Patent Description:
Gas turbine engines may be employed to power various devices. For example, a gas turbine engine may be employed to propel or supply power to a vehicle, such as an aircraft. In some examples, the gas turbine engine may include a thrust reverser, which is deployable to move relative to the gas turbine engine to redirect turbine engine exhaust flow in order to generate reverse thrust to assist in stopping the aircraft. In certain instances, multiple flexible shafts or flexshafts may be driven to move the thrust reverser relative to the gas turbine engine. The use of multiple flexshafts, however, also requires the use of an additional motor to drive the flexshafts, which is mounted remotely from the thrust reverser. The additional motor increases a weight associated with the thrust reverser. The additional motor also increases an amount of space required around the thrust reverser for the mounting of the additional motor.

Accordingly, it is desirable to provide actuators and an actuator system for a thrust reverser, which eliminates the use of an additional motor and thereby reduces a weight of the thrust reverser. In addition, it is desirable to provide actuators and an actuator system that reduces an amount of space required for the actuator system. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.

<CIT> shows an actuator according to the prior art.

According to various embodiments, provided is an actuator for a thrust reverser. The actuator includes a ball screw configured to be coupled to the thrust reverser, and a ball nut coupled to the ball screw. The actuator includes a gerotor coupled to the ball screw. The gerotor includes an inner rotor coupled to the ball screw and an outer rotor. A movement of the inner rotor relative to the outer rotor is configured to rotate the ball screw relative to the ball nut to move the thrust reverser between at least a first position and a second position. The outer rotor includes a plurality of bores spaced apart about a perimeter of the outer rotor. The actuator includes a lock system coupled to the outer rotor and movable between an unlocked state and a lock state. The lock system is configured to enable the gerotor to rotate the ball screw in the unlocked state and to inhibit a rotation of the ball screw in the lock state. The lock system includes a piston coupled to a piston housing and a grippable member coupled to the piston housing. The piston is received in one of the plurality of bores of the outer rotor in the lock state, and the grippable member is configured to move the piston housing relative to the gerotor to move the lock system to the unlocked state.

The actuator includes a gerotor housing, the gerotor is disposed within the gerotor housing and the gerotor housing includes a lock receiving bore. The lock system includes a trunnion, and the trunnion is coupled to the lock receiving bore and the piston housing. The trunnion defines a central trunnion bore that receives the piston housing, the central trunnion bore defines a trunnion key slot, the piston housing defines a housing key slot, and the trunnion key slot and the housing key slot cooperate to receive a key to inhibit a rotation of the piston housing relative to the trunnion. The piston housing defines a detent groove along an exterior surface of the piston housing, and the grippable member includes a detent pin that is received within the detent groove. The piston housing includes a piston spring and a fitting, the piston includes a head and a shaft, the shaft is configured to engage the one of the plurality of bores of the outer rotor and the piston spring is disposed between the head and the fitting to bias the piston into engagement with the one of the plurality of bores of the outer rotor. The plurality of bores of the outer rotor includes a pair of overstow bores, which have a dimension that is different than a remainder of the plurality of bores. The actuator includes an extension shaft coupled to the ball nut and configured to be coupled to the thrust reverser, the ball screw is received within the extension shaft, and the rotation of the ball screw is configured to translate the ball nut to move the extension shaft. An end of the actuator opposite the gerotor includes a coupling portion coupled to the extension shaft with a pin and an attachment portion, and the coupling portion and the attachment portion are configured to couple the actuator to the thrust reverser. An end of the actuator opposite the gerotor includes a coupling portion and an attachment portion, the coupling portion coupled to the extension shaft with a connecting shaft, and the coupling portion and the attachment portion are configured to couple the actuator to the thrust reverser. The actuator includes a bevel gear set coupled to at least one of the ball screw and the inner rotor for rotation with the ball screw in the unlocked state. The actuator includes a second actuator configured to be coupled to the thrust reverser, a flex shaft coupled to the bevel gear set and the second actuator, and the flex shaft is configured to be driven by the bevel gear set to drive the second actuator.

Also provided is an actuator system for a thrust reverser. The actuator system includes a source of a fluid, and a lock system. The lock system is in fluid communication with the source of the fluid and movable between an unlocked state and a lock state. The lock system includes a piston coupled to a piston housing and a grippable member coupled to the piston housing. The piston is movable based on a pressure of the fluid to move the lock system between the unlocked state and the lock state, and the grippable member is configured to move the piston housing relative to a gerotor to move the lock system to the unlocked state. The actuator system includes an actuator including a ball screw configured to be coupled to the thrust reverser and the gerotor having an inner rotor and an outer rotor. The outer rotor includes at least one bore configured to receive the piston in the lock state. The ball screw is coupled to the inner rotor and to a ball nut, and the gerotor is configured to rotate the ball screw relative to the ball nut to move the thrust reverser between at least a first position and a second position in the unlocked state.

The actuator system includes a bevel gear set coupled to at least one of the ball screw and the inner rotor for rotation with the ball screw in the unlocked state. The actuator system includes a second actuator configured to be coupled to the thrust reverser, a flex shaft coupled to the bevel gear set and the second actuator, and the flex shaft is configured to be driven by the bevel gear set to drive the second actuator. The gerotor is in fluid communication with the source of the fluid and is responsive to the fluid to rotate the ball screw relative to the ball nut in the unlocked state. The actuator system includes a second actuator configured to be coupled to the thrust reverser, the actuator having a first port and a second port, the second actuator having a third port and a fourth port, the first port and the fourth port in selective fluid communication with the source of the fluid and the second port is fluidly coupled to the third port such that the fluid received to the first port is configured to flow to the second actuator or the fluid received to the fourth port is configured to flow to the second port of the actuator. The piston housing defines a detent groove along an exterior surface of the piston housing, and the grippable member includes a detent pin that is received within the detent groove. The at least one bore of the outer rotor comprises a plurality of bores, and the plurality of bores includes a pair of overstow bores that have a dimension that is different than a remainder of the plurality of bores. The actuator system includes a gerotor housing, the gerotor is disposed within the gerotor housing. The gerotor housing includes a lock receiving bore, and the lock system includes a trunnion coupled to the lock receiving bore and the piston housing. The trunnion defines a central trunnion bore that receives the piston housing, and the central trunnion bore defines a trunnion key slot. The piston housing defines a housing key slot, and the trunnion key slot and the housing key slot cooperate to receive a key to inhibit a rotation of the piston housing relative to the trunnion.

In addition, those skilled in the art will appreciate that embodiments of the present disclosure may be practiced in conjunction with any type of device that would benefit from actuators or an actuator system, and the use of the actuators and actuator system for a thrust reverser of a gas turbine engine associated with a vehicle described herein is merely one exemplary embodiment according to the present disclosure. In addition, while the actuator system is described herein as being used with a gas turbine engine onboard a vehicle, such as a bus, motorcycle, train, automobile, marine vessel, aircraft, rotorcraft and the like, the various teachings of the present disclosure can be used with a gas turbine engine in other applications. Further, it should be noted that many alternative or additional functional relationships or physical connections may be present in an embodiment of the present disclosure. In addition, while the figures shown herein depict an example with certain arrangements of elements, additional intervening elements, devices, features, or components may be present in an actual embodiment. It should also be understood that the drawings are merely illustrative and may not be drawn to scale.

As used herein, the term "axial" refers to a direction that is generally parallel to or coincident with an axis of rotation, axis of symmetry, or centerline of a component or components. For example, in a cylinder or disc with a centerline and generally circular ends or opposing faces, the "axial" direction may refer to the direction that generally extends in parallel to the centerline between the opposite ends or faces. In certain instances, the term "axial" may be utilized with respect to components that are not cylindrical (or otherwise radially symmetric). For example, the "axial" direction for a rectangular housing containing a rotating shaft may be viewed as a direction that is generally parallel to or coincident with the rotational axis of the shaft. Furthermore, the term "radially" as used herein may refer to a direction or a relationship of components with respect to a line extending outward from a shared centerline, axis, or similar reference, for example in a plane of a cylinder or disc that is perpendicular to the centerline or axis. In certain instances, components may be viewed as "radially" aligned even though one or both of the components may not be cylindrical (or otherwise radially symmetric). Furthermore, the terms "axial" and "radial" (and any derivatives) may encompass directional relationships that are other than precisely aligned with (e.g., oblique to) the true axial and radial dimensions, provided the relationship is predominantly in the respective nominal axial or radial direction. As used herein, the term "substantially" denotes within <NUM>% to account for manufacturing tolerances. Also, as used herein, the term "about" denotes within <NUM>% to account for manufacturing tolerances.

With reference to <FIG> and <FIG>, an actuator system <NUM> is shown. In one example, the actuator system <NUM> is used to deploy a thrust reverser <NUM> associated with a vehicle <NUM>, such as an aircraft. In this example, the thrust reverser <NUM> includes a translating cowl <NUM>, which is movable relative to a frame <NUM> of the thrust reverser <NUM>. As the thrust reverser <NUM> is generally known, the thrust reverser <NUM> will not be discussed in detail herein. Briefly, the translating cowl <NUM> is movable by the actuator system <NUM> between a first, deployed position in which the thrust reverser <NUM> is open to generate reverse thrust; a second, stowed position in which the thrust reverser <NUM> is closed; and a third, overstowed position in which the translating cowl <NUM> is advanced forward beyond the second, stowed position. Thus, the thrust reverser <NUM> is movable by the actuator system <NUM> between the first, deployed position, the second, stowed position and the third, overstowed position relative to a gas turbine engine <NUM> associated with the vehicle <NUM>. It should be noted that while the thrust reverser <NUM> is described and illustrated herein as including the translating cowl <NUM> for use with the actuator system <NUM>, the actuator system <NUM> may be employed with any suitable thrust reverser for use with the vehicle <NUM>.

With additional reference to <FIG>, a schematic diagram of the actuator system <NUM> is shown. In one example, the actuator system <NUM> includes a controller <NUM>, an isolation control unit <NUM>, a regulator <NUM>, a direction control unit <NUM>, a solenoid <NUM>, a pump <NUM> and at least one actuator <NUM>. In this example, the actuator system <NUM> includes two actuators <NUM>, with one actuator 122a mounted at a first end or upper end 102a of the thrust reverser <NUM>, and one actuator 122b mounted at a second end or lower end 102b of the thrust reverser <NUM>, with the upper end 102a opposite the lower end 102b.

The controller <NUM> is in communication with the isolation control unit <NUM>, the regulator <NUM>, the direction control unit <NUM> and the solenoid <NUM> over a suitable communication architecture that supports the transfer of data, commands, power, etc., including, but not limited to a bus. The controller <NUM> is also in communication with a source of input, such as a human-machine interface associated with the vehicle <NUM> (<FIG>). The controller <NUM> includes at least one processor <NUM> and a computer readable storage device or media <NUM>. The processor <NUM> can be any custom made or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), an auxiliary processor among several processors associated with the controller <NUM>, a semiconductor based microprocessor (in the form of a microchip or chip set), a macroprocessor, any combination thereof, or generally any device for executing instructions. The computer readable storage device or media <NUM> may include volatile and nonvolatile storage in read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM), for example. KAM is a persistent or non-volatile memory that may be used to store various operating variables while the processor <NUM> is powered down. The computer-readable storage device or media <NUM> may be implemented using any of a number of known memory devices such as PROMs (programmable read-only memory), EPROMs (electrically PROM), EEPROMs (electrically erasable PROM), flash memory, or any other electric, magnetic, optical, or combination memory devices capable of storing data, some of which represent executable instructions, used by the controller <NUM> in controlling the isolation control unit <NUM>, the regulator <NUM>, the direction control unit <NUM> and the solenoid <NUM>, respectively.

The instructions may include one or more separate programs, each of which comprises an ordered listing of executable instructions for implementing logical functions. The instructions, when executed by the processor <NUM>, receive and process signals from the isolation control unit <NUM> and the human-machine interface of the vehicle <NUM> (<FIG>), perform logic, calculations, methods and/or algorithms for automatically controlling the components of the actuator system <NUM>, and generate control signals to the isolation control unit <NUM>, the regulator <NUM>, the direction control unit <NUM> and the solenoid <NUM> to control the position of the actuators <NUM> based on the logic, calculations, methods, and/or algorithms. In this example, the controller <NUM> is illustrated as part of the actuator system <NUM>, but it should be understood that the controller <NUM> may be a controller associated with the gas turbine engine <NUM> (<FIG>), such as a FADEC, or a controller associated with the vehicle <NUM>.

The isolation control unit <NUM> is in fluid communication with the pump <NUM> and the regulator <NUM>. The isolation control unit <NUM> is responsive to one or more control signals from the controller <NUM> to open to enable fluid to flow to the regulator <NUM>, and is responsive to one or more control signals to close to inhibit the flow of fluid to the regulator <NUM>. In one example, the isolation control unit <NUM> is a control valve. Generally, based on the receipt of input from the human-machine interface to move the thrust reverser <NUM> to the first, deployed position or the second, stowed position, the controller <NUM> outputs the one or more control signals to the isolation control unit <NUM> to open to enable fluid to flow from the pump <NUM>. The controller <NUM> outputs the one or more control signals to the isolation control unit <NUM> to close to inhibit the flow of fluid based on sensor feedback that indicates that the thrust reverser <NUM> has reached the desired position, for example. Based on the receipt of input from the human-machine interface to move the thrust reverser <NUM> to the first, deployed position or second, stowed position, the controller <NUM> also outputs one or more control signals to the regulator <NUM>. Once the isolation control unit <NUM> opens, the controller <NUM> also determines whether the solenoid <NUM> should be energized or if the isolation control unit <NUM> is in a fault state. If the isolation control unit <NUM> is not in the fault state, the controller <NUM> outputs one or more control signals to the solenoid <NUM> to move lock systems <NUM> associated with the actuators <NUM> to an unlocked state.

The regulator <NUM> is in fluid communication with the isolation control unit <NUM> and the direction control unit <NUM>. The regulator <NUM> is responsive to the one or more control signals from the controller <NUM> to limit an amount of fluid that flows through the regulator <NUM> to the direction control unit <NUM>. By limiting the amount of fluid that flows to the direction control unit <NUM>, the regulator <NUM> allows for snubbing at the beginning and ending of a stroke of the actuators <NUM>.

The direction control unit <NUM> is responsive to one or more control signals from the controller <NUM> to supply fluid to a first port <NUM> of the actuator 122a or to a second port <NUM> of the actuator 122b. Stated another way, the direction control unit <NUM> switches a direction of flow to the actuators <NUM>, which in turn, results in the rotation of the actuators <NUM> in a clockwise or counterclockwise direction. For example, the flow of fluid to the first port <NUM> from the direction control unit <NUM> results in a counterclockwise rotation of the actuators 122a, 122b, and the flow of fluid to the second port <NUM> results in a clockwise rotation of the actuators 122a, 122b. The counterclockwise rotation of the actuators 122a, 122b extends the actuators 122a, 122b, thereby moving the thrust reverser <NUM> (<FIG>) to the first, deployed position. The clockwise rotation of the actuators 122a, 122b retracts the actuators 122a, 122b, thereby moving the thrust reverser <NUM> (<FIG>) to the second, stowed position and to the third, overstowed position. Generally, the direction control unit <NUM> directs the pressurized fluid to the second port <NUM> to turn the actuators <NUM> clockwise, which stows and overstows the thrust reverser <NUM>. In one example, the direction control unit <NUM> is a three-way control valve. The direction control unit <NUM> is in fluid communication with the regulator <NUM>, the pump <NUM> and the actuators <NUM>. The direction control unit <NUM> receives the fluid from the regulator <NUM>, directs the fluid to the actuators <NUM> and returns the fluid to the pump <NUM>. The direction control unit <NUM> is also responsive to one or more control signals from the controller <NUM> to close or to inhibit the flow of the fluid back to the pump <NUM>, which results in a closed loop system for the actuators <NUM>. This enables a single one of the actuators <NUM> to be manually driven, which in turn, drives the other actuator <NUM> by the same amount without requiring any additional fluid. In the position shown in <FIG>, the direction control unit <NUM> allows the pressurized fluid to return to the pump <NUM> without any affect to the actuators <NUM>.

The actuator 122a has the first port <NUM> and a second port <NUM>. Similarly, the actuator 122b has a first port <NUM> and the second port <NUM>. The first port <NUM> of the actuator 122a is fluidly coupled to the second port <NUM> of the actuator 122a such that when the first port <NUM> is an inlet, the second port <NUM> is an outlet and vice versa. The first port <NUM> of the actuator 122b is fluidly coupled to the second port <NUM> of the actuator 122b such that when the first port <NUM> is an inlet, the second port <NUM> is an outlet and vice versa. The first port <NUM> of the actuator 122b is fluidly coupled to or in fluid communication with the second port <NUM> of the actuator 122a, and the second port <NUM> of the actuator 122a is fluidly coupled to the first port <NUM> of the actuator 122b. Thus, the fluid supplied to the first port <NUM> of the actuator 122a from the direction control unit <NUM> is supplied from the second port <NUM> (the outlet of the actuator 122a) to the first port <NUM> of the actuator 122b. The second port <NUM> returns the fluid to the direction control unit <NUM>. Similarly, fluid supplied to the second port <NUM> of the actuator 122b from the direction control unit <NUM> is supplied from the first port <NUM> (the outlet of the actuator 122b) to the second port <NUM> of the actuator 122a. The first port <NUM> returns the fluid to the direction control unit <NUM>.

The solenoid <NUM> is responsive to the one or more control signals received from the controller <NUM> to move the lock systems <NUM> associated with the actuators <NUM> to an unlocked state. The solenoid <NUM> is fluidly coupled to the lock systems <NUM>. The solenoid <NUM> is an electronically actuated solenoid, such as a one way, spring return, electronically actuated hydraulic solenoid. In this example, the solenoid <NUM> includes a piston and a spring, which is disposed in a chamber. The one or more control signals received by the solenoid <NUM> causes the solenoid <NUM> to overcome the spring force and retract the piston or move the piston relative to the chamber. Considering this is a closed loop fluid system, the volume of the pressurized fluid is constant or unchanging, so any motion of the solenoid <NUM> is transferred by the pressurized fluid to the pistons <NUM> of the lock system <NUM>. Upon receipt of the one or more control signals, the solenoid <NUM> retracts the piston, which creates a vacuum that draws the fluid associated with the lock systems <NUM> into the chamber of the solenoid <NUM>. This flow of fluid into the solenoid <NUM> moves the lock systems <NUM> to the unlocked state. With the piston and the spring disposed in the chamber, the solenoid <NUM> maintains the lock systems <NUM> is a lock state as will be discussed.

The pump <NUM> is fluidly coupled to the isolation control unit <NUM> and the direction control unit <NUM>. The pump <NUM> supplies the fluid to the isolation control unit <NUM>, and receives the fluid from the direction control unit <NUM>. In one example, the pump <NUM> is a hydraulic pump and the fluid is hydraulic fluid. In this example, the pump <NUM> is coupled to a gearbox associated with the gas turbine engine <NUM> (<FIG>).

The actuators <NUM> are fluidly coupled to the direction control unit <NUM> to receive the fluid, and are responsive to the fluid to move the thrust reverser <NUM> (<FIG>) relative to the gas turbine engine <NUM> (<FIG>). With reference back to <FIG>, the actuators <NUM> are each coupled to the frame <NUM> with a mounting bracket <NUM>. The mounting bracket <NUM> includes a frame coupling flange <NUM> and a pair of actuator coupling flanges <NUM>. The frame coupling flange <NUM> is coupled to the frame <NUM> with mechanical fasteners, such as bolts, and the actuator coupling flanges <NUM> extend outwardly from the frame coupling flange <NUM> so as to be substantially perpendicular to the frame coupling flange <NUM>. The actuator coupling flanges <NUM> are spaced apart on the frame coupling flange <NUM> to enable a portion of the actuators <NUM> to pass through the frame <NUM> to be coupled to the translating cowl <NUM> (<FIG>). The actuator coupling flanges <NUM> also define a bore, which enables a portion of the actuators <NUM> to pass through the actuator coupling flanges <NUM>.

As each of the actuators 122a, 122b is the same and operate in the same or similar manner, a single one of the actuators 122a, 122b will be described herein for ease of description. With reference to <FIG>, the actuator 122a is shown. The actuator 122a includes a first actuator end <NUM> opposite a second actuator end <NUM>. The first actuator end <NUM> is accessible from the exterior of the frame <NUM> (<FIG>) to enable a manual actuation of the actuator 122a, as will be discussed. The second actuator end <NUM> is coupled to the translating cowl <NUM> (<FIG>). In one example, with reference to <FIG>, the actuator 122a includes a gerotor housing <NUM>, a gerotor <NUM>, at least one bearing <NUM>, a seal <NUM>, a ball screw <NUM>, a ball nut <NUM>, an extension shaft <NUM> and the lock system <NUM>.

The gerotor housing <NUM> encloses the gerotor <NUM>. The gerotor housing <NUM> includes a housing cover <NUM>, a seal plate <NUM> and a cylindrical housing body <NUM>. The housing cover <NUM> is circular, and defines the first port <NUM> and the second port <NUM>. The housing cover <NUM> also includes a plurality of bores 180a, which each receive a respective mechanical fastener <NUM>, such as a bolt, to couple the housing cover <NUM> to the housing body <NUM>. The plurality of bores 180a may be defined on a flange 180b of the housing cover <NUM>, which has a reduced thickness when compared to a remainder of the housing cover <NUM> (<FIG>). Hydraulic fittings <NUM> are coupled to the first port <NUM> and the second port <NUM> to enable fluid communication between the gerotor <NUM> and the direction control unit <NUM> (<FIG>). The seal plate <NUM> is circular, and defines a central opening 182a. The central opening 182a enables the ball screw <NUM> to be coupled to the seal plate <NUM>. In one example, the central opening 182a includes a plurality of splines <NUM> to couple the seal plate <NUM> to the ball screw <NUM>. The seal plate <NUM> pilots on the ball screw <NUM>. The seal plate <NUM> assists in forming a seal against the housing body <NUM> to inhibit the fluid from escaping the gerotor housing <NUM>.

The housing body <NUM> receives the gerotor <NUM>. The housing body <NUM> has a first housing end <NUM> opposite a second housing end <NUM>. The first housing end <NUM> is coupled to or interconnected with the second housing end <NUM> via a sidewall <NUM>. The first housing end <NUM> is circumferentially open. The first housing end <NUM> defines a plurality of bores 184a, which are coaxially aligned with the plurality of bores 180a of the housing cover <NUM> to couple the housing cover <NUM> to the housing body <NUM> with the respective mechanical fasteners <NUM>. The second housing end <NUM> defines an internal flange <NUM> and includes a coupling projection <NUM>. The internal flange <NUM> extends radially inward at the second housing end <NUM> and provides a seat for the seal plate <NUM>. With reference to <FIG>, the coupling projection <NUM> extends axially outward from the internal flange <NUM> toward the second actuator end <NUM>. The coupling projection <NUM> is cylindrical. The coupling projection <NUM> is circumferentially closed, and defines a central opening 196a. The central opening 196a enables a portion of the ball screw <NUM> to be received within the housing body <NUM>. With reference back to <FIG>, the sidewall <NUM> may include a plurality of struts for reinforcement about the perimeter of the housing body <NUM>. The sidewall <NUM> defines a pair of lock receiving bores <NUM>. The lock receiving bores <NUM> are opposite each other about the perimeter or circumference of the housing body <NUM>, and each lock receiving bore <NUM> receives a respective portion of the lock system <NUM> to couple the lock system <NUM> to the gerotor <NUM>.

The gerotor <NUM> is disposed within the gerotor housing <NUM>, and is fluidly coupled to the first port <NUM> and the second port <NUM>. The gerotor <NUM> includes an inner rotor <NUM> and an outer rotor <NUM>. The inner rotor <NUM> rotates about an axis, which is offset from an axis of rotation of the outer rotor <NUM>. The inner rotor <NUM> defines an inner central bore <NUM> about an inner perimeter or diameter of the inner rotor <NUM>, and has a plurality of teeth <NUM> defined about an outer perimeter or diameter of the inner rotor <NUM>. The inner central bore 200a includes a plurality of splines <NUM>. The plurality of splines <NUM> couple the inner rotor <NUM> to the ball screw <NUM>. The inner rotor <NUM> pilots on the ball screw <NUM>. The inner rotor <NUM> also includes at least one pilot bore <NUM>, which assists in coupling the ball screw <NUM> to the inner rotor <NUM>. The inner rotor <NUM> generally has a number of the teeth <NUM> that is one less than a number of a plurality of teeth <NUM> of the outer rotor <NUM>. The difference in the number of teeth <NUM>, <NUM> results in a volumes or chambers being defined between the teeth <NUM>, <NUM>. Generally, as the fluid enters the gerotor <NUM> via the first port <NUM>, the volume of the fluid increases, which causes the chambers to want to expand, resulting in the counterclockwise rotation of the inner rotor <NUM> and the outer rotor <NUM>. As the fluid circulates within the gerotor <NUM>, the chambers on the opposite side of the first port <NUM> experience compression, which causes the fluid to be pumped through the second port <NUM> to the actuator 122b (<FIG>). When the fluid enters the gerotor <NUM> via the second port <NUM>, the volume of the fluid increases, which causes the chambers to want to expand, resulting in the clockwise rotation of the inner rotor <NUM> and the outer rotor <NUM>. As the fluid circulates within the gerotor <NUM>, the chambers on the opposite side of the second port <NUM> experience compression, which causes the fluid to be pumped through the first port <NUM> to the direction control unit <NUM> (<FIG>). It should be noted that while the inner rotor <NUM> is illustrated herein as including <NUM> teeth <NUM>, and the outer rotor <NUM> is illustrated herein as including <NUM> teeth <NUM>, the inner rotor <NUM> may include any number of teeth <NUM> and the outer rotor <NUM> may include any number of teeth <NUM> that is one tooth greater than the number of teeth <NUM>. The inner rotor <NUM> and the outer rotor <NUM> may also include timing marks to assist in the alignment of the inner rotor <NUM> relative to the outer rotor <NUM>.

The outer rotor <NUM> has the teeth <NUM> defined about an inner perimeter or diameter 202a of the outer rotor <NUM>, and the outer rotor <NUM> has a plurality of rotor lock bores <NUM> defined about the outer perimeter or diameter 202b of the outer rotor <NUM>. The rotor lock bores <NUM> are spaced apart about the outer diameter 202b to receive a portion of the lock system <NUM> as will be discussed. In this example, the rotor lock bores <NUM> include a first overstow bore <NUM>, a second overstow bore <NUM> and lock bores <NUM>. The first overstow bore <NUM> and the second overstow bore <NUM> each has a dimension that is different and greater than the lock bores <NUM>. In one example, the first overstow bore <NUM> and the second overstow bore <NUM> are substantially elliptical, grooved, slotted, or elongated holes (<FIG>), and enable for additional movement of the gerotor <NUM> to move the thrust reverser <NUM> (<FIG>) to the third, overstowed position. In this example, the first overstow bore <NUM> and the second overstow bore <NUM> have a major axis with a length that is greater than a diameter of the lock bores <NUM> or a remainder of the rotor lock bores <NUM>. The first overstow bore <NUM> and the second overstow bore <NUM> are defined on opposite sides of the outer rotor <NUM> to receive the portion of the lock system <NUM>. The first overstow bore <NUM> is defined about <NUM> degrees apart from the second overstow bore <NUM> about the circumference of the outer rotor <NUM>. The lock bores <NUM> are defined about the outer diameter 202b between the first overstow bore <NUM> and the second overstow bore <NUM>, and are spaced apart about the outer diameter 202b. Generally, the lock bores <NUM> are defined about the circumference of the outer rotor <NUM> such that there is a respective lock bore <NUM> about <NUM> degrees apart from another opposing lock bore <NUM> between the first overstow bore <NUM> and the second overstow bore <NUM>. In addition, one or more sealing rings <NUM>, <NUM>, such as elastomeric O-rings, may be coupled to grooves formed in opposed sides of both the inner rotor <NUM> and the outer rotor <NUM>, respectively. The sealing rings <NUM>, <NUM> assist in defining a seal between the inner rotor <NUM>, the outer rotor <NUM> and the housing cover <NUM> on a first side of the inner rotor <NUM> and the outer rotor <NUM>, and assist in defining a seal between the inner rotor <NUM>, the outer rotor <NUM> and the seal plate <NUM>.

In one example, the least one bearing <NUM> is a duplex bearing and includes a first bearing 164a and a second bearing 164b. The bearings 164a, 164b include, but are not limited to, ball bearings. In this example, with reference to <FIG>, the bearings 164a, 164b each include an inner race <NUM> and an outer race <NUM> with a plurality of rolling elements <NUM> retained between the inner race <NUM> and the outer race <NUM>. The bearings 164a, 164b are coupled to the housing body <NUM> so as to be press-fit within the coupling projection <NUM>. Generally, the bearings 164a, 164b are positioned within the coupling projection <NUM> such that the seal plate <NUM> contacts the inner race <NUM> of the bearing 164a. The seal plate <NUM> does not typically contact the outer race <NUM> of the bearing 164a. The ball screw <NUM> is piloted by the bearings 164a, 164b.

The seal <NUM> is coupled to the housing body <NUM> so as to be proximate or at the second housing end <NUM>. Generally, the seal <NUM> is coupled to the housing body <NUM> at the second housing end <NUM> to extend about or circumscribe the coupling projection <NUM>. The seal <NUM> is annular, and in one example, is a thermal event seal. The seal <NUM> is generally composed of one or more high temperature resistant materials, which assist in inhibiting the spread of a thermal event to or from the thrust reverser <NUM> (<FIG>).

The ball screw <NUM> cooperates with the ball nut <NUM> to move or translate the extension shaft <NUM>. In one example, the ball screw <NUM> is coupled to the gerotor <NUM>, and the rotation of the gerotor <NUM> rotates the ball screw <NUM>. The rotation of the ball screw <NUM> results in a translation of the ball nut <NUM>, and thus, the extension shaft <NUM> coupled to the ball nut <NUM>. The ball screw <NUM> has a first screw end <NUM> opposite a second screw end <NUM>. The first screw end <NUM> includes a plurality of screw splines <NUM>. The plurality of screw splines <NUM> are keyed or configured to mate with the plurality of splines <NUM> of the inner rotor <NUM> of the gerotor <NUM> to couple the ball screw <NUM> to the inner rotor <NUM>. The plurality of screw splines <NUM> are also keyed or configured to mate with the plurality of splines <NUM> of the seal plate <NUM> to couple the seal plate <NUM> to the ball screw <NUM>. In one example, the first screw end <NUM> also defines a screw bore <NUM>. The screw bore <NUM> receives a locking insert <NUM> and a mechanical fastener <NUM>. The locking insert <NUM> is a sleeve, which is fixedly coupled to the ball screw <NUM> at the first screw end <NUM>. The locking insert <NUM> defines a plurality of internal threads, which cooperate with a plurality of threads of the mechanical fastener <NUM>. In one example, a washer <NUM> is coupled to the side of the inner rotor <NUM>, and the position of the washer <NUM> is clocked to the inner rotor <NUM> via at least one pin <NUM> that is press-fit into the pilot bore <NUM> to inhibit a rotation of the washer <NUM>. It should be noted that while a single pin <NUM> and pilot bore <NUM> are shown, multiple pins <NUM> and pilot bores <NUM> may be employed. In addition, two serrated washers <NUM> may be coupled between a head 250a of the mechanical fastener <NUM> and the washer <NUM>. The serrated washers <NUM> lock the position of the mechanical fastener <NUM> when a torque is not being applied to the head 250a of the mechanical fastener <NUM>.

The mechanical fastener <NUM>, in one example, is a bolt that includes the head 250a and a shank 250b. The head 250a is shaped and is configured to receive a tool, such as a socket wrench, ratchet, etc. to enable the tool to rotate or drive the mechanical fastener <NUM>. Thus, the head 250a may be a hex-head, etc. The shank 250b includes the plurality of external threads that engage with the internal threads of the locking insert <NUM>. By providing the mechanical fastener <NUM>, which is manually rotatable by a tool, a technician may use the tool to manually move the thrust reverser <NUM> (<FIG>). Stated another way, the rotation of the mechanical fastener <NUM> rotates the ball screw <NUM> via the locking insert <NUM>, which is fixed to the ball screw <NUM>. The rotation of the ball screw <NUM> counterclockwise or clockwise translates the ball nut <NUM> and thereby moves the thrust reverser <NUM> (<FIG>) between the first, deployed position, the second, stowed position and the third, overstowed position. Generally, the locking insert <NUM> and the serrated washers <NUM> ensure that a breakaway torque for the mechanical fastener <NUM> is not exceeded during manual translation of the thrust reverser <NUM> (<FIG>).

The second screw end <NUM> includes a travel stop <NUM>. In one example, the travel stop <NUM> is an annular ring, which inhibits the further advancement of the ball nut <NUM>. The travel stop <NUM> is coupled to the ball screw <NUM> at the second screw end <NUM> via one or more pins <NUM>, however, other techniques may be employed to couple the travel stop <NUM> to the ball screw <NUM>.

The ball screw <NUM> also defines a plurality of ball screw threads <NUM>. The ball screw threads <NUM> are defined about the perimeter or circumference of the ball screw <NUM> from proximate the first screw end <NUM> to the second screw end <NUM>. The ball screw threads <NUM> cooperate with ball nut threads <NUM> to enable roller elements <NUM>, such as balls, to be received between the ball screw <NUM> and the ball nut <NUM> to guide the motion of the ball nut <NUM> relative to the ball screw <NUM>. In one example, the ball screw threads <NUM> and the ball nut threads <NUM> are each right hand threads.

The ball nut <NUM> is substantially cylindrical, and includes a first nut end <NUM> opposite a second nut end <NUM>. The ball nut threads <NUM> are defined from the first nut end <NUM> to the second nut end <NUM>. The ball nut threads <NUM> are defined about an inner perimeter of the ball nut <NUM>. The ball nut <NUM> is coupled to the extension shaft <NUM> at the second nut end <NUM>. In one example, an adaptor <NUM> couples the ball nut <NUM> to the extension shaft <NUM>. In this example, the adaptor <NUM> is cylindrical, and includes a first adaptor end <NUM> and an opposite second adaptor end <NUM>. The first adaptor end <NUM> defines a receptacle <NUM> that receives the second nut end <NUM>. The adaptor <NUM> may include a flange 280a that extends radially inward to provide a stop for the advancement of the second nut end <NUM>. The first adaptor end <NUM> is coupled to the second nut end <NUM> via interference fit, welding, etc. The second adaptor end <NUM> is coupled to the extension shaft <NUM>. The second adaptor end <NUM> includes a taper <NUM> that surrounds an opening <NUM>. The taper interfaces with a first shaft end <NUM> of the extension shaft <NUM> to couple the extension shaft <NUM> to the adaptor <NUM>. Generally, the taper <NUM> defines an internal contact surface 282a, which abuts and contacts the first shaft end <NUM> when the extension shaft <NUM> is coupled to the adaptor <NUM>. The opening <NUM> is sized to enable the extension shaft <NUM> to pass through.

The extension shaft <NUM> includes the first shaft end <NUM> and an opposite second shaft end <NUM>. The extension shaft <NUM> is hollow from the first shaft end <NUM> to the second shaft end <NUM> to enable the ball screw <NUM> to be received within and to move relative to the extension shaft <NUM>. The first shaft end <NUM> includes a collar <NUM>. The collar <NUM> includes a tapered surface 288a. The tapered surface 288a of the collar <NUM> cooperates with the taper <NUM> of the adaptor <NUM> to couple the extension shaft <NUM> to the adaptor <NUM>. The collar <NUM> is annular. The extension shaft <NUM> may also be coupled to the adaptor <NUM> via welding, adhesives, etc. The second shaft end <NUM> is coupled to the second actuator end <NUM>. With reference to <FIG>, in one example, the second shaft end <NUM> defines a bore 286a, which receives a press-fit pin <NUM> to couple the second actuator end <NUM> to the extension shaft <NUM>. It should be noted that the second shaft end <NUM> may also include a collar about the second shaft end <NUM> to provide reinforcement for the pressed in pin <NUM>.

The second actuator end <NUM> includes a coupling portion <NUM> integrally formed with an attachment portion <NUM>. The coupling portion <NUM> is substantially cylindrical, and is shaped to be partially received within the extension shaft <NUM>. The coupling portion <NUM> defines a bore 292a, which is coaxial with the bore 286a to receive the pin <NUM> to couple the second actuator end <NUM> to the extension shaft <NUM>. The attachment portion <NUM> defines an attachment bore <NUM> and an anti-rotation flange <NUM>. With reference to <FIG>, the attachment bore <NUM> has a central axis that is substantially perpendicular to a longitudinal axis L of the actuator 122a. The attachment bore <NUM> is sized to receive a bearing <NUM>, such as a spherical bearing. A mechanical fastener, such as a bolt, may be installed through the bearing <NUM> to couple the second actuator end <NUM> to the thrust reverser <NUM> (<FIG>). The anti-rotation flange <NUM> is a substantially planar portion of the second actuator end <NUM>, and is defined to extend axially over the attachment bore <NUM>. The anti-rotation flange <NUM> is spaced a distance apart from the attachment bore <NUM>. The anti-rotation flange <NUM> is configured to contact a surface of the thrust reverser <NUM> (<FIG>) to inhibit a rotation of the actuator 122a during a movement of the thrust reverser <NUM>. A strut <NUM> may be defined between the coupling portion <NUM> and the anti-rotation flange <NUM> to provide reinforcement.

It should be noted that in other embodiments, the second actuator end <NUM> may be coupled to the extension shaft <NUM> differently. For example, with reference to <FIG>, a connecting shaft <NUM> may be employed to couple a second shaft end <NUM>' of an extension shaft <NUM>' to a second actuator end <NUM>'. As the second actuator end <NUM>' is substantially similar or the same as the second actuator end <NUM>, the same reference numerals will be used to denote the same or similar components. In this example, the second actuator end <NUM>' includes a coupling portion <NUM>' and the attachment portion <NUM>. The coupling portion <NUM>' includes a coupling bore <NUM>. The coupling bore <NUM> is threaded to matingly engage with threads defined on a connecting shaft <NUM>. Alternatively, the connecting shaft <NUM> may be press-fit into the coupling bore <NUM>. The extension shaft <NUM>' includes the first shaft end <NUM> and the second shaft end <NUM>'. The second shaft end <NUM>' may also include a plurality of threads, which matingly engage with the threads defined on the connecting shaft <NUM>. Alternatively, the connecting shaft <NUM> may be press-fit into the second shaft end <NUM>' of the extension shaft <NUM>. Thus, the connecting shaft <NUM> has a first end 312a coupled to the second shaft end <NUM>', and a second end 312b coupled to the coupling bore <NUM> of the coupling portion <NUM>'. Pins <NUM>, <NUM> may be press-fit into the second shaft end <NUM>' and the connecting shaft <NUM>, and into the coupling portion <NUM>' and the connecting shaft <NUM>, respectively, to further couple the second actuator end <NUM>' to the second shaft end <NUM>' of the extension shaft <NUM>'.

With reference back to <FIG>, the lock system <NUM> includes a grippable member or handle <NUM> and at least one lock assembly <NUM>. In this example, the lock system <NUM> includes two lock assemblies 352a, 352b, which are the same and are symmetric about the longitudinal axis L of the actuator 122a (<FIG>). The handle <NUM> is movable by a technician to move the actuator 122a between the lock state and the unlocked state in a manual override of the lock system <NUM>. This enables a technician to manually move the actuator 122a when the controller <NUM> is powered down or off, for example. Generally, the handle <NUM> is movable between a locked position and an unlocked position. In the locked position of the handle <NUM>, the state of the lock system <NUM> is controlled by the controller <NUM>. In the unlocked position of the handle <NUM>, the lock system <NUM> is in the unlocked state. The handle <NUM> is substantially C-shaped, and includes a first handle arm <NUM>, a second handle arm <NUM> and a connecting arm <NUM>. The first handle arm <NUM> is opposite the second handle arm <NUM>. Each of the first handle arm <NUM> and the second handle arm <NUM> define a lock receiving bore <NUM> and a detent bore <NUM> at a first arm end <NUM>. Each of the first handle arm <NUM> and the second handle arm <NUM> are coupled to the connecting arm <NUM> at a second arm end <NUM>, and the first arm end <NUM> is opposite the second arm end <NUM>. Generally, the second arm end <NUM> extends outwardly from the first arm end <NUM> at an angle such that when assembled, the handle <NUM> is positioned above or outboard of the first port <NUM> and the second port <NUM> of the actuator 122a so that the technician does not interfere with the hydraulic coupling at the first port <NUM> and the second port <NUM> while gripping the handle <NUM>.

The lock receiving bore <NUM> has a central axis that is substantially perpendicular to the longitudinal axis L (<FIG>). The lock receiving bore <NUM> of the first handle arm <NUM> is coaxial with the lock receiving bore <NUM> of the second handle arm <NUM>. The lock receiving bore <NUM> of the first handle arm <NUM> is coupled to the lock assembly 352a, while the lock receiving bore <NUM> of the second handle arm <NUM> is coupled to the lock assembly 352b. The detent bore <NUM> is in communication with the lock receiving bore <NUM>. The detent bore <NUM> is sized to receive a portion of the respective lock assembly 352a, 352b. The detent bore <NUM> is defined through the lock receiving bore <NUM>, and in one example, includes a plurality of threads. The connecting arm <NUM> is integrally formed with the first handle arm <NUM> and the second handle arm <NUM>. The connecting arm <NUM> is arcuate to provide a graspable or manipulatable surface for the technician to grip to move the handle <NUM>.

Each of the lock assemblies 352a, 352b include a trunnion <NUM>, a piston housing <NUM>, a piston <NUM>, a piston biasing member or piston spring <NUM>, a fitting <NUM>, a key <NUM>, a detent pin <NUM> and a detent pin biasing member or detent spring <NUM>. The trunnion <NUM> is composed of a metal or metal alloy, and is cast, forged, stamped, additively manufactured, etc. The trunnion <NUM> has a first trunnion end <NUM> opposite a second trunnion end <NUM>. The first trunnion end <NUM> includes a trunnion flange <NUM>, which is substantially triangular. It should be noted that the trunnion flange <NUM> may have any desired shape. The trunnion flange <NUM> couples the actuator 122a to the thrust reverser <NUM> (<FIG>). In this example, the trunnion flange <NUM> defines a plurality of coupling bores 394a, which each receive a mechanical fastener, such as a bolt, pin, etc. for coupling the trunnion <NUM> to the respective one of the actuator coupling flanges <NUM> of the mounting bracket <NUM> (<FIG>). The coupling bores 394a are spaced apart about the trunnion flange <NUM>. The trunnion <NUM> also includes a trunnion projection <NUM>. A central trunnion bore <NUM> (<FIG>) is defined through the trunnion flange <NUM> and the trunnion projection <NUM>, from the first trunnion end <NUM> to the second trunnion end <NUM>, and is configured to receive the piston housing <NUM>. In this example, the trunnion projection <NUM> is cylindrical and extends from the trunnion flange <NUM> to the second trunnion end <NUM>. In this example, the trunnion <NUM> also defines a trunnion key slot <NUM> that extends axially along an inner diameter 395a of the trunnion bore <NUM> from proximate the second trunnion end <NUM> to the trunnion flange <NUM>. With reference to <FIG>, a cross-section through the actuator 122a at the lock system <NUM> is shown. In <FIG>, the lock system <NUM> is in an unlocked state. The trunnion key slot <NUM> is defined through the trunnion <NUM> to be spaced a distance apart from the second trunnion end <NUM>. This ensures that the key <NUM> remains retained within the trunnion key slot <NUM> during a movement of the piston housing <NUM> toward the gerotor <NUM>. The trunnion key slot <NUM> is defined through the trunnion flange <NUM> to enable the key <NUM> to be inserted into the trunnion <NUM> during assembly.

The piston housing <NUM> is composed of metal or metal alloy, and is cast, stamped, additively manufactured, etc. With reference back to <FIG>, the piston housing <NUM> includes a first housing end <NUM> opposite a second housing end <NUM>. A central housing bore <NUM> (<FIG>) is defined through the piston housing <NUM> from the first housing end <NUM> to the second housing end <NUM>, and is configured to receive the piston <NUM>, the piston spring <NUM> and a portion of the fitting <NUM>. The central housing bore <NUM> may include threads at the first housing end <NUM> for coupling the fitting <NUM> to the piston housing <NUM>. The first piston end <NUM> includes a piston collar <NUM>. With reference to <FIG>, the piston housing <NUM> is shown assembled with the piston <NUM>, the piston spring <NUM>, the fitting <NUM> and the key <NUM>. The piston collar <NUM> includes a detent groove <NUM>. The detent groove <NUM> is a helical groove defined to extend along an arc on an exterior surface 404a of the piston collar <NUM>. With reference to <FIG>, the detent groove <NUM> receives the detent pin <NUM> and cooperates with the detent pin <NUM> to limit a range of travel of the handle <NUM>. In this example, a distance Dt between a first groove end 406a and a second groove end 406b results in the handle <NUM> moving vertically a predetermined amount. Generally, the handle <NUM> moves vertically a distance to create an interference with a portion of the thrust reverser <NUM> (<FIG>) as will be discussed. In addition, the distance Dt is the amount the piston housing <NUM> is allowed to move relative to the trunnion <NUM> between the lock state and the unlocked state. In this regard, when the detent pin <NUM> is in the first groove end 406a, the piston housing <NUM> is retracted relative to the trunnion <NUM> and the lock system <NUM> is in the lock state. When the detent pin <NUM> is in the second groove end 404b, the piston housing <NUM> travels within the trunnion <NUM> toward the second trunnion end <NUM> (<FIG>) and the lock system <NUM> is in the unlocked state.

With reference back to <FIG>, the piston housing <NUM> also includes a housing projection <NUM>. In this example, the housing projection <NUM> is cylindrical and extends from the piston collar <NUM> to the second piston end <NUM>. The housing projection <NUM> includes a flange <NUM> that extends radially inward at the second housing end <NUM>, which serves as a stop for a further advancement of the piston <NUM> (<FIG>). In this example, the piston housing <NUM> also defines a housing key slot <NUM> that extends axially along an outer diameter 410a of the housing projection <NUM> from proximate the second housing end <NUM> to proximate the piston collar <NUM>. With reference to <FIG>, the housing key slot <NUM> is defined on the piston housing <NUM> to be spaced a distance apart from the second housing end <NUM> and to be spaced a distance apart from the piston collar <NUM>. This ensures that the key <NUM> remains retained within the housing key slot <NUM> during a movement of the piston housing <NUM> toward the gerotor <NUM>. The housing key slot <NUM> cooperates with the trunnion key slot <NUM> to retain the key <NUM>, and inhibits the key <NUM> from becoming uncoupled from the lock system <NUM> once the actuator 122a is installed.

With reference to <FIG>, the piston <NUM> includes a first piston end <NUM> opposite a second piston end <NUM>. The piston <NUM> may be composed of metal or metal alloy, and may be cast, forged, additively manufactured, etc. The piston <NUM> includes a head <NUM> at the first piston end <NUM> and a shaft <NUM> that extends axially from the head <NUM> to the second piston end <NUM>. The head <NUM> is fluidly coupled to the fitting <NUM> and the piston spring <NUM> acts on the head <NUM>. As will be discussed, the fluid is received between the head <NUM> and the fitting <NUM> in the lock state, and when the solenoid <NUM> is energized by the controller <NUM> (<FIG>), the fluid is drawn through the fitting <NUM> to the solenoid <NUM> creating a vacuum that draws the head <NUM> toward the fitting <NUM>, compressing the piston spring <NUM>, to move the lock system <NUM> to the unlocked state (<FIG>). In the unlocked state, the shaft <NUM> is uncoupled from a respective one of the bores <NUM>, <NUM>, <NUM>, which enables the gerotor <NUM> to rotate. In the lock state, the shaft <NUM> of the piston <NUM> at the second piston end <NUM> engages with a respective one of the bores <NUM>, <NUM>, <NUM>, which inhibits the rotation of the gerotor <NUM>. In the lock state, the head <NUM> of the piston <NUM> generally abuts the flange <NUM> of the piston housing <NUM> (<FIG>). Generally, the shaft <NUM> is sized to extend beyond the second housing end <NUM> in both the lock state and the unlocked state. The shaft <NUM> defines at least one or a plurality of seal grooves <NUM>. In this example, the shaft <NUM> includes three seal grooves <NUM>, which each receive a respective sealing member <NUM>, such as an O-ring. The sealing members <NUM> inhibit the fluid from flowing past the head <NUM> of the piston <NUM> down the shaft <NUM>.

With reference back to <FIG>, the piston spring <NUM> is disposed between the head <NUM> of the piston <NUM> and the fitting <NUM>. The piston spring <NUM> has a first spring end 376a that seats against the head <NUM> of the piston <NUM> and a second spring end 376b that seats against the fitting <NUM>. The piston spring <NUM> is composed of spring steel, and is extruded and coiled. The piston spring <NUM> is a compression spring, which biases the piston <NUM> into engagement with the respective one of the bores <NUM>, <NUM>, <NUM> in the lock state.

The fitting <NUM> is a hydraulic fitting, which is fluidly coupled to the central housing bore <NUM> and to the solenoid <NUM>. The fitting <NUM> is any suitable hydraulic fitting that is capable of directing the fluid to and from the piston housing <NUM>. In one example, the fitting <NUM> is at least partially received within the central housing bore <NUM> at the first housing end <NUM>. The fitting <NUM> may include threads for coupling to the piston housing <NUM>.

The key <NUM> is rectangular and is received within the trunnion key slot <NUM> and the housing key slot <NUM>. The key <NUM> is composed of metal or metal alloy, and is stamped, cast, additively manufactured, etc. The key <NUM> enables axial motion of the piston housing <NUM> relative to the trunnion <NUM>, but inhibits the rotation of the piston housing <NUM> relative to the trunnion <NUM>. The key <NUM> has a key longitudinal axis, which is substantially perpendicular to the longitudinal axis L of the actuator 122a.

With reference back to <FIG>, the detent pin <NUM> includes a ball <NUM> and a detent housing <NUM>. The ball <NUM> is sized to be received within the detent groove <NUM>, and is movable within the detent groove <NUM> between the first groove end 406a and the second groove end 406b based on a movement of the handle <NUM>. The detent housing <NUM> retains the detent spring <NUM>, and is coupled to the detent bore <NUM>. In one example, the detent housing <NUM> is coupled to the detent bore <NUM> via a plurality of threads such that the detent housing <NUM> may be retracted to enable the assembly of the handle <NUM> to the piston housing <NUM>. The detent housing <NUM> is cylindrical, and includes a seat for the detent spring <NUM> at one end. The ball <NUM> is disposed at the opposite end of the detent housing <NUM>. The detent spring <NUM> is a compression spring, and is composed of spring steel, which is extruded and coiled. The detent spring <NUM> biases the ball <NUM> into engagement with the detent groove <NUM>. Generally, when the handle <NUM> is in the locked position, the ball <NUM> is fully extended into the detent groove <NUM> by the force of the detent spring <NUM>, and the ball <NUM> is touching the first groove end 406a of the piston housing <NUM>. When the handle <NUM> is between the locked and unlocked position, the detent spring <NUM> is slightly compressed, and the ball <NUM> is touching the piston housing <NUM> within the detent groove <NUM>. When the handle <NUM> is in the unlocked position, the ball <NUM> is fully extended from the force of the detent spring <NUM>, and the ball <NUM> is touching the second groove end 406b.

In one example, in order to assemble the actuator 122a, with reference to <FIG>, with the ball nut and the roller elements <NUM> coupled to the ball screw <NUM>, the ball screw <NUM> is coupled to the housing body <NUM>. The bearings 164a, 164b are coupled to the ball screw <NUM> and the housing body <NUM>. The ball screw <NUM> is coupled to the inner rotor <NUM>. The outer rotor <NUM> is coupled about the inner rotor <NUM>. The sealing rings <NUM>, <NUM> are coupled to the respective one of the inner rotor <NUM> and the outer rotor <NUM>. The washer <NUM> is coupled to the inner rotor <NUM> with the pin <NUM>. The locking insert <NUM> is coupled to the ball screw <NUM>. The housing cover <NUM> is coupled to the housing body <NUM> with the mechanical fasteners <NUM>. The mechanical fastener <NUM> with the serrated washers <NUM> is coupled to the locking insert <NUM>. With the extension shaft <NUM> coupled to the adaptor <NUM>, the adaptor <NUM> is coupled to the ball nut <NUM>. The travel stop <NUM> is coupled to the ball screw <NUM> with the pin <NUM>. With the bearing <NUM> coupled to the attachment bore <NUM>, the second actuator end <NUM> is coupled to the extension shaft <NUM> with the pin <NUM>. The seal <NUM> is coupled to the housing body <NUM>.

With reference to <FIG> and <FIG>, the second actuator end <NUM> of the actuator 122a is inserted through the mounting bracket <NUM> and a bore <NUM> defined in the frame <NUM> to couple the second actuator end <NUM> to the translating cowl <NUM> of the thrust reverser <NUM>. In one example, the second actuator end <NUM> is coupled to the translating cowl <NUM> by inserting a mechanical fastener <NUM>, such as a bolt, through the bearing <NUM> with the anti-rotation flange <NUM> resting on a planar surface <NUM> of the thrust reverser <NUM>. The anti-rotation flange <NUM> and the planar surface <NUM> cooperate to inhibit the rotation of the actuator 122a as the actuator 122a moves the thrust reverser <NUM> between the first, deployed position, the second, stowed position and the third, overstowed position. The trunnions <NUM> are inserted through the actuator coupling flanges <NUM>, and into the lock receiving bores <NUM>. The trunnions <NUM> are coupled to the actuator coupling flanges <NUM> and the gerotor housing <NUM> by inserting mechanical fasteners through the coupling bores 394a (<FIG>). With the sealing members <NUM> coupled to the pistons <NUM>, the pistons <NUM> are coupled to the respective piston housing <NUM>. The piston springs <NUM> are inserted into the central housing bore <NUM> of the respective piston housing <NUM>. The fittings <NUM> are coupled to the respective piston housing <NUM>. When there is no fluid pressure in the fluid cavity defined between the head <NUM> of the pistons <NUM> and the fittings <NUM>, the pistons <NUM> are forced against the flange <NUM> of the respective piston housing <NUM> (<FIG>) via the force of the respective piston spring <NUM>. The keys <NUM> are coupled to the respective housing key slot <NUM> and the piston housings <NUM> are coupled to the respective trunnions <NUM>. The detent springs <NUM> are coupled to the respective detent housing <NUM>, and the balls <NUM> are coupled to the respective detent housing <NUM>. The detent pins <NUM> are coupled to the handle <NUM>, and the handle <NUM> is coupled to the piston housing <NUM>. The detent housing <NUM> may be advanced by the threads of the detent bore <NUM> such that the balls <NUM> are disposed in the first groove end 406a of the detent groove <NUM> with the handle <NUM> in the locked position (<FIG>). The above process for the assembly of the actuator 122a and the coupling of the actuator 122a to the thrust reverser <NUM> is repeated for the actuator 122b.

With the actuators 122a, 122b coupled to the thrust reverser <NUM>, with reference to <FIG>, the first port <NUM> of the actuator 122a and the second port <NUM> of the actuator 122b are fluidly coupled to the direction control unit <NUM>. The second port <NUM> of the actuator 122a is fluidly coupled to the first port <NUM> of the actuator 122b. The direction control unit <NUM> is fluidly coupled to the regulator <NUM> and the pump <NUM>. The isolation control unit <NUM> is fluidly coupled to the pump <NUM> and the regulator <NUM>. The solenoid <NUM> is fluidly coupled to the fittings <NUM> of the lock system <NUM>. The controller <NUM> is placed in communication with the solenoid <NUM>, the regulator <NUM>, the isolation control unit <NUM> and the direction control unit <NUM>. The controller <NUM> outputs one or more control signals to the solenoid <NUM> to enable the fluid to flow to the fittings <NUM> to maintain the lock system <NUM> in the lock state. With reference to <FIG>, the lock system <NUM> is shown in the lock state with the handle <NUM> in the lock position. In the lock state, the positive fluid pressure in the fluid cavity defined between the head <NUM> and the fitting <NUM> forces the piston <NUM> against the flange <NUM> along with the force of the piston spring <NUM>. In the lock state, the shaft <NUM> of the piston <NUM> at the second piston end <NUM> is inserted into and received within the respective bore <NUM>, <NUM>.

With the actuator system <NUM> coupled to the thrust reverser <NUM> (<FIG>), based on the receipt of input to move the thrust reverser <NUM> to the first, deployed position, with reference back to <FIG> and <FIG>, the controller <NUM> outputs one or more control signals to the solenoid <NUM> to open the solenoid <NUM>. The opening of the solenoid <NUM> results in a vacuum being created in the fluid cavity defined between the head <NUM> and the fitting <NUM>. The negative pressure caused by the vacuum draws the piston <NUM> toward the fitting <NUM>, overcoming the force of the piston spring <NUM> and compressing the piston spring <NUM>. With reference to <FIG>, the translation of the piston <NUM> caused by the vacuum disengages or removes the shaft <NUM> of the piston <NUM> from the respective bores <NUM>, <NUM>, which places the lock system <NUM> in the unlocked state. With the lock system <NUM> in the unlocked state and the handle <NUM> in the lock position, the controller <NUM> outputs the one or more control signals to the isolation control unit <NUM> to open to enable fluid to flow to the regulator <NUM>. The controller <NUM> also outputs one or more control signals to the direction control unit <NUM> to supply fluid to the first port <NUM> of the actuator 122a. The supply of fluid to the first port <NUM> results in the counterclockwise rotation of the inner rotor <NUM> and the outer rotor <NUM>. The counterclockwise rotation of the inner rotor <NUM> and the outer rotor <NUM> rotates the ball screw <NUM>, which translates the ball nut <NUM> to extend the extension shaft <NUM>, thereby moving the thrust reverser <NUM> (<FIG>) to the first, deployed position.

Based on the receipt of input to move the thrust reverser <NUM> from the first, deployed position to the second, stowed position, with the lock system <NUM> in the unlocked state and the handle <NUM> in the lock position, the controller <NUM> outputs the one or more control signals to the isolation control unit <NUM> to open to enable fluid to flow to the regulator <NUM>. The controller <NUM> also outputs one or more control signals to the direction control unit <NUM> to supply fluid to the second port <NUM> of the actuator 122a. The supply of fluid to the second port <NUM> results in the clockwise rotation of the inner rotor <NUM> and the outer rotor <NUM>. The clockwise rotation of the inner rotor <NUM> and the outer rotor <NUM> rotates the ball screw <NUM>, which translates the ball nut <NUM> to retract the extension shaft <NUM>, thereby moving the thrust reverser <NUM> (<FIG>) to the second, stowed position. The controller <NUM> also outputs one or more control signals to the direction control unit <NUM> to supply fluid to the second port <NUM> of the actuator 122a to move the thrust reverser <NUM> (<FIG>) from the second, stowed position to the third, overstowed position. In the third, overstowed position, the controller <NUM> outputs one or more control signals to the solenoid <NUM> to close the solenoid <NUM>. The closing of the solenoid <NUM> results fluid returning to the fittings <NUM>. With the positive fluid pressure applied to the fittings <NUM>, the lock system <NUM> returns to the lock state, as discussed above.

In certain instances, it may be desirable to move the thrust reverser <NUM> (<FIG>) to the third, overstowed position while the lock system <NUM> is in the lock state and the handle <NUM> is in the lock position. For example, it may be desirable to move the thrust reverser <NUM> (<FIG>) to the third, overstowed position unlock a primary locking system associated with the thrust reverser <NUM>. Generally, the primary locking system is unlocked in the third, overstowed position. The first overstow bore <NUM> and the second overstow bore <NUM> enable the thrust reverser <NUM> to move to the third, overstowed position while the lock system <NUM> remains in the lock state. In these instances, the controller <NUM> outputs the one or more control signals to the isolation control unit <NUM> to open to enable fluid to flow to the regulator <NUM>. The controller <NUM> also outputs one or more control signals to the direction control unit <NUM> to supply fluid to the second port <NUM> of the actuator 122a. The supply of fluid to the second port <NUM> results in the clockwise rotation of the inner rotor <NUM> and the outer rotor <NUM>. The clockwise rotation of the inner rotor <NUM> and the outer rotor <NUM> rotates the ball screw <NUM>, which translates the ball nut <NUM> to further retract the extension shaft <NUM>, to move the thrust reverser <NUM> (<FIG>) to the third, overstowed position. In the third, overstowed position, with reference to <FIG>, the elongated shape of the bores <NUM>, <NUM> enables the rotation of the outer rotor <NUM> and the inner rotor <NUM> to enable the movement of the thrust reverser <NUM> to the third, overstowed position without requiring a movement of the lock system <NUM> to the unlocked state. Rather, the shaft <NUM> of the pistons <NUM> slides within the bores <NUM>, <NUM> as the gerotor <NUM> rotates to further retract the thrust reverser <NUM> to the third, overstowed position.

With reference to <FIG>, when the actuators 122a, 122b are coupled to the thrust reverser <NUM> and the handle <NUM> is in the locked position, the handle <NUM> is stowed beneath or is not in contact with an access panel <NUM> disposed outboard of the actuators 122a, 122b. The access panel <NUM> inhibits the movement of the handle <NUM> from the lock position to the unlocked position. Stated another way, due to the shape of the detent groove <NUM> (<FIG>) the handle <NUM> rotates upward to move from the lock position to the unlock position, which interferes with the access panel <NUM>. In certain instances, for maintenance, for example, the technician may need to manually actuate the actuators 122a, 122b to move the thrust reverser <NUM> to the first, deployed position. In these instances, the technician removes the access panel <NUM>. With the access panel <NUM> removed, with reference to <FIG>, the technician grasps the handle <NUM> and moves the handle <NUM> from the lock position to the unlocked position along the arc defined by the detent groove <NUM> (<FIG>), which causes the handle <NUM> to extend through an opening <NUM> covered by the access panel <NUM> (<FIG>) and beyond an external surface <NUM> of the thrust reverser <NUM>. With reference to <FIG>, the movement of the handle <NUM> within the detent groove <NUM> to the unlocked position moves the piston housings <NUM> outboard or away from the gerotor <NUM>. Since the pistons <NUM> are each coupled to the respective piston housing <NUM>, the outboard movement of the piston housings <NUM> retracts or disengages the shaft <NUM> of the pistons <NUM> with the bores <NUM>, <NUM>. With the pistons <NUM> disengaged with the bores <NUM>, <NUM>, the lock system <NUM> is in the unlocked state even with positive fluid pressure contained within the fluid cavity defined between the respective head <NUM> and the fitting <NUM>. With the lock system <NUM> in the unlocked state, a tool, such as a socket head, ratchet, etc. is coupled to the mechanical fastener <NUM> and is rotated clockwise or counterclockwise to turn the mechanical fastener <NUM>, and thus, the ball screw <NUM> in the clockwise or clockwise direction. Once the manual movement of the thrust reverser <NUM> is completed, the technician moves the handle <NUM> to the locked position. As the bores <NUM>, <NUM>, <NUM> are defined about the perimeter of the outer rotor <NUM>, the lock system <NUM> is movable to the lock state by the handle <NUM> regardless of the position of the outer rotor <NUM>. Thus, the bores <NUM>, <NUM>, <NUM> enable the lock system <NUM> to be placed in the lock state at different intervals of extensions of the extension shaft <NUM> between the third, overstowed position and the first, deployed position in the instances where the handle <NUM> is rotated back to the lock position at some state of deployment. The handle <NUM> must be returned to the lock position to replace the access panel <NUM> (<FIG>) prior to flight of the vehicle <NUM> (<FIG>).

It should be noted that in other embodiments, the actuator system <NUM> may be configured differently to move the thrust reverser <NUM> (<FIG>). For example, with reference to <FIG>, an actuator system <NUM> is shown. As the actuator system <NUM> includes components that are the same or similar to components of the actuator system <NUM> discussed with regard to <FIG>, the same reference numerals will be used to denote the same or similar components. The actuator system <NUM> includes the controller <NUM> (<FIG>), the isolation control unit <NUM> (<FIG>), the regulator <NUM> (<FIG>), the direction control unit <NUM> (<FIG>), the solenoid <NUM> (<FIG>), the pump <NUM>, a driven actuator <NUM>, a driving actuator system <NUM> and a flexshaft <NUM>. In this example, the driven actuator <NUM> is mounted at the first end or upper end 102a of the thrust reverser <NUM>, and the driving actuator system <NUM> is mounted at the second end or lower end 102b of the thrust reverser <NUM>. The driven actuator <NUM> and the driving actuator system <NUM> are coupled to the thrust reverser <NUM> using the mounting brackets <NUM>. The driven actuator <NUM> comprises any suitable actuator capable of being driven by the flexshaft <NUM>, including, but not limited to the actuator system <NUM> of commonly assigned <CIT>. The flexshaft <NUM> is any suitable flexible shaft for transferring torque from the driving actuator system <NUM> to the driven actuator <NUM>. The flexshaft <NUM> may include a plurality of gear teeth 606a at each end of the flexshaft <NUM>, such as bevel gear teeth, etc. to assist in coupling the flexshaft <NUM> to the driven actuator <NUM> and the driving actuator system <NUM>. In this example, the plurality of gear teeth 606a comprise bevel gear teeth, however, other tooth configurations may be employed.

In this example, the driving actuator system <NUM> includes one of the actuators 122a, 122b and a bevel gear drive system <NUM>. The bevel gear drive system <NUM> is coupled to the flexshaft <NUM>. The flexshaft <NUM> transmits the torque from the actuator 122a, 122b to the driven actuator <NUM>. With reference to <FIG>, the driving actuator system <NUM> is shown in greater detail. In the example of <FIG>, the first ports <NUM>, <NUM> and the second ports <NUM>, <NUM> are rotated about <NUM> degrees to facilitate the coupling of the bevel gear drive system <NUM> to the actuator 122a, 122b. The bevel gear drive system <NUM> is coupled to the actuator 122a, 122b at the first actuator end <NUM>. In one example, the bevel gear drive system <NUM> includes a bevel housing <NUM> and a bevel gear set including a first bevel gear <NUM> and a second bevel gear <NUM>. The bevel housing <NUM> substantially encloses the first bevel gear <NUM> and the second bevel gear <NUM>. The bevel housing <NUM> is coupled to the gerotor housing <NUM> at the first actuator end <NUM>. The first bevel gear <NUM> is disposed about the mechanical fastener <NUM>, and is coupled to the inner rotor <NUM> and the ball screw <NUM> to rotate with the inner rotor <NUM> and the ball screw <NUM> as the inner rotor <NUM> and the ball screw <NUM> rotate. The first bevel gear <NUM> includes a hub <NUM> and a plurality of gear teeth <NUM>. The hub <NUM> is coupled to the inner rotor <NUM> and the ball screw <NUM> via welding, for example. The plurality of gear teeth <NUM> are defined at a distal end of the first bevel gear <NUM> and comprise a plurality of bevel gear teeth, however, other tooth configurations may be employed. The plurality of gear teeth <NUM> of the first bevel gear <NUM> engage a plurality of gear teeth <NUM> of the second bevel gear <NUM>.

The second bevel gear <NUM> includes the plurality of gear teeth <NUM>, which are defined about an outer perimeter or circumference of the second bevel gear <NUM>. In one example, the second bevel gear <NUM> is hollow, and a plurality of second gear teeth <NUM> are defined about the inner perimeter or circumference of the second bevel gear <NUM>. In this example, each of the plurality of gear teeth <NUM>, <NUM> are bevel gear teeth, however, other tooth configurations may be employed. The plurality of second gear teeth <NUM> engage with the gear teeth 606a of the flexshaft <NUM>. The second bevel gear <NUM> is coupled to and meshes with the first bevel gear <NUM> and the flexshaft <NUM>.

Generally, as the assembly and installation of the actuator system <NUM> is substantially the same as the assembly and installation of the actuator system <NUM>, the differences will be discussed herein. Briefly, once the actuator 122a, 122b is coupled to the thrust reverser <NUM>, the first bevel gear <NUM> is coupled to the inner rotor <NUM> and the ball screw <NUM>. The second bevel gear <NUM> is coupled to the first bevel gear <NUM>. The flexshaft <NUM> is coupled to the second bevel gear <NUM> and the bevel housing <NUM> is positioned about the bevel gear drive system <NUM>. The flexshaft <NUM> is coupled to the driven actuator <NUM>.

As the actuator system <NUM> operates substantially the same as the actuator system <NUM>, the differences will be discussed herein. Briefly, as the gerotor <NUM> rotates the ball screw <NUM> clockwise or counterclockwise, the first bevel gear <NUM> rotates the second bevel gear <NUM> clockwise or counterclockwise, respectively. The rotation of the second bevel gear <NUM>, in turn, rotates the flexshaft <NUM> clockwise or counterclockwise. The clockwise or counterclockwise rotation of the flexshaft <NUM> drives the driven actuator <NUM> clockwise or counterclockwise, respectively, which cooperates with the movement of the actuator 122a, 122b to move the thrust reverser <NUM> (<FIG>).

Thus, the actuator system <NUM>, <NUM> enables the movement of the thrust reverser <NUM> (<FIG>) without requiring an additional motor to be mounted external from the thrust reverser <NUM> (<FIG>). By eliminating the additional motor, a weight of the actuator system <NUM>, <NUM> is reduced, which in turn, reduces a weight of the thrust reverser <NUM>. In addition, the use of the lock system <NUM> ensures that the actuators 122a, 122b are locked during flight as the handle <NUM> interferes with the coupling of the access panel <NUM> (<FIG>) to the opening <NUM> (<FIG>). Further, the use of the lock system <NUM>, with the handle <NUM>, enables the technician to manually operate the actuators 122a, 122b to move the thrust reverser <NUM> without requiring the disconnection of the hydraulic system, which reduces service time. In addition, this movement of the actuators 122a, 122b may be performed when the gas turbine engine <NUM> is off. In other words, the movement of the actuators 122a, 122b does not require electrical or hydraulic power to stow or deploy the thrust reverser <NUM>. This may be beneficial during maintenance of the thrust reverser <NUM> or if there may be an issue with the thrust reverser <NUM> requiring inspection or maintenance when the gas turbine engine <NUM> is off. This also provides safety to the technicians, the thrust reverser <NUM>, and the actuators 122a, 122b, when the thrust reverser <NUM> may need components replaced that are used during the movement of the thrust reverser <NUM> between the first deployed position and/or the second, stowed position. The use of the lock bores <NUM> defined on the outer rotor <NUM> of the gerotor <NUM> also enable the thrust reverser <NUM> to be locked at any position between the second, stowed position and the first, deployed position for safety during maintenance procedures. This prevents inadvertent motion of a partially or fully deployed thrust reverser <NUM> if technicians are working around the thrust reverser <NUM> area.

Claim 1:
An actuator (<NUM>) for a thrust reverser, comprising
a ball screw (<NUM>) configured to be coupled to the thrust reverser;
a ball nut (<NUM>) coupled to the ball screw;
a gerotor (<NUM>) coupled to the ball screw, the gerotor including an inner rotor coupled to the ball screw and an outer rotor, a movement of the inner rotor relative to the outer rotor is configured to rotate the ball screw relative to the ball nut to move the thrust reverser between at least a first position and a second position, and the outer rotor includes a plurality of bores spaced apart about a perimeter of the outer rotor; and
a lock system (<NUM>) coupled to the outer rotor and movable between an unlocked state and a lock state, the lock system configured to enable the gerotor to rotate the ball screw in the unlocked state and to inhibit a rotation of the ball screw in the lock state, the lock system including a piston coupled to a piston housing and a grippable member coupled to the piston housing, the piston is received in one of the plurality of bores of the outer rotor in the lock state, and the grippable member is configured to move the piston housing relative to the gerotor to move the lock system to the unlocked state.