Abstract:
An electrically actuated aircraft brake and method characterized by radial mount actuator modules which can be easily and quickly replaced as a unit. Quick and easy replacement of the actuator modules can be effected without disassembly of the overall brake and wheel assembly. Accordingly, brake manufacturing, repair costs, overhaul, parts stocking and maintenance costs and requirements are minimized and/or greatly simplified compared to integrated brake designs used in the prior art. Also, a malfunctioning actuator module on an aircraft can be replaced and preferably quickly enough to allow the aircraft to remain in scheduled service and/or with a minimum of downtime.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority of U.S. Provisional Application No. 60/987,854 filed Nov. 14, 2007, which are hereby incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The invention herein described relates generally to brakes and methods, more particularly to brakes and methods using electromechanical actuators, and still more particularly to electrically actuated aircraft brakes and methods. 
       BACKGROUND OF THE INVENTION 
       [0003]    Aircraft wheel and brakes heretofore have included a non-rotatable wheel support, a wheel rotatably mounted to the wheel support, and a brake disk stack having alternating rotor and stator disks mounted with respect to the wheel support and wheel for relative axial movement. Each rotor disk is coupled to the wheel for rotation therewith and each stator disk is coupled to the wheel support against rotation. A back plate is located at the rear end of the disk pack and a brake head is located at the front end. The brake head may house a plurality of actuator rams that extend to compress the brake disk stack against the back plate. Torque is taken out by the stator disks through a static torque tube or the like. 
         [0004]    Electrically actuated aircraft brakes of various configurations are known, as exemplified by U.S. Pat. Nos. 4,381,049, 4,432,440, 4,542,809 and 4,567,967. The brakes shown in these patents include electric motors which respond to an electrical control signal to effect rotation of a ring gear member which interacts through a plurality of balls to drive a linearly movable ram member into contacting engagement with a brake disk stack to effect compression thereof and braking of a wheel. 
         [0005]    In U.S. Pat. No. 4,596,316, another configuration of an electrically actuated brake uses a roller screw drive wherein a ring gear member interacts through a plurality of roller screws to drive a ram member into engagement with a brake pressure plate to effect compression of the brake disk stack for braking action. A plurality of electric motors and their associated pinions drive a ring gear into rotation and the plurality of roller screws effect linear axial movement of the ram member. 
         [0006]    In U.S. Pat. No. 4,865,162, a further electrically actuated aircraft brake employs a roller screw drive mechanism driven by an electric torque motor through a gear drive associated with either the screw or the nut of the roller screw drive mechanism. Rotation of the gear drive by the torque motor moves the other one of the screw or nut into axial engagement with a brake disk stack to compress the stack for braking. A plurality of the roller screw drive mechanisms and respective gear drives and torque motors are assembled in a brake head in a balanced arrangement about the axis of the wheel to apply and release a brake pressure force on the brake disk stack in response to an electrical control signal to the torque motors. 
         [0007]    The repair or maintenance of these presently known brakes including torque motor driven rams heretofore has required significant disassembly of the brake. The complex integrated nature of prior art designs normally require substantial teardown of the assembly for maintenance, repair and/or overhaul of the assembly even if minor repair or only replacement of a single faulty component is required. Associated with extensive teardown is a lengthy reassembly and retest procedure to verify flight worthiness. Also, a highly integrated design and assembly with complex machining and assembly procedures is costly to process and manufacture. Distribution and parts stocking of individual components of such an assembly is similarly complex and inefficient as cam be appreciated by those knowledgeable in this area. Consequently, an aircraft, for example a commercial passenger aircraft, would most likely have to be taken out of scheduled service until a faulty actuator could be serviced. This results in lost revenue for the airline, scheduling adjustments, considerable inconvenience for customers, etc. 
         [0008]    A design that overcomes many of the drawbacks of the aforementioned designs is set forth in commonly-owned U.S. Pat. No. 6,095,293 which discloses an electromechanical actuator module for a braking system. The brake system includes a brake disk stack, a brake head, and at least one actuator module mounted to the brake head. The actuator module includes a module housing, a reciprocating ram and a motive device operatively connected to the reciprocating ram for selectively moving the reciprocating ram into and out of forceful engagement with the brake disk stack for applying and releasing braking force. The actuator module is mounted to a surface of the brake head that is parallel to a friction surface of the brake disk stack. While this mounting configuration is adequate for many applications, removal and/or installation of the modules on a brake head can be difficult especially in applications having limited space for movement of the module in an axial direction. 
       SUMMARY OF THE INVENTION 
       [0009]    The present invention provides a brake and method characterized by radial mount actuator modules each of which can be easily and quickly replaced as a unit. The radial mount actuators eliminate the need for a mounting surface parallel to the friction surface of the brake stack thereby reducing the overall weight of the brake. Further, the radial mount actuators enable quick and easy replacement of the actuator modules, preferably without requiring disassembly of the overall brake and wheel assembly, even in applications that have limited space axially adjacent to the brake. Also, it is conceivable that a malfunctioning actuator module could be replaced on an aircraft and tested with a minimum of equipment preferably quickly enough to allow the aircraft to remain in scheduled service and/or with a minimum of downtime. In addition, periodic maintenance of the brake can be done quicker and more efficiently by replacing the actuator modules with reconditioned and/or new actuator modules. 
         [0010]    Accordingly, a brake comprises a brake disk stack, a brake head, and at least one actuator module mounted to the brake head, wherein the at least one actuator module can be removed radially from the brake head as a unit. The brake head can include at least one radial mount having a module mounting surface, and wherein the at least one actuator module is configured to mount radially to the radial mount. The radial mount can include one or more radially extending splines having a radially outer circumferential end face including the module mount surface. The at least one actuator module can be configured to mount radially to two radial mounts. The at least one actuator module can be secured to a circumferential surface of the brake head with at least one radially extending fastener that can be accessible from a radially outer side of the brake. 
         [0011]    The brake head can include a recess or protrusion for mating with a corresponding recess or protrusion on the module. The at least one module can include an electrical connector for coupling with an electrical connector on the brake head for supplying electricity to the module, and the connectors can be configured to automatically couple when the at least one actuator module is mounted to the brake head. The actuator module can further include a module housing, a reciprocating ram and a motive device operatively connected to the reciprocating ram for selectively moving the reciprocating ram into and out of forceful engagement with the brake disk stack for applying and releasing braking force. 
         [0012]    In accordance with another aspect, a method for servicing a brake including a brake disk stack and a brake head to which a plurality of actuator modules are removably mounted comprises the steps of identifying a brake module to be replaced, and radially removing and replacing the identified brake module with another brake module without disassembly of the brake disk stack. 
         [0013]    In accordance with another aspect, a wheel and brake assembly comprises a rotatable wheel, a brake disk stack operatively connected to the wheel for applying and releasing braking torque on the rotatable wheel, a brake head, and a plurality of radial mount actuator modules. The plurality of actuator modules are removable as units from a radially outer side of the brake head. The plurality of actuator modules can be circumferentially equally spaced around a center axis of the brake head, and the brake head can include a plurality of circumferentially spaced apart radial mounts each having a module mounting surface. Each radial mount can include a radially extending spline having a radially outer circumferential end face including the module mount surface. Each actuator module can be configured to mount radially to two or more radial mounts. Each of the plurality of actuator modules can be secured to a circumferential surface of the brake head with at least one radially extending fastener which can be accessible from a radially outer side of the brake. 
         [0014]    The brake head can include a plurality of recesses or protrusions for mating with corresponding recesses or protrusions on the plurality of actuator modules. Each actuator module can also include an electrical connector for coupling with an electrical connector on the brake head for supplying electricity to each respective actuator module. The electrical connectors can be configured to automatically couple when the actuator modules are mounted to the brake head. Each actuator module can further include a module housing, a reciprocating ram and a motive device operatively connected to the reciprocating ram for selectively moving the reciprocating ram into and out of forceful engagement with the brake disk stack for applying and releasing braking force. 
         [0015]    According to another aspect, an actuator module for use in a wheel and brake assembly including a rotatable wheel, a brake disk stack operatively connected to the wheel for applying and releasing braking force on the rotatable wheel, and a brake head comprises a reciprocating ram, a motive device operatively connected to the reciprocating ram for selectively moving the reciprocating ram into and out of forceful engagement with the brake disk stack for applying and releasing braking force on the rotatable wheel, and a module housing in which the ram and motive device are carried and which is configured for removable radial attachment to the brake head. The actuator module is removably attachable radially as a unit to the brake head. The actuator module can further comprise an electrical connector for coupling with an electrical connector on the brake head for supplying electricity to the module. The actuator model can be securable to a circumferential surface of the brake head with at least one radially extending fastener which can be accessible from a radially outer side of the brake. The actuator module can further include a recess or protrusion for mating with a corresponding recess or protrusion on the brake head. 
         [0016]    The foregoing and other features of the invention are hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail one or more illustrative embodiments of the invention, such being indicative, however, of but one or a few of the various ways in which the principles of the invention may be employed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]      FIG. 1  is a cross-sectional view of an aircraft brake including plural actuator modules mounted to an axial end face of a brake head. 
           [0018]      FIG. 2  is an axial end view of the actuator modules and brake head looking from the line  2 - 2  of  FIG. 1 , with one of the modules removed. 
           [0019]      FIG. 3  is a cross-sectional view of an exemplary aircraft brake including plural radial mount actuator modules mounted to a brake head in accordance with the invention. 
           [0020]      FIG. 4  is a partial perspective assembly view of the aircraft brake of  FIG. 3  showing the brake head and an actuator module. 
           [0021]      FIG. 5  is side view of the brake head and radial mount actuator module of  FIG. 4  showing the actuator module mounted to the brake head. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]    Because the invention was conceived and developed for use in an aircraft braking system, it will be herein described chiefly in this context. However, the principles of the invention in their broader aspects can be adapted to other types of braking systems, such as in train brake systems. 
         [0023]    Referring now in detail to the drawings and initially to  FIG. 1 , a wheel and brake assembly having axial mount actuator modules is generally indicated at  10 . The assembly  10  generally comprises a brake  11  and an aircraft wheel  12  which is supported for rotation by bearings  13  and  14  on an axle  15 . The axle  15  forms a wheel mount and is attached to the end of an aircraft landing gear strut (not shown) or a truck attached to the end of a landing gear strut. 
         [0024]    The brake  11  includes a brake head or housing  20  which is attached by bolt fasteners  21  to a torque tube  22  which in turn is attached by bolt fasteners  23  to a torque take-out flange on the axle  15 . The illustrated brake head is a generally planar disk-like plate member having a bolt circle surrounding a central opening as best shown in  FIGS. 1 and 2 . 
         [0025]    The torque tube  22  is surrounded by stationary brake elements and rotary brake elements that are interleaved. The stationary and rotary brake elements are in the form of stator disks  25  and rotor disks  26 , and the interleaved arrangement thereof is commonly referred to as a brake disk stack, the same being designated by reference numeral  27 . The stator disks  25  are splined to the torque tube and the rotor disks  26  are splined to the wheel  12  interiorly of the wheel&#39;s rim. As is conventional, the splined connection may be effected by a plurality of spline or drive keys that are spaced around the circumference of the rim/torque tube to permit axial movement of the rotor/stator disks while being held to the wheel/torque tube against relative rotation. 
         [0026]    The disk stack  27  is located between a back pressure member  31  and the brake head  20 . The back pressure member  31  is formed by a radial flange at the outer end of the torque tube  22 . The radial flange carries thereon a plurality of circumferentially spaced torque pucks  33  engaged with the last brake disk  34  at the rear end of the disk stack  27 . The torque pucks  33  may be attached in a known manner to the radial flange  31  by several torque pucks which have the stems thereof loosely fitted in holes in the radial flange to permit some swiveling movement thereof. The torque pucks in the illustrated embodiment secure the last brake disk  34  against rotation relative to the torque tube. In a modified arrangement, the radial flange could be configured to engage directly the disk stack, and still other arrangements could be used. 
         [0027]    Pressure is applied to the front end of the disk stack  27  by one or more disk engaging members such as the inboard ends of one or more actuator rams  35 . The actuator rams  35  are included in respective actuator modules  36  mounted to the brake head  20  by removable bolt fasteners  37  or other suitable means enabling quick and easy attachment and detachment of the actuator modules to and from the brake head. 
         [0028]    The actuator modules  36 , being mounted to a surface of the brake head that is generally parallel to a surface of the brake disks  26 , can be removed by first axially removing bolts  37  and then removing the actuator  36 . As will be appreciated, some clearance will typically be needed axially adjacent the bolts  37  to permit installation and/or removal of the bolts  37 . Further details of the wheel and brake assembly  10  can be found in commonly-owned U.S. Pat. No. 6,095,293, which is hereby incorporated herein by reference in its entirety. 
         [0029]    Turning now to  FIGS. 3-5 , and initially to  FIG. 3 , a brake assembly in accordance with the invention is illustrated having actuator modules  44  radially mounted to the brake head  20  such that the actuator modules  44  can be removed and/or installed radially from the brake head  20  as a unit. The brake assembly is substantially similar to the brake assembly described in connection with  FIGS. 1 and 2  with the exception of the radial mount actuator modules  44 . 
         [0030]    The brake head  20  includes a plurality of circumferentially spaced-apart radial mounts  50  to which the actuator modules  44  are securable. Each radial mount  50  generally includes a radially extending spline  54  having a radially outer circumferential end face including a module mount surface  56 . It will be appreciated that the end face need not be curved, and in fact can be flat or have any other suitable form. The mount surface  56  can include mounting holes  58  for receiving a fastener, such as a bolt  60 , for securing the actuator module  44  to the brake head  20 . Other fasteners can also be used, such as clamps, for example. 
         [0031]    Each actuator module  44  includes a housing  62  for supporting one or more actuator rams  35  and motive devices  63  ( FIG. 5 ) operatively connected to the reciprocating rams  35  for selectively moving the reciprocating ram  35  into and out of forceful engagement with the brake disk stack for applying and releasing braking force. The housing  62  further includes housing mounting holes  64  through which bolts  60  extend to secure the actuator module  44  to the brake head  20 . As will be appreciated, bolts  60  generally extend radially towards a central axis of the brake head  20  and are accessible from a radially outer circumference of the brake. Thus, access to an end face of the brake head  20  is not necessary to install and/or remove an actuator module  44 . 
         [0032]    To facilitate alignment of the actuator modules  44  on the brake head  20  during assembly, the brake head  20  can include a recess or protrusion for mating with a corresponding recess or protrusion on each actuator module  44 . In the illustrated embodiment, each actuator module  44  includes an undercut lip  70  configured to mate with a protrusion  72  on each radial mount  50 . The undercut lip  70  can also facilitate load distribution during operation of the actuator modules  44 . As will be appreciated, the recesses and protrusions can take a wide variety of forms. 
         [0033]    The actuator modules  44  can also include an electrical connector  74  for coupling with an electrical connector  76  on the brake head  20  for supplying electricity to the actuator modules  44 . The electrical connectors  74  and  76  can be configured such that a secure electrical connection is made when the actuator modules  44  are mounted to the brake head  20 . Accordingly, a secure electrical connection can be made as part of the physical securement of the module  44  to the brake head  20 . This feature can eliminate the need to electrically connect the actuator modules  44  in a separate step, and can provide a more secure connection than other methods. 
         [0034]    It will now be appreciated that the actuator modules  44  can be removed from and/or installed on the brake head  20  from a radial direction. For example, the bolts  60  can be removed and/or installed from an outer circumference of the brake assembly and, thus, the actuator modules  44  can be removed and/or installed by shifting them radially inwardly/outwardly. This configuration eliminates or reduces the need for a module mounting surface parallel to a friction surface of the brake stack thereby tending to reduce the overall weight of the brake. Further, because the bolts  60  and actuator modules  44  can be installed and removed radially, the need for axial clearance adjacent to the brake head  20  is reduced. 
         [0035]    In view of the foregoing, it will now be appreciated that there is provided a brake assembly that enables easy and quick replacement of a malfunctioning electromechanical actuator. No longer must a brake be substantially dissembled to repair a malfunctioning actuator or other actuator identified for repair and/or replacement. Instead, a malfunctioning actuator module  44  (or all of the actuator modules if the malfunctioning module can not be determined) can be removed radially from the brake head  20  simply by removing the fasteners  60  and withdrawing the module  44  radially from the brake head  20 . This can be accomplished without having to disassemble the brake disk stack and potentially even with the wheel in place on the axle, as access usually can be gained in most wheel and brake assemblies to the radially outer side of the brake head. As described, to facilitate the easy removal and replacement of the actuator modules, the electrical connectors  74  and  76  can be configured to automatically electrically couple/decouple the actuator modules  44  during installation or removal of the actuator  44 . 
         [0036]    Although the invention has been illustrated in the context of a flange mounted type of brake, the principles of the invention may be applied to other types of brakes such as to a torque lug type of brake as will be appreciated by those skilled in the art. 
         [0037]    Aspects of the invention considered to be novel and inventive are set out in the following lettered clauses: 
         [0038]    A1. A brake comprising a brake disk stack, a brake head, and at least one actuator module mounted to the brake head, wherein the at least one actuator module can be removed radially from the brake head as a unit. 
         [0039]    A2. A brake as set forth in claim A1, wherein the brake head includes at least one radial mount having a module mounting surface, and wherein the at least one actuator module is configured to mount radially to the radial mount. 
         [0040]    A3. A brake as set forth in any preceding claim, wherein the radial mount includes a radially extending spline having a radially outer circumferential end face including the module mount surface. 
         [0041]    A4. A brake as set forth in any preceding claim, wherein the brake head includes a plurality of radial mounts each having a module mounting surfaces, and wherein the at least one actuator module is configured to mount radially to two radial mounts. 
         [0042]    A5. A brake as set forth in any preceding claim, wherein the at least one actuator module is secured to a circumferential surface of the brake head with at least one radially extending fastener. 
         [0043]    A6. A brake as set forth in any preceding claim, wherein the at least one radially extending fastener is accessible from a radially outer side of the brake. 
         [0044]    A7. A brake as set forth in any preceding claim, wherein the brake head includes a recess or protrusion for mating with a corresponding recess or protrusion on the module. 
         [0045]    A8. A brake as set forth in any preceding claim, wherein the at least one module includes an electrical connector for coupling with an electrical connector on the brake head for supplying electricity to the module. 
         [0046]    A9. A brake as set forth in any preceding claim, wherein the electrical connector of the module and the electrical connector on the brake head are configured to automatically couple when the at least one actuator module is mounted to the brake head. 
         [0047]    A10. A brake as set forth in any preceding claim, wherein the module includes a module housing, a reciprocating ram and a motive device operatively connected to the reciprocating ram for selectively moving the reciprocating ram into and out of forceful engagement with the brake disk stack for applying and releasing braking force. 
         [0048]    A11. A brake as set forth in any preceding claim, in combination with an aircraft wheel assembly. 
         [0049]    A12. A method for servicing a brake including a brake disk stack and a brake head to which a plurality of actuator modules are removably mounted, the method comprising the steps of identifying a brake module to be replaced, and radially removing and replacing the identified brake module with another brake module without disassembly of the brake disk stack. 
         [0050]    B13. A wheel and brake assembly comprising: 
         [0051]    a rotatable wheel; 
         [0052]    a brake disk stack operatively connected to the wheel for applying and releasing braking torque on the rotatable wheel; 
         [0053]    a brake head; and 
         [0054]    a plurality of radial mount actuator modules; 
         [0055]    wherein the plurality of actuator modules are removable as units from a radially outer side of the brake head. 
         [0056]    B14. A wheel and brake assembly as set forth in claim B13, wherein the plurality of actuator modules are circumferentially equally spaced around a center axis of the brake head. 
         [0057]    B15. A wheel and brake assembly as set forth in any one of claims B13-B14, wherein the brake head includes a plurality of circumferentially spaced apart radial mounts each having a module mounting surface, and wherein the plurality of actuator modules are configured to mount radially to the radial mounts. 
         [0058]    B16. A wheel and brake assembly as set forth in any one of claims B13-B15, wherein each radial mount includes a radially extending spline having a radially outer circumferential end face including the module mount surface. 
         [0059]    B17. A wheel and brake assembly as set forth in any one of claims B13-B16, wherein each actuator module is configured to mount radially to two radial mounts. 
         [0060]    B18. A wheel and brake assembly as set forth in any one of claims B13-B17, wherein each of the plurality of actuator modules are secured to a circumferential surface of the brake head with at least one radially extending fastener. 
         [0061]    B19. A wheel and brake assembly as set forth in any one of claims B13-B18, wherein the at least one radially extending fastener is accessible from a radially outer side of the brake. 
         [0062]    B20. A wheel and brake assembly as set forth in any one of claims B13-B19, wherein the brake head includes a plurality of recesses or protrusions for mating with corresponding recesses or protrusions on the plurality of actuator modules. 
         [0063]    B21. A wheel and brake assembly as set forth in any one of claims B13-B20, wherein the plurality of actuator modules each include an electrical connector for coupling with an electrical connector on the brake head for supplying electricity to each respective actuator module. 
         [0064]    B22. A wheel and brake assembly as set forth in any one of claims B13-B21, wherein the electrical connectors of the actuator modules and the electrical connectors on the brake head are configured to automatically couple when the actuator modules are mounted to the brake head. 
         [0065]    B23. A wheel and brake assembly as set forth in any one of claims B13-B22, wherein each actuator module includes a module housing, a reciprocating ram and a motive device operatively connected to the reciprocating ram for selectively moving the reciprocating ram into and out of forceful engagement with the brake disk stack for applying and releasing braking force. 
         [0066]    C24. An actuator module for use in a wheel and brake assembly including a rotatable wheel, a brake disk stack operatively connected to the wheel for applying and releasing braking force on the rotatable wheel, and a brake head; said actuator module comprising a reciprocating ram, a motive device operatively connected to the reciprocating ram for selectively moving the reciprocating ram into and out of forceful engagement with the brake disk stack for applying and releasing braking force on the rotatable wheel, and a module housing in which the ram and motive device are carried and which is configured for removable radial attachment to the brake head, wherein the actuator module is removably attachable radially as a unit to the brake head. 
         [0067]    C25. An actuator module as set forth in claim C24, further comprising an electrical connector for coupling with an electrical connector on the brake head for supplying electricity to the module. 
         [0068]    C26. An actuator module as set forth in any one of claims C24-C25, wherein the actuator model is securable to a circumferential surface of the brake head with at least one radially extending fastener. 
         [0069]    C27. An actuator module as set forth in any one of claims C24-C26, wherein the at least one radially extending fastener is accessible from a radially outer side of the brake. 
         [0070]    C28. An actuator module as set forth in any one of claims C24-C27, wherein the actuator module includes a recess or protrusion for mating with a corresponding recess or protrusion on the brake head. 
         [0071]    C29. A brake assembly including a brake disk stack, a brake head, and at least one actuator module as set forth in any one of claims C24-C28 mounted to the brake head. 
         [0072]    Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described integers (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such integers are intended to correspond, unless otherwise indicated, to any integer which performs the specified function of the described integer (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application. 
         [0073]    In addition, the invention is considered to reside in all workable combinations of features herein disclosed, whether initially claimed in combination or not and whether or not disclosed in the same embodiment.