Splined coupling

A flight control surface actuation system comprising:

• an actuator configured to actuate a flight control surface;
• a transmission operably connected to the actuator;
• a drive shaft operably connected to the transmission;
• and
• a splined coupling assembly operably connecting the drive shaft to the transmission, the spline coupling assembly comprising:
• a transfer gear having a first end, a second end opposite the first end, and a plurality of splines at the first end;
• a transfer housing having a first side, a second side opposite the first side, and a tubular portion located at the second side, the tubular portion comprising:
• a plurality of splines, wherein the plurality of splines of the transfer housing are configured to mesh with the plurality of splines of the transfer gear;
• a shear ring located in a shear ring groove in the tubular portion;
• and
• a retainer configured to retain the shear ring within the shear ring grove.

A method of manufacturing a splined coupling assembly, the method comprising:

• forming a transfer gear having a first end, a second end opposite the first end, and a plurality of external splines at the first end;
• forming a transfer housing having a first side, a second side opposite the first side, and a tubular portion located at the second side, the tubular portion comprising a first face, a second face opposite the first face, a radially inward surface, a radially outward surface opposite the radially inward surface, and a plurality of internal splines in the radially inward surface, wherein the plurality of internal splines are configured to mesh with the external splines of the transfer gear, and wherein the second face includes an orifice that opens to a chamber defined by the radially inward surface;
• and
• inserting the first end of the transfer gear into the chamber of the transfer housing;
• aligning the plurality of external splines with the plurality of internal splines, such that the plurality of external splines mesh with the plurality of internal splines;
• and
• securing a retainer around the tubular portion of the transfer housing such that the retainer initiates at a location in the chamber and wraps around the second face, the radially outward surface, and the first face.