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Electrically or hydraulically powered, hermetically sealed angular or rotary actuator deflects mechanical members over a range of plus or minus 180 degrees. The actuator design provides incremental flexures which keep the local deflection rate within elastic limits.
Special actuators are needed to control the orientation of large structures in space-based precision pointing systems. Electromagnetic actuators that presently exist are too large in size and their bandwidth is too low. Hydraulic fluid actuation also presents problems for many space-based applications. Hydraulic oil can escape in space and contaminate the environment around the spacecraft. A research study was performed that selected an electrically-powered linear actuator that can be used to control the orientation of a large pointed structure. This research surveyed available products, analyzed the capabilities of conventional linear actuators, and designed a first-cut candidate superconducting linear actuator. The study first examined theoretical capabilities of electrical actuators and determined their problems with respect to the application and then determined if any presently available actuators or any modifications to available actuator designs would meet the required performance. The best actuator was then selected based on available design, modified design, or new design for this application. The last task was to proceed with a conceptual design. No commercially-available linear actuator or modification capable of meeting the specifications was found. A conventional moving-coil dc linear actuator would meet the specification, but the back-iron for this actuator would weigh approximately 12,000 lbs. A superconducting field coil, however, eliminates the need for back iron, resulting in an actuator weight of approximately 1000 lbs.
Development of reliable power-by-wire actuation systems for both aeronautical and space applications has been sought recently to eliminate hydraulic systems from aircraft and spacecraft and thus improve safety, efficiency, reliability, and maintainability. The Electrically Powered Actuation Design (EPAD) program was a joint effort between the Air Force, Navy, and NASA to develop and fly a series of actuators validating power-by-wire actuation technology on a primary flight control surface of a tactical aircraft. To achieve this goal, each of the EPAD actuators was installed in place of the standard hydraulic actuator on the left aileron of the NASA F/A-18B Systems Research Aircraft (SRA) and flown throughout the SRA flight envelope. Numerous parameters were recorded, and overall actuator performance was compared with the performance of the standard hydraulic actuator on the opposite wing. This paper discusses the integration and testing of the EPAD electromechanical actuator (EMA) on the SRA. The architecture of the EMA system is discussed, as well as its integration with the F/A-18 Flight Control System. The flight test program is described, and actuator performance is shown to be very close to that of the standard hydraulic actuator it replaced. Lessons learned during this program are presented and discussed, as well as suggestions for future research.
Development of reliable power-by-wire actuation systems for both aeronautical and space applications has been sought recently to eliminate hydraulic systems from aircraft and spacecraft and thus improve safety, efficiency, reliability, and maintainability. The Electrically Powered Actuation Design (EPAD) program was a joint effort between the Air Force, Navy, and NASA to develop and fly a series of actuators validating power-by-wire actuation technology on a primary flight control surface of a tactical aircraft. To achieve this goal, each of the EPAD actuators was installed in place of the standard hydraulic actuator on the left aileron of the NASA F/A-18B Systems Research Aircraft (SRA) and flown throughout the SRA flight envelope. Numerous parameters were recorded, and overall actuator performance was compared with the performance of the standard hydraulic actuator on the opposite wing. This paper discusses the integration and testing of the EPAD electromechanical actuator (EMA) on the SRA. The architecture of the EMA system is discussed, as well as its integration with the F/A-18 Flight Control System. The flight test program is described, and actuator performance is shown to be very close to that of the standard hydraulic actuator it replaced. Lessons learned during this program are presented and discussed, as well as suggestions for future research.
This presents a method to improve the thruster vector servo elasticity (TVSE) stability. TVSE is the coupling between the TVC system engine dynamics and the vehicle flexible modes. It can lead to instability of the flexible modes due to the energy injection from the thrust. For large boosters with heavy TVC engine, TVSE is more likely to cause instability. This instability is part of the plant dynamics and is not detected by the flight control. In this paper, the TVSE is treated as a disturbance rejection problem with the inertial force of the flexible motion viewed as an external disturbance to the TVC actuator control system. By effectively rejecting this disturbance, the engine can be decoupled from the flexible dynamics thus improving TVSE stability. The actuator disturbance transfer function is modified by inserting a TVSE filter into the control system. The filter aims to reduce the magnitude and introduce phase lead of the disturbance transfer function over the TVSE sensitive frequency range while maintaining adequate stability margins of the actuator control system. A prefilter is also designed for good command tracking. The filter and prefilter resulting from this method are usually of low order and can be included to the existing actuator controller if the controller is programmable. This method was demonstrated for a hydraulic Simplex actuator model. Its applications to SLS B1 and B2 TVC actuator are also described. B2 actuator controller is modified based on this method. The tradeoff between TVSE stability and the control system stability can be balanced by adjusting the amount of phase lead introduced by the TVSE filter. This method provides a useful way to solve the TVSE instability issue without costly and time-consuming a TVC system redesign. This method is based on the basic control principles of loop shaping and disturbance rejection and has been proven to be effective under proper circum-stances.
Dual hydraulic rotary actuator for rotating umbilical swing arms from launch vehicle
Rapid Compression Machines (RCMs) are widely utilized to study combustion phenomena at engine-relevant conditions, and significant efforts are typically made to create a quiescent environment, particularly for investigations of autoignition chemistry. Opposed-piston configurations can be advantageous due to shorter compression times and reduced surface area to volume ratios. Each side must be actuated simultaneously, but this can be challenging in practice. These devices, like most RCMs, utilize hydraulics for actuation, speed control and arrestation of the piston at the end of the stroke; there is no mechanical control or linkage of the two piston trajectories. To quantify the magnitudes and effects of piston asynchronous behavior, this work employs both detailed experimental measurements and, for the first time, high-fidelity, Direct Numerical Simulation (DNS). The boundary conditions are carefully considered applying insight from high-resolution linear variable differential transformer (LVDT) measurements of the piston trajectory and a zero-dimensional kinematics model of the piston-shaft assembly. Sufficient resolution in the piston crevice region is used. The complicated fluid dynamical behavior that can evolve during piston compression and the ensuing delay processes due to offset timings from t offset = 0-10 ms is elucidated. It is found that near t offset = 6 ms and beyond, the boundary layer on the face of the first-seating piston can be sufficiently perturbed, due initially to reemergence of gas from the crevice of the firstseating piston, so that the adiabatic core can become degraded at long ignition delay times. Substantial mixing of colder gas into the interior of the reaction chamber can alter the measurements, similar to effects previously observed for improper piston crevice configuration. In conclusion, experimental techniques to mitigate asynchronous behavior are discussed and demonstrated.
Off-road mobile machines, such as excavators and wheel-loaders, are typically actuated by hydraulics using internal combustion engines as their power sources. There is a trend towards fully electrifying these machines and improving their efficiencies due to environmental regulations and concerns. In this paper, a control co-design methodology is used to design a Fully Electrified Hybrid Hydraulic-Electric Architecture (FE-HHEA) for an excavator that drastically reduces energy consumption and minimizes the sizes of costly electric components. By optimizing both control operation and the physical design, the co-design methodology takes into account the interaction between these two aspects. The design methodology also illustrates how the system architecture evolves from the previously developed IC engine powered HHEA with the engine replaced by an electric motor to a seemingly very different architecture with fewer components. The optimized system reduces energy consumption by 71% over the baseline system and uses electrical components that are 1/3 the size of an alternate fully electric architecture.
Low speed high torque pneumatic nutator actuator motor for manipulating control drums of nuclear rocket reactors
The main objectives were to select an advanced low heat rejection diesel reference engine (ADRE) and to carry out systems analysis and design. The ADRE concept selection consisted of: (1) rated point performance optimization; (2) study of various exhaust energy recovery scenarios; (3) components, systems and engine configuration studies; and (4) life cycle cost estimates of the ADRE economic worth. The resulting ADRE design proposed a reciprocator with many advanced features for the 1995 technology demonstration time frame. These included ceramic air gap insulated hot section structural components, high temperature tribology treatments, nonmechanical (camless) valve actuation systems, and elimination of the cylinder head gasket. ADRE system analysis and design resulted in more definition of the engine systems. These systems include: (1) electro-hydraulic valve actuation, (2) electronic common rail injection system; (3) engine electronic control; (4) power transfer for accessory drives and exhaust energy recovery systems; and (5) truck installation. Tribology and performance assessments were also carried out. Finite element and probability of survival analyses were undertaken for the ceramic low heat rejection component.
A displacer piston which is driven pneumatically by a high-pressure or low-pressure gas is included in a free-piston regenerative hydraulic engine. Actuation of the displacer piston circulates the working fluid through a heater, a regenerator and a cooler. The present invention includes an inertial mass such as a piston or a hydraulic fluid column to effectively store and supply energy during portions of the cycle. Power is transmitted from the working fluid to a hydraulic fluid across a diaphragm or lightweight piston to achieve a hydraulic power out-put. The displacer piston of the present invention may be driven pneumatically, hydraulically or electromagnetically. In addition, the displacer piston and the inertial mass of the present invention may be positioned on the same side of the diaphragm member or may be separated by the diaphragm member.
For a decade, induction motor drive-based electrical actuators have been under investigation as potential replacement for the conventional hydraulic and pneumatic actuators in aircraft. Advantages of electric actuator include lower weight and size, reduced maintenance and operating costs, improved safety due to the elimination of hazardous fluids and high pressure hydraulic and pneumatic actuators, and increased efficiency. Recently, the emphasis of research on induction motor drives has been on sensorless vector control which eliminates flux and speed sensors mounted on the motor. Also, the development of effective speed and flux estimators has allowed good rotor flux-oriented (RFO) performance at all speeds except those close to zero. Sensorless control has improved the motor performance, compared to the Volts/Hertz (or constant flux) controls. This report evaluates documented schemes for speed sensorless drives, and discusses the trends and tradeoffs involved in selecting a particular scheme. These schemes combine the attributes of the direct and indirect field-oriented control (FOC) or use model adaptive reference systems (MRAS) with a speed-dependent current model for flux estimation which tracks the voltage model-based flux estimator. Many factors are important in comparing the effectiveness of a speed sensorless scheme. Among them are the wide speed range capability, motor parameter insensitivity and noise reduction. Although a number of schemes have been proposed for solving the speed estimation, zero-speed FOC with robustness against parameter variations still remains an area of research for speed sensorless control.
A full-scale wind tunnel test was recently conducted (March 2009) in the National Full-Scale Aerodynamics Complex (NFAC) 40- by 80-FootWind Tunnel to evaluate the potential of an individual blade control (IBC) system to improve rotor performance and reduce vibrations, loads, and noise for a UH-60A rotor system [1]. This test was the culmination of a long-termcollaborative effort between NASA, U.S. Army, Sikorsky Aircraft Corporation, and ZF Luftfahrttechnik GmbH (ZFL) to demonstrate the benefits of IBC for a UH-60Arotor. Figure 1 shows the UH-60Arotor and IBC system mounted on the NFAC Large Rotor Test Apparatus (LRTA). The IBC concept used in the current study utilizes actuators placed in the rotating frame, one per blade. In particular, the pitch link of the rotor blade was replacedwith an actuator, so that the blade root pitch can be changed independently. This concept, designed for a full-scale UH-60A rotor, was previously tested in the NFAC 80- by 120-FootWind Tunnel in September 2001 at speeds up to 85 knots [2]. For the current test, the same UH-60A rotor and IBC system were tested in the 40- by 80-FootWind Tunnel at speeds up to 170 knots. Figure 2 shows the servo-hydraulic IBC actuator installed between the swashplate and the blade pitch horn. Although previous wind tunnel experiments [3, 4] and analytical studies on IBC [5, 6] have shown the promise to improve the rotor s performance, in-depth correlation studies have not been performed. Thus, the current test provides a unique resource that can be used to assess the accuracy and reliability of prediction methods and refine theoretical models, with the ultimate goal of providing the technology for timely and cost-effective design and development of new rotors. In this paper, rotor performance and loads calculations are carried out using the analyses CAMRAD II and coupled OVERFLOW-2/CAMRAD II and the results are compared with these UH-60A/IBC wind tunnel test data.
Abstract The Hybrid Hydraulic-Electric Architecture (HHEA) combines the respective power density and control advantages of hydraulic and electric actuation to save energy for off-road vehicles. It uses a set of selectable common pressure rails to transmit the majority of power and electric actuation to modulate that power. As it is critical that off-road vehicles can perform tasks dexterously and exactly as commanded by the operator, the switchings between discrete pressure rails pose a potential challenge for smooth and precise motion. A control strategy consisting of a backstepping nominal control and least norm transition control has previously been developed to address this issue. It has been tested on 1 degree of freedom (DOF) testbeds where known trajectories were able to be tracked precisely. This paper presents the implementation of the HHEA motion control strategy on a 2-DOF backhoe operated by a human operator via a 2-DOF joystick. Unlike previous studies, the duty cycle is unknown beforehand and the decision to change pressure rails is taken in real-time. The efficacy of the motion control strategy has been validated experimentally. Several strategies to improve the user interface: control in workspace coordinates, pressure feedback, and velocity field-based task specification, have also been implemented and demonstrated to make operating the multiple DOF, HHEA actuated machine more intuitive to novice operators.
"Micromachining" is a chemical means of etching three-dimensional structures, typically in single- crystalline silicon. These techniques are leading toward what is coming to be referred to as MEMS (Micro Electro Mechanical Systems), where in addition to the ordinary two-dimensional (planar) microelectronics, it is possible to build three-dimensional n-ticromotors, electrically- actuated raicrovalves, hydraulic systems and much more on the same microchip. These techniques become possible because of differential etching rates of various crystallographic planes and materials used for semiconductor n-ticrofabfication. The University of Cincinnati group in collaboration with Karl Baker at NASA Lewis were the first to form micro heat pipes in silicon by the above techniques. Current work now in progress using MEMS technology is now directed towards the development of the next generation in MCM (Multi Chip Module) packaging. Here we propose to develop a complete electronic thermal management system which will allow densifica6on in chip stacking by perhaps two orders of magnitude. Furthermore the proposed technique will allow ordinary conu-nercial integrated chips to be utilized. Basically, the new technique involves etching square holes into a silicon substrate and then inserting and bonding commercially available integrated chips into these holes. For example, over a 100 1/4 in. by 1 /4 in. integrated chips can be placed on a 4 in. by 4 in. silicon substrate to form a Multi-Chip Module (MCM). Placing these MCM's in-line within an integrated rack then allows for three-diniensional stacking. Increased miniaturization of microelectronic circuits will lead to very high local heat fluxes. A high performance thermal management system will be specifically designed to remove the generated energy. More specifically, a compact heat exchanger with milli / microchannels will be developed and tested to remove the heat through the back side of this MCM assembly for moderate and high heat flux applications, respectively. The high heat load application of particular interest in mind is the motor controller developed by Martin Marietta for Nasa to control the thruster's directional actuators on space vechicles. Work is also proposed to develop highly advanced and improved porous wick structures for use in advanced heat loops. The porous wick will be micromachined from silicon using MEMS technology, thus permitting far superior control of pore size and pore distribution (over wicks made from sintered n-ietals), which in turn is expected to led to significantly improved heat loop performance.
In recent years, increasingly stringent emission regulations have spurred an electrification trend in off-highway vehicle technology. To address challenges such as the high cost of power electronics components, limited battery capacity, and the substantial modifications required for the vehicles, there is a pressing need to develop high-speed, cost-effective, compact, and efficient electro-hydraulic units capable of powering vehicle functions. In response to these demands, this paper introduces an innovative morphology for an electro-hydraulic unit and outlines the integration method for a crescent-type internal gear machine with a permanent magnet synchronous electric machine. The proposed morphology aims to minimize component count through a shaftless solution while incorporating a cooling system that utilizes the same working fluid as the hydraulic machine. The design approach utilizes a genetic algorithm optimization process to maximize overall energy efficiency and compactness. Insights gained from the optimization results shed light on the relationship between key design parameters and unit performance, enhancing the understanding of this electro-hydraulic unit. A prototype of the unit was manufactured and tested, demonstrating a volumetric efficiency ranging from 81 % to 97 % at a maximum rotational velocity of the pinion of 6000 rpm. Finally, these results validate both the morphology and the design approach, indicating the feasibility of designing compact electro-hydraulic units that leverage hydraulic machines with higher maximum rotational velocities than commercially available counterparts as a mean to enhance efficiency and compactness.
Low temperature hydraulic system development and testing for space applications
Two control schemes are compared for parallel robotic mechanisms actuated by hydraulic cylinders. One scheme, the 'rate based scheme', uses the position and rate information only for feedback. The second scheme, the 'force based scheme' feeds back the force information also. The force control scheme is shown to improve the response over the rate control one. It is a simple constant gain control scheme better suited to parallel mechanisms. The force control scheme can be easily modified for the dynamic forces on the end effector. This paper presents the results of a computer simulation of both the rate and force control schemes. The gains in the force based scheme can be individually adjusted in all three directions, whereas the adjustment in just one direction of the rate based scheme directly affects the other two directions.