Electromechanical Actuation Feasibility Study

190 Pages·2012·5.63 MB·English

U.5. OLPARTUENT Of CMWERCE
Na8i~mse Teche"ca m11%atiu service
AD-k031 146
Electromechanical Actuat~on
Feasibility Study
:
AiResearch Mfg Co of Californic Torrance
May 76
302083
InEEECTROMECMANICA ACTUAIMfO FLAITYM STLTrY
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AmR 703CR IIGRT DYNAM1U8 LABORATOY
AMR 706C YST TM- COMMAND
~WRIGUT-PATTEAWNk AIR POW= RASL OHIO 45M8
gins Gowgm dawmiW, specificatiots, or other date are used for
mW purpose other then in nection, with a dsf uiitely related Govsrnmet
prcopemmt €eration, the United Statea Covwrmt thereby incurs n
%mstie nbillbty o(cid:127) r ma obligatam Astaoewr; ad the fact that the
Iae3meat Lay hr"m formulated, fumtshd. ot In an7 way supplied the
saM drwigs, epscifftctions. or other data, is not to be regarded by
Implicat(cid:127)Ler or otherwise as In any nner Irnilng the holder or amy
other pearam or corporation, oT c(cid:127)ano nveying rightb or peCsiUon to
wmafmctaer, wu or sell any patented Lnvemtim that roy In amy 'my be
tWtatud tbmraeo.
TWie techaical rqmwt haw been reviewed and 1I approved for publication.
WMYlL . si '%N
Project IngiWaee/Tecbaical No=itor
Chief. Flight Cantrol DiTi(cid:127)iou
AF Mlight Dynmmca laboratory
Copies of this report should not be returned unless return is required by
secrity considerations, contractual obligations, or notice on a *pocific
document.
This report bas bwe revim(cid:127)ed by the Information Office (M) and is
releasable to the National Technical Infcrmation Service (N!IS). At
WTIS it will be available to the enmeral public, including foreign
nations.
A0 M k - 11 7 -
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SI&CURn?.' CLaASSIZATION Do Ts"m1 PAGIF foohD.. n..d
REPORT DOCUMEN1ATIOI4 PAGE
BFRE COMPLETCIkNMG4
1 pRIENT fou"Sift 12 0OV7 ACCNLSSION NO. 3 RICIPICNTTI CAT ALOG wusgU19111
AFFDL-TR- 76-1.2 A___________________
4 7OLIC imlel 1.41IIIA1 TY Pf5 OF IRtPONR1 a loftoC COVIRECC
Electromechanical Actuation Feasibility Study FINAL REPORT
__-5to 12-7 S
6PE'fftU'MO1IN 05013 AIRPORTNy'SulE0
Neal L. Wood, E.F. Echols. John H. A~hmove CNR~ f RN .NE
3361 5-75-C-3055
PIRTORMS.GOKNAGFA sIZATNS I
9 IRORt'11" X'a A'ANDGREISS 10 01tOMNfi tEMEN7 PAJJE!CT. 7431(
AiftasearchAMCa nu ic turing Company AREA f *OftK UNI'T NUMGENS
ADI-vision of the Garrett Corporation Project 1987
e 2525 West 190th Street Task 198701
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II CONTROLLING OWCAIC I N AMIE AND0 ACGRIESS _____________5_2_ ___R_I_E_POR01TD ATE
Air Force Flight Dy-namics Labcratory May 1976
AFSC/AFWAL, United States Air Force 11 sNjsBsIm OF PAGIES
Wright-Patterson AFB, Ohio 45433
L____ U14.7N. CLASSIFIED
_T4 MO-NITORINOG AOENCY MAIME Gt AOOAEIS.M, dill* -, It- Ltwftl~llins Clfioj ICE J "ITV CL ASV (.1 1.* -I5OII
-15.
-6F CL i ss I--, N 00 W G WAOI NGý
SCHIEDULE
01S TgRGUTI$AO tSI . S oSa.l,.
Approved for Public Release, Distribu~ion Unlimited
'7 DISTPIMIUrION STATIEMENT roS t'I* bel-5 -rii-. In 9).1h 20. Of dlleoý. 'It prI
S0 SUPPLIENEN-ARY NOTES
1It ELY 1VOPIS (Co'i~n-, oý le"P.* 0,20 it "F.OOS WW Idend'l by blerh n.Sb.
Po'~ier-by-Wi re
________________________ _________________ ________________
"Pare &irth" Sammariucn-Cobalt Magnets
brushleas D.C. tletor
Imaterials
Permanent Magnet Ro.cor
20 48STNACT (r-#,- . - -, o l8 o*d00. it . -, d b0O ~.b i . -6-1
An alternate to hydraulic actuation of primiary flig~it control su-faces is
desiroble. Electromechatiical actUadlon of primary Ii i,%bt controls is feasible
and practical using the most recent advances in the state-oft-he-art in masnetic
for hi~h-perforuazice servomotors, high- current -capa i ty transistor
switches f or motor power contiol, and dipital microprocei~sors for servo and re-
dundancy managemen!? logiý.> Elict-omechanical actuation Is consisten~t with
current, proven, fly-by-wire technology and with the developing fpoier-by-w1re
t.ýchniques. 7the control surface performance requirements and metho~ds of analvsi
FOR 43 ESOO 1 OSIOSLT UNCLASSIFIED
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A"ifIFlC(IALTI,OSN oSrU BTHJIS EPUATG E T12O0% WVotieN XGff~toE.d)
UCLASs IFIED
SICU.OTIV CLAVFWCAjr O Om TsWIS PAOqgfUt Date "et",,
ir trise~nted for direct drtve mtectiromechanical powrar servos. Tra'ide studlee
were conducted to evaluate the aircraft power source and dlstributrok, options;
lactuator motor and controller optiovai; and gcared rotary hinge actuator con-
figuration options. A weight compsrlacn it :Ivor between the hydraulic actuatit
system for tbh F-100 and the al@ctcromechanical system studied. Reliability
assea~e..tL &ad redundaccy managment considerations also are included. A pro-
11minary design of the electrosechanicsl actuition ayeteu and test plan are pre-
sented. These data were developwd ujxng a selected baseline problem statement
which was derived from existing hy,raulic actuator specifications.
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AFFOL-TR-76-42
FORE WORD
This document is the tinal report of a Study conductecd for the United
States Air Force under Contract Fý3615-75-C-305, Electronechanical Actuation
Feasibility Study. The contract was aaministereu by the Air Force Flioht
Dynamics Labcratory, hriaht-lPatterson Air Force 8ase, Ohio, Wr. Daniel K. bird
(FUL), Project Engiveer. The technical etfort, performed tromi January 15, 1975
to Noventer 3D0 197), was undertaken by AiResearch kanufactur:no Company of
Calito,'ni.). Wc'. Neal Wooo was principal investioator.
Rockwell International, Los Anoeies Aircraft Uivision, contributed to this
study as a subcontractor. Mr. John L. Schibler. Project Enoineer, provided
detailed analyses. air frame data, and actuation system consultatiun for the
figoht control requirements and interfaces based upon the F-100 aircraft.
This document has been reviewed arid approved.
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AFFOL-TR-76-42
TABLE OF CoNTLNrI
Section Page
I. INTROOUCTION I
1.1 Bakground 1
1.2 Program Objectives and Scope 2
2. SUMMARY 4
3. BASELINE SYSrEM REQUIREMENTS 6
4. ACTUATION SYSTEM REQUIREMENTS ANALYSIS 9
4.1 Requirements Review 9
4.2 Baseline Actuat;on System Problem .laten.ent 9
4.3 Analysis of Actuation System Requirements 10
5. ACTUATION SYSTEM STUDIES 19
5.1 Power Source Options 19
5.2 Actuator Drive Options 25
5.3 Actuator Element Options 51
5.5 Aircraft Actuation System Integration 71
6. PRELIMINARY DESIGN 79
6.1 Design 79
6.2 Preliminary Performance Specification 93
6.3 Analog Analysis 104
6.4 Mockup 104
7. PROGRAM PLANS 108
7.1 Program Plan 108
7.2 Preliminary Test Plan ft)r Actuation System 111
Demonst rat ion
8. REFERENCES 121
A F-100 AIRCRAFT CHARACTERISTICS 123
8 B-52 RUDDER AND ELEVATOR CONTROL SYSTEM 138
C F-15 RUDDER CONTROL SURFACE ,CTUATOR PERFORMANCE 141
o F-8 RUDIDER CONTROL SURFACE ACTL,NTOR PERFORMANCE 142
E TOROIJAL DRIVE ANALYSIS 143
!V
AFF L-TR- 76-42
ILLUSTRATIONS
Figure Page
I Versatility of Electromechanical Actuation can be Fully 2
Realized Through Recent Technological Advances
2 The 10-Month Program Comprised Six Tasks 3
3 Generalized Ele-tromechanlcal Actuation System 6
4 Amplitude Ratio 8
5 Phase Lag 8
6 Characterization of Control Surface Velocity and Torque if
7 Load Acceleration Capability 13
8 liltial Screening of 0cwer Options 20
9 Control Approach Similarity 21
i Pc..r Svrca ChAracteristics 21
11 Alternator Characteristics 22
12 Rectifier 23
13 Power Transmission, Continuous Duty 24
14 Candidate Orive Options 26
15 Power Cap ibility of Stopper Designs 27
16 Typical Motor Perforimance 29
17 Comparison of Magnet Materials 30
18 Rotor Critical Speed 31
19 Motor Power Characteristics 33
20 Variable-Frequency Motor Drive 34
21 Ac Inverter Voltage Schedule 34
22 Motor Thermal Analysis for MtL Power Dash 56
23 Thermal Analysis Results for Parked Aircraft on USAF 37
Standard Hot Day
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AfFCL-TR-Tb-42
ILLUSTRATIONS (C(cid:127)ontinued)
F igure Pages
24 ThermAl Analysis Results for )50,000-fCt ruise 37
25 SCR Conmututlon Circuit 41
26 Transistor Comnutation Circuit 41
27 Dc Drive Functiona' Block Diagram 43
21 Ac Drive Block Diagram 45
29 4armOnic Contents of 5V Notching 3-Phase Inverter 47
.)C Ac and Dc Motor Thermal Management Compa,-Ison 49
31 Selcctedl Drive Sysem 52
32 initial Screening of Actuolor Elume~ts 53
33 HarmonIc Drive 54
34 Hinge:ine Actuator 50
35 Parametric Rotary Actuator Data 56
36 Harmonic Drive 57
37 Mechanical No-Brx-k Characteristics 58
38 Mechanical NI,- Bacl s 60
39 Ball Ramp Typo of NO-Back 60
40 Energy Absorbing No-Back: Input )riving and Opposing Load 61
41 [-orgy Absorbli.1 No-BacK: Input Driving and Aiding Load 61
42 Output rj.-que Limiting of F-100 Aileron 63
43 Power Reo~neration 63
44 Theermal Capablity of Energy Absorbing No-Back 64
45 Cor,trol Surtacoe Drive Redundancy Arrangement 68
46 Rellabi'ty Sys'em Model 69
47 Study Concept 70
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AFFI IX-1 R-111-41
ILLUSTRATIONS (Continued)
Figure pg
48 F-100 Electromechanica: Actuator Block Oiagram 74
49 F-100 Electromwctianlal Actuator Installation at 75
Aileron Station 199.250
50 Microprocessor Motor Controe 81
51 WMtor lhermal Analysis Results 87
52 Functions implemented by a Mlcrooroce~sor 89
53 Microorocessor Prograom Flow Chart for Dc Motor Controller 90
54 Nonracursive Digital Filter Mechanization Diagram 94
55 PWM Generator Functional 3txck 'iagram 94
56 Shaft Pcsition Sensr 95
57 Analog Input Encoder Mechanization Uiagram 96
J8 System Model 97
59 Motoi- Per formance 99
60 Actuator Servo-Loop Funk tlonM 3lock Diaqram 105
61 Amplitude Ratio vs Frequency 106
62 Phase Lag vs Frequency 106
63 EM Actuator Mockup 107
(4 Program Schedule for DOsiqn, tabrication, and Evaluation 109
Testing of Electromechanical Rotary Hl,'ge-Line Actuator
65 Test Logi: Olagraw 113
66 Performance lest and lost Setup 114
67 Frgquoncy Response 115
68 Stiffness Test 116
69 Power Efficiency Test 117
70 Acceleratioi Test 118
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