake disk stack or pad to exert a stopping force on a wheel or other suitable moving structure. This stopping force may load and/or exert a corresponding force on the EMA structures such as, for example, an EMA housing. 
         [0014]    The EMA may traditionally be sealed to help protect the EMA and its internal components from foreign substances, such as water. However, as the pressure generating device moves, the internal volume of the EMA changes. Accordingly, the internal pressure of the EMA changes as well. Moreover, heating and cooling may also cause the internal pressure of the EMA to change. This change in pressure may encourage foreign substances, such as water, to breach the EMA&#39;s seals and ingress into the EMA. Over time, the ingressed foreign substances may damage the EMA. 
         [0015]    Various solutions to this limitation of traditional EMAs are presented below. 
         [0016]    With reference to  FIG. 1 , a vented EMA  2  is illustrated. A vented EMA  2  comprises a motor  4 , a gear train  6 , and a ball screw assembly  8 . The motor  4  drives the gear train  6  in order to translate the ball screw assembly  8 . In response to this translating, the ball screw assembly  8  exerts pressure, such as on a brake stack, or another device desired to be acted upon. 
         [0017]    The vented EMA  2  may further comprise a liner  10 , a cover  12 , a vent  14 , and a housing  16 . With reference to  FIG. 3 , the vented EMA  2  may further comprise an air flow path  18 , which permits air to flow into and out the vented EMA  2  via the vent  14 . 
         [0018]    With renewed reference to  FIG. 1 , the vented EMA  2  may comprise a housing  16 . The housing  16  may comprise a structural support member, such as a member whereby the vented EMA  2  may be attached to surrounding structures, such as an aircraft static structure, for example, a brake assembly. The housing  16  may comprise a cylindrical member having an internal space wherein different components, such as the motor  4 , the gear train  6 , and the ball screw assembly  8  may be at least partially disposed. 
         [0019]    The vented EMA  2  may further comprise a cover  12 . The cover  12  may connect to the housing  16 , and may protect the different components disposed within the housing  16  from exposure to the external environment. For example, the cover  12  may comprise a cylindrical member with an open end into which a portion of the housing  16  may be inserted. Thus, in various embodiments, the cover  12  has an inner diameter greater than the outer diameter of the housing  16 , so that the housing  16  extends axially into the cover  12 . 
         [0020]    The vented EMA  2  may further comprise a liner  10 . The liner  10  may comprise an cylinder section, open on both ends, and having an outer diameter less than an inner diameter of the housing  16 , and having an inner diameter greater than an outer diameter of the motor  4 . In this manner, the liner  10  encircles at least a portion of the motor  4 . The liner  10  may provide a barrier between the motor  4  and the ball screw assembly  8 . For example, when retracted (as discussed below) the ball screw assembly  8  may annularly encircle a portion of the motor  4 . The liner  10  may be disposed annularly between the motor  4  and the ball screw assembly  8 , and may protect the motor  4  from contact with grease and/or lubricant, such as that applied to the ball screw assembly  8  to ameliorate friction. 
         [0021]    With continuing reference to  FIG. 1 , the motor  4  may comprise a brushless electrical motor. In further embodiments, the motor  4  may comprise a brushed electrical motor. However, the motor  4  may comprise a hydraulic actuator, or a pneumatic actuator, or any other apparatus whereby motive energy may be imparted to, for example, gear train  6 . 
         [0022]    The gear train  6  comprises one or more gears disposed between the motor  4  and the ball screw assembly  8 , whereby the ball screw assembly  8  is operatively connected to the motor  4  and enabled to translate in response to motive energy imparted by the motor  4 . In various embodiments, the gear train  6  comprises a speed reduction drive. In this manner, the gear train  6  may receive a low-torque, high speed motive input, and may output a high-torque, low speed motive output, thus driving the ball screw assembly  8 . However, any gear train  6  with any desired characteristics may be implemented. For example, in embodiments wherein the motor  4  comprises a hydraulic actuator, the gear train  6  may comprise a direct mechanical interconnection between the motor  4  and the ball screw assembly  8 , with no gear reduction, although any arrangement may be contemplated. 
         [0023]    The ball screw assembly  8  may comprise any pressure exerting apparatus, whereby motive energy imparted by the motor  4  through the gear train  6  may be conveyed to another device or system, such as a brake stack. In various embodiments, the ball screw assembly  8  is configured to convert rotary motion into linear motion. In further embodiments, the ball screw assembly  8  comprises a hydraulically actuated ram, although any desired configuration may be implemented. 
         [0024]    Thus, one may appreciate that as the ball screw assembly  8  translates, the internal volume of the vented EMA  2  may change as well. For example, the ball screw assembly  8  may translate outwardly away from the housing  16  along a central axis of the housing (e.g., the X-axis as depicted in  FIG. 1 ) (e.g., “extension”), so that the volume of the vented EMA  2  increases as the ball screw assembly  8  moves out the internal volume of the vented EMA  2 .  FIG. 1  illustrates the ball screw assembly  8  at full extension. Also, the ball screw assembly  8  may translate inward along a central axis of the housing (e.g., the X-axis as depicted in  FIG. 1 ) (e.g., “retraction”), so that the volume of the vented EMA  2  decreases as the ball screw assembly  8  is received back into the housing  16  of the vented EMA  2 . 
         [0025]    As such, the ball screw assembly  8  may comprise a free air volume  20 . The free air volume  20  may be bounded by the radially inner surface of the ball screw assembly  8 . The free air volume  20  may be disposed within the ball screw assembly  8  and may increase and decrease in response to the extension and retraction of the ball screw assembly  8 . 
         [0026]    As the free air volume  20  changes, the gas within the vented EMA  2  may undergo fluid flow. Because a vent  14  (discussed herein) is provided, the gas may be expelled from, or drawn in through the vent  14  in response to the pressure and/or suction caused by the change in free air volume  20 . 
         [0027]    Accordingly, the vented EMA  2  may comprise various additional features whereby the fluid flow of the gas may be facilitated, among other features. 
         [0028]    Having discussed various aspects of the vented EMA  2 , with continuing reference to  FIG. 1 , and with additional reference to  FIG. 2 , the liner  10  may comprise orifice air channels  22 . Orifice air channels  22  may comprise grooves extending axially along a central axis of the liner (e.g., the X-axis as depicted in  FIGS. 1 and 2 ) along the inner surface of the liner  10 . As the size of the free air volume  20  changes, gas may be expelled from or drawn into the free air volume  20  via the orifice air channels  22 . In various embodiments, the orifice air channels  22  comprise anti-rotation keying grooves, whereby the liner  10  is prevented from unwanted rotation, such as under the influence of the ball screw assembly  8 . The orifice air channels  22  may comprise any structure whereby gas may be fluidically conducted into and out the free air volume  20 . 
         [0029]    In various embodiments, the orifice air channels  22  transit the entire axial length of the liner  10  (e.g., the X-axis as depicted in  FIG. 2 ). The orifice air channels  22  may further be in fluidic communication with orifice holes  36  of the housing  16 , as discussed below. 
         [0030]    The housing  16  may comprise orifice holes  36 . Orifice holes  36  may comprise apertures extending radially through the housing  16  whereby fluid may be conducted from the inner circumferential face of the housing  16  to the outer circumferential face of the housing  16 . The housing  16  may comprise a plurality of orifice holes  36  spaced circumferentially about the housing  16 . However, in further embodiments, the housing  16  may comprise a single orifice hole  36 . Thus, as one may appreciate, the housing  16  may comprise any number of orifice holes  36 , as desired, to conduct a desired volume of gas at a desired flow rate and/or pressure. The orifice holes  36  may be disposed proximate to one end of the housing  16 , for example, the negative-X most end of the housing, along the X axis depicted in  FIGS. 1-3  (e.g., the end of the housing disposed within the cover  12 ). The orifice holes  36  may be arranged circumferentially around housing  16 , although any desired arrangement may also be selected. The orifice holes  36  may be disposed in a portion of the housing  16  within the cover  12 . Thus, the orifice holes  36  may conduct gas from the orifice air channels  22  to the cover air space  13 . 
         [0031]    The cover  12  may comprise a cover air space  13 . The cover air space  13  may comprise a volume of space within the cover  12  bounded by the radially inner surface of the cover  12 . The cover air space may fluidically connect between the orifice holes  36  and at least one of a vent  14  or a desiccant material  26 . However, the cover air space  13  may comprise any feature whereby gas from the orifice air channels  22  may flow to/from at least one of the vent  14  or the desiccant material  26 . 
         [0032]    Having discussed various features of the vented EMA  2  whereby the fluid flow of gas may be facilitated, attention is directed to  FIG. 3 , whereby an example flow path of gas is illustrated. An air flow path  18  may comprise any path whereby gas may be conducted between the free air volume  20  and the vent  14 . In various embodiments, the air flow path  18  comprises a route terminating at the free air volume  20 , extending annularly outward of the motor  4  (e.g., radially away from a central axis of the housing such as the X-axis as depicted in  FIG. 1 ), through an orifice air channel  22 , extending axially away from the free air volume  20  (e.g., axially parallel to a central axis of the housing such as the X-axis as depicted in  FIG. 1 ) to one or more orifice hole  36  disposed in the housing  16 , extending annually outward (e.g., radially away from a central axis of the housing such as the X-axis as depicted in  FIG. 1 ) of the housing  16  and conducted annularly inward (e.g., radially toward a central axis of the housing such as the X-axis as depicted in  FIG. 1 ) of the cover  12  through a cover air space  13 , and finally conducted to a vent  14 . In various embodiments, the air flow path  18  is further in fluidic communication with a desiccant material  26  (with momentary reference to  FIG. 1 ). 
         [0033]    With reference now to  FIGS. 1 and 3 , various aspects of the cover  12  are explicated in further detail. In various embodiments, the cover  12  may comprise a cover channel  24 . A desiccant material  26  may be disposed within the cover channel  24 , and may be retained in position by a desiccant retainer  28 . 
         [0034]    A cover channel  24  may comprise an annular groove cut in the cover  12 , wherein a desiccant may be disposed. In further embodiments, the cover channel  24  may not comprise an annulus, but may comprise a channel, depression, or cavity of any shape, for example, a cylindrical depression, a trapezoidal cutout, or any other shape wherein a desiccant may be retained. In still further embodiments, the cover  12  does not have a cover channel  24 , and instead a desiccant is affixed to an internal face of the cover  12 . However, one may appreciate that a cover channel  24  may comprise any shape or arrangement whereby a desiccant may be retained in position. 
         [0035]    A desiccant retainer  28  may comprise a gas permeable membrane disposed over a desiccant material  26  positioned in the cover channel  24 , so that the desiccant material  26  does not escape the cover channel  24  during operation, but so that gas traveling along the air flow path  18  ( FIG. 3 ) may contact the desiccant material  26 . A desiccant retainer  28  may comprise an annular ring inserted into a portion of a cover channel  24 . Furthermore, a desiccant retainer  28  may comprise glue, detents, fasteners or any other mechanism whereby a desiccant material  26  may be retained in the cover channel  24 . 
         [0036]    Finally, as mentioned above, a desiccant material  26  may be disposed in the cover channel  24 . A desiccant material  26  may comprise any material whereby liquid water and/or or other desired fluids may be absorbed/adsorbed and retained. In various embodiments, the desiccant material  26  is capable of being dried, for example, as the vented EMA  2  warms during operation, the desiccant material  26  may be warmed so that retained liquid evaporates as a vapor, and is subsequently carried away along air flow path  18  ( FIG. 3 ). 
         [0037]    A cover  12  may also comprise a vent  14 . The cover  12  may comprise a vent receiver  30 , whereby the vent  14  is retained in connection to the cover  12 . The vent  14  may comprise a vent-cover affixment member  34  that interfaces with the vent receiver  30 , thereby holding the vent  14  in position. 
         [0038]    For example, the cover  12  may comprise a vent receiver  30 . A vent receiver  30  may comprise an aperture disposed in a face of the cover  12  and extending through the cover  12 . In further embodiments, the vent receiver  30  comprises threads. 
         [0039]    The vent  14  may comprise a vent-cover affixment member  34 . The vent-cover affixment member  34  may be configured to interface with the vent receiver  30  in order to hold the vent  14  in position. In various embodiments wherein the vent receiver  30  comprises threads, the vent-cover affixment member  34  may comprise corresponding threads, such as on a shaft, thus resembling a bolt, whereby the vent  14  may be screwed into the vent receiver  30  and retained. In further embodiments, wherein the vent receiver  30  comprises an aperture disposed in a face of the cover  12  and extending through the cover  12 , but not having threads, the vent-cover affixment member  34  may comprise a threaded shaft configured to receive a nut, whereby the vent  14  may be retained in connection to the cover  12 . 
         [0040]    Finally, the vent  14  may comprise a gas exchange apparatus whereby gas and/or vapor is permitted to travel from the cover air space  13 , through the vent  14  and out or into the vented EMA  2 . However, the gas exchange apparatus may further be configured to prevent the ingress or egress of liquid from the vented EMA  2 . In various embodiments, the vent  14  comprises an expanded polytetrafluoroethylene (“ePTFE”) material. However, the vent  14  may comprise any gas exchange apparatus that is gas permeable, but liquid impermeable. As such, the vent may comprise a gas permeable-liquid impermeable membrane. For instance, the vent  14  may comprise a material with pores approximately 700 times larger than an air molecule, but about 20,000 smaller than a typical water droplet, thus serving as a gas permeable barrier against water, dirt, and debris. In this manner, the vent  14  may permit the pressure of the gas within the free air volume  20  to equalize with the pressure of the ambient environment, but prevent the transfer of liquid into or out the internal area of the vented EMA  2 . 
         [0041]    Liquid that has condensed inside the vented EMA  2  may be absorbed by the desiccant, until heat causes the liquid to evaporate, whereupon it may be conveyed as vapor through the vent  14  and escape the vented EMA  2 . In this manner, the vented EMA  2  may be permitted to exchange gas with the external environment so as to equalize pressure, yet may be protected from liquid ingress, such as the infiltration of water and subsequent degradation of performance that may occur. 
         [0042]    Having discussed various aspects of a vented EMA  2 , a method  100  of operating a vented EMA  2  is presented. With reference to  FIGS. 1 and 4 , a method of operating a vented EMA  2  may comprise extending a ball screw assembly  8  from a vented EMA (Step  102 ). The ball screw assembly  8  may translate away from the housing  16  along a central axis of the housing (e.g., the X-axis as depicted in  FIG. 1 ) (e.g., “extension”). A free air volume  20  of the vented EMA  2  may be increased in response to the extending. (Step  104 ). A liquid water droplet may come into contact with the vent  14 . (Step  105 ). A gas comprising a first quantity of water vapor may be drawn into a vent  14  in response to the increasing while the liquid water drop may be prevented from passing through the vent  14  (Step  106 ). The first quantity of water vapor may condense inside the vented EMA  2  and may be absorbed by the desiccant material  26  (Step  108 ). Subsequently, a second quantity of water vapor may evaporate from the desiccant material  26 . (Step  110 ). The ball screw assembly  8  may retract into a vented EMA (Step  112 ). The ball screw assembly  8  may translate inward along a central axis of the housing (e.g., the X-axis as depicted in  FIG. 1 ) (e.g., “retraction”), so that the volume of the vented EMA  2  decreases as the ball screw assembly  8  is received back into the housing  16  of the vented EMA  2 . Thus, in response to the retracting, the free air volume  20  of the vented EMA  2  may be decreased. (Step  114 ). Consequently, a gas comprising a second quantity of water vapor may be expelled from the vent  14  in response to the decreasing (Step  116 ). In various embodiments, the second quantity of water vapor may be equal to the first quantity of water vapor, although in further embodiments it may be lesser, or may be greater. 
         [0043]    In various embodiments, the vented EMAs described herein provide improved reliability as compared to prior EMAs because the parts are not subject to pressure differentials with the outside environment, which may degrade seals, and because the parts are not subject to infiltration by liquid contaminants, such as water. Furthermore, the instrumented housings described herein provide improved performance because component degradation over time is ameliorated. 
         [0044]    Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the inventions. The scope of the inventions is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. 
         [0045]    Systems, methods and apparatus are provided herein. In the detailed description herein, references to “one embodiment”, “an embodiment”, “various embodiments”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments. 
         [0046]    Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f), unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover  12  a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.