Actuator system

1. A valve system comprising a valve assembly, a drive assembly, and a control assembly; wherein:

the valve assembly comprises an inner spool, an outer spool, and a sleeve, the inner spool being situated within the outer spool, and the outer spool being situated within the sleeve;

the drive assembly directly drives the inner spool to move axially relative to the outer spool;

the outer spool is hydromechanically caused to move axially relative to the sleeve upon movement of the inner spool, thereby opening/closing flow paths between ports in the sleeve;

the control assembly provides current input to the drive assembly;

the drive assembly converts current input into mechanical motion, proportional and directional to the current input, to directly drive the inner spool; and

the control assembly senses positions of the inner spool and regulates current input in accordance with the sensed inner-spool positions.

2. A valve system as set forth in claim 1 , wherein the control assembly comprises a memory having calibrated positional data stored therein and a processor, that compares the sensed inner-spool positions with the calibrated positional data and adjusts the current input accordingly.

3. A valve system as set forth in claim 1 , wherein the drive assembly comprises an armature connected to the inner spool, and wherein current input to the drive assembly creates a magnetic bias in the armature that displaces it in a first direction or second direction, and this displacement directly drives the inner spool.

4. A valve system as set forth in claim 1 ,

wherein the inner spool is directly driven within an axial bore of the outer spool among a rest position, a first position removed from the rest position in a first direction, and a second position removed from the rest position in a second direction;

wherein the outer spool is movable within an axial bore of the sleeve; among a rest position, a first position removed from the rest position in a first direction, and a second position removed from the rest position in a second direction;

wherein, when the inner spool is in its rest position, the outer spool is hydromechanically caused to move to and remain in its rest position;

wherein, when the inner spool is directly driven from its rest position to its first position, the outer spool is hydromechanically caused to move to and remain in its first position; and

wherein, when the inner spool is directly driven from its rest position to its second position, the outer spool is hydromechanically caused to move to and remain in its second position.

5. A valve system as set forth in claim 4 ,

wherein the outer spool comprises a cylindrical wall surrounding its axial bore, a first radial passage through the cylindrical wall to the axial bore, and a second radial passage through the cylindrical wall to the axial bore; and wherein:

when the inner spool and the outer spool are in their rest positions, the inner spool blocks communication through the first radial passage to the axial bore of the outer spool and blocks communication through the second radial passage to the axial bore of the outer spool;

when the inner spool and the outer spool are in their first positions, the inner spool blocks communication through the first radial passage to the axial bore of the outer spool and blocks communication through the second radial passage to the axial bore of the outer spool;

when the inner spool and the outer spool are in their second positions, the inner spool blocks communication through the first radial passage to the axial bore of the outer spool and blocks communication through the second radial passage to the axial bore of the outer spool;

when the outer spool is in its rest position and the inner spool is directly driven to its first position, the inner spool allows communication through the first radial passage to the axial bore of the outer spool and blocks communication through the second radial passage to the axial bore of the outer spool, and fluid flows through the first radial passage creating hydromechanical forces causing the outer spool to move to its first position; and

when the outer spool is in its rest position and the inner spool is directly driven to its second position, the inner spool blocks communication through the first radial passage to the axial bore of the outer spool and allows communication through the second radial passage to the axial bore of the outer spool, and fluid flows through the second radial passage creating hydromechanical forces causing the outer spool to move to its second position.

6. A valve system as set forth in claim 1 , wherein the sleeve comprises at least one supply port, at least one return port, a first cylinder port, and a second cylinder port, and wherein the outer spool connects or disconnects flow paths between the supply port(s) and the cylinder ports, and connects or disconnects flow paths between the cylinder ports and the return port(s).

7. A valve system as set forth in claim 6 ,

wherein when outer spool is movable relative to an axial bore of the sleeve among a rest position, a first position removed from the rest position in a first direction, and a second position removed from the rest position in a second direction; and

wherein:

when the outer spool is in its rest position, the flow path between the first cylinder port and the supply port is disconnected, the flow path between the first cylinder port and the return port is disconnected, the flow path between the second cylinder port and the supply port is disconnected, and the flow path between the second cylinder port and the return port is disconnected; and

when the outer spool is in its first position, the flow path between the first cylinder port and the supply port is connected, the flow path between the first cylinder port and the return port is disconnected, the flow path between the second cylinder port and the supply port is disconnected, and the flow path between the second cylinder port and the return port is connected.

8. A valve system as set forth in claim 7 , wherein the outer spool has circumferential grooves that extend between the sleeve's ports to connect flow paths when the outer spool is in its first position and in its second position.

9. A valve system as set forth in claim 8 ,

wherein the sleeve comprises a common return port, a first supply port, and a second supply port,

wherein, when the outer spool is in its first position, the flow path between the first supply port and the first cylinder port is connected, and the flow path between the second cylinder port and the return port is connected; and

wherein, when the outer spool is in its second position, the flow path between the second supply port and the second cylinder port is connected, and the flow path between the first cylinder port and the return port is connected.

10. A valve system as set forth in claim 8 ,

wherein the inner spool is directly driven within an axial bore of the outer spool among a rest position, a first position removed from the rest position in a first direction, and a second position removed from the rest position in a second direction;

wherein, when the inner spool is in its rest position, the outer spool is hydromechanically caused to move to and remain in its rest position;

wherein, when the inner spool is directly driven from its rest position to its first position, the outer spool is hydromechanically caused to move to and remain in its first position; and

wherein, when the inner spool is directly driven from its rest position to its second position, the outer spool is hydromechanically caused to move to and remain in its second position.

11. A valve system as set forth in claim 10 ,

wherein the outer spool comprises a cylindrical wall surrounding its axial bore, a first radial passage through the cylindrical wall to the axial bore, and a second radial passage through the cylindrical wall to the axial bore; and wherein:

when the inner spool and the outer spool are in their rest positions, the inner spool blocks communication through the first radial passage to the axial bore of the outer spool and blocks communication through the second radial passage to the axial bore of the outer spool;

when the inner spool and the outer spool are in their first positions, the inner spool blocks communication through the first radial passage to the axial bore of the outer spool and blocks communication through the second radial passage to the axial bore of the outer spool;

when the inner spool and the outer spool are in their second positions, the inner spool blocks communication through the first radial passage to the axial bore of the outer spool and blocks communication through the second radial passage to the axial bore of the outer spool;

when the outer spool is in its rest position and the inner spool is directly driven to its first position, the inner spool allows communication through the first radial passage to the axial bore of the outer spool and blocks communication through the second radial passage to the axial bore of the outer spool, and fluid flows through the first radial passage creating hydromechanical forces causing the outer spool to move to its first position; and

when the outer spool is in its rest position and the inner spool is directly driven to its second position, the inner spool blocks communication through the first radial passage to the axial bore of the outer spool and allows communication through the second radial passage to the axial bore of the outer spool, and fluid flows through the second radial passage creating hydromechanical forces causing the outer spool to move to its second position.

12. A valve system as set forth in claim 6 ,

in combination with a cylinder assembly comprising a piston, a first cylinder chamber on one side of the piston, and a second cylinder chamber on the other side of the piston, and

wherein the sleeve's first cylinder port is fluidly connected to the first cylinder chamber and the sleeve's second cylinder port is fluidly connected to the second cylinder chamber.

13. A combination as set forth in claim 12 , wherein the piston is mechanically coupled to a control surface component.

14. A combination as set forth in claim 13 , installed on an aircraft having a control surface component, and wherein the piston is mechanically coupled to the control surface component.

15. A valve system as set forth in claim 1 ,

wherein the control assembly comprises a memory having calibrated positional data stored therein and a processor, that compares the sensed inner-spool positions with the calibrated positional data and adjusts the current input accordingly; and

wherein the drive assembly comprises an armature connected to the inner spool, and wherein current input to the drive assembly creates a magnetic bias in the armature that displaces it in a first direction or second direction, and this displacement directly drives the inner spool.

16. A valve system as set forth in claim 15 ,

wherein the inner spool is directly driven within an axial bore of the outer spool among a rest position, a first position removed from the rest position in a first direction, and a second position removed from the rest position in a second direction;

wherein the outer spool is movable within an axial bore of the sleeve; among a rest position, a first position removed from the rest position in a first direction, and a second position removed from the rest position in a second direction;

wherein, when the inner spool is in its rest position, the outer spool is hydromechanically caused to move to and remain in its rest position;

wherein, when the inner spool is directly driven from its rest position to its first position, the outer spool is hydromechanically caused to move to and remain in its first position; and

wherein, when the inner spool is directly driven from its rest position to its second position, the outer spool is hydromechanically caused to move to and remain in its second position.

17. A valve system as set forth in claim 1 ,

wherein the control assembly comprises a memory having calibrated positional data stored therein and a processor, that compares the sensed inner-spool positions with the calibrated positional data and adjusts the current input accordingly; and

wherein the inner spool is directly driven within an axial bore of the outer spool among a rest position, a first position removed from the rest position in a first direction, and a second position removed from the rest position in a second direction; and

wherein the outer spool is movable within an axial bore of the sleeve; among a rest position, a first position removed from the rest position in a first direction, and a second position removed from the rest position in a second direction.

18. A valve system as set forth in claim 17 ,

wherein, when the inner spool is in its rest position, the outer spool is hydromechanically caused to move to and remain in its rest position;

wherein, when the inner spool is directly driven from its rest position to its first position, the outer spool is hydromechanically caused to move to and remain in its first position; and

wherein, when the inner spool is directly driven from its rest position to its second position, the outer spool is hydromechanically caused to move to and remain in its second position.

19. A valve system as set forth in claim 1 ,

wherein the inner spool is directly driven within an axial bore of the outer spool among a rest position, a first position removed from the rest position in a first direction, and a second position removed from the rest position in a second direction; and

wherein the drive assembly comprises an armature connected to the inner spool, and wherein current input to the drive assembly creates a magnetic bias in the armature that displaces it in a first direction or second direction, and this displacement directly drives the inner spool from the rest position to the first position and the second position, respectively.

20. A valve system as set forth in claim 19 , wherein the outer spool is hydromechanically caused to move within an axial bore of the sleeve; among a rest position, a first position removed from the rest position in a first direction, and a second position removed from the rest position in a second direction.