Incremental Virtual Prototyping of Electromechanical Actuators for Position Synchronization

242 Pages·2017·13.17 MB·English

by  Jian Fu

Incremental Virtual Prototyping of Electromechanical
Actuators for Position Synchronization
Jian Fu
To cite this version:
Jian Fu. Incremental Virtual Prototyping of Electromechanical Actuators for Position Synchro-
nization. Mechanical engineering [physics.class-ph]. INSA de Toulouse, 2016. English. ￿NNT:
2016ISAT0008￿. ￿tel-01511290￿
HAL Id: tel-01511290
https://theses.hal.science/tel-01511290
Submitted on 20 Apr 2017
HAL is a multi-disciplinary open access L’archive ouverte pluridisciplinaire HAL, est
archive for the deposit and dissemination of sci- destinée au dépôt et à la diffusion de documents
entific research documents, whether they are pub- scientifiques de niveau recherche, publiés ou non,
lished or not. The documents may come from émanant des établissements d’enseignement et de
teaching and research institutions in France or recherche français ou étrangers, des laboratoires
abroad, or from public or private research centers. publics ou privés.
THÈSE

En vue de l'obtention du

DOCTORAT DE L’UNIVERSITÉ DE TOULOUSE

Délivré par :
Institut National des Sciences Appliquées de Toulouse (INSA de Toulouse)
Discipline ou spécialité :
Génie Mécanique, Mécanique des Matérieux

Présentée et soutenue par :
Jian FU
Le mercredi 6 Juillet 2016

Titre :
Prototypage Virtuel Incrémental des Actionneurs Electromécanique
pour la Synchronisation en Position

JURY
Geneviève DAUPHIN-TANGUY, Professeur, Ecole Centrale de Lille, Rapporteur
Jesús FELEZ, Professeur, Universidad Politécnica de Madrid, Rapporteur
Jean-Charles MARE, Professeur, INSA de Toulouse, Examinateur
Ion HAZYUK, Maître de Conférences, INSA deToulouse, Examinateur
Yongling FU, Professeur, Beihang University, Invité

Ecole doctorale :
Mécanique, Energétique, Génie civil, Procédés (MEGEP)
Unité de recherche :
Institut Clément Ader (ICA, CNRS UMR 5312)
Directeur(s) de Thèse :
Jean-Charles MARE
Université fédérale de Toulouse Midi-Pyrénées
Institut National des Sciences Applique e de Toulouse
Institut Cle ment Ader (CNRS UMR 5312)

Incremental Virtual Prototyping of Electromechanical
Actuators for Position Synchronization

Doctoral Thesis

Prepared by: Jian FU
Supervisor: Prof. Jean-Charles MARE
Reviewers: Prof. Genevie ve DAUPHIN-TANGUY
Prof. Jesu s FELEZ
Examiner: Mcf. Ion HAZYUK
Inviter: Prof. Yongling FU

Toulouse
July 2016

Abstract
In the aerospace field, the concepts based on extended use of electricity in “More Electric
Aircraft” (MEA) and even “All Electric Aircraft” (AEA), electromechanical actuators (EMAs) are
increasingly being implemented in place of conventional hydraulic servo actuators (HSAs).
When EMAs are used for safety-critical actuation applications like flight controls, some
specific issues related to thermal balance, reflected inertia, parasitic motion due to
compliance, response to failure (jamming and free-run) and synchronization of EMAs driving
independent loads cannot be ignored. The simulation-aided design process can efficiently
support the assessment and validation of the concepts fixing these issues. For that, virtual
prototypes of EMAs at system-level have to be developed in a structured way that meets the
engineers’ needs. Unfortunately, the physical effects governing the EMAs behavior are
multidisciplinary, coupled and highly nonlinear. Although numerous multi-domain and
system-level simulation packages are now available in the market of simulation software, the
modelling process and the engineers’ needs are rarely addressed as a whole because of lack of
scientific approaches for model-based architecting, multi-purpose incremental modelling and
model implementation for efficient numerical simulation. In this thesis, the virtual
prototyping of EMAs is addressed using the Bond-Graph formalism. New approaches are
proposed to enable incremental modelling of EMAs that provides models supporting control
design, energy consumption and thermal analysis, calculation of reaction forces, power
network pollution simulation, prediction of response to faults and influence of temperature.
The case of preliminary design of EMAs position synchronization is used to highlight the
interests and advantages of the proposed process and models of EMAs.
Keywords: Bond-Graph, More Electric Aircraft, Power-by-Wire, EMA, Energy Losses, Response to
Faults, Synchronization

Acknowledgements

First of all, I am grateful to China Scholarship Council (CSC) for providing me with 40
months of financial grant and support for my doctoral studies in France.
I would like to express my sincere gratitude to my supervisor, Mr. Jean-Charles MARE, at
INSA-Toulouse, Institut Cle ment Ader (ICA). I am indebted to him for his guidance and
help during my PhD thesis. His rigorous research attitude and good work ethics will have
an everlasting impact on my life.
I would also like to specially thank Mr. FU Yongling, in Beihang University, for his
instructive advice during my M.S and first year of PhD in Beihang. I am deeply grateful
for his recommendation, which gave me the opportunity to pursue my PhD degree in
France.
I would also like to express my thanks to Mr. Ion HAZYUK, in INSA-Toulouse, ICA, for his
discussion and contribution towards my thesis. I would like to thank Mr. Nicolas
LAURIEN and Mr. Ste phane ORIEUX, for their assistance and suggestions during the
experimental tests in my PhD.
I am also deeply indebted to all my Chinese and international friends in the laboratory of
ICA, for their help, encouragement and friendship during my Ph.D studies.
Finally, the last words are for my family. In the most difficult time, during the mid of my
Ph.D study, my father was no more. I would especially like to thank my mother for her
continued support and encouragement during these tough moments of my overseas
study, and she is indeed a great mother. I dedicate this thesis to my father in heaven,
thank you very much!

Contents
Nomenclature .................................................................................................................................. I
Introduction .................................................................................................................................... 1
Chapter 1 State of the Art ............................................................................................................................. 7
1.1 Flight Control Actuators ........................................................................................................................... 7
1.2 Safety Cirtical Requirments and Position Synchronization ................................................. 13
1.3 Virtual Prototyping Methodology ....................................................................................................... 21
1.4 Performance Requirements ................................................................................................................... 26
1.5 Conclution of Chapter 1 ............................................................................................................................ 27
References ........................................................................................................................................................................ 27
Chapter 2 Individual EMA Controller Design ....................................................... 31
2.1 Individual EMA System Description ................................................................................................... 31
2.2 Linear Virtual Prototype .......................................................................................................................... 35
2.3 Power Limitation and Saturation Effects ........................................................................................ 42
2.4 Motor Current Loop Effects ..................................................................................................................... 45
2.5 Imperfections due to Mechanical Compliances .......................................................................... 53
2.6 Force Feedback Compensation for Position Control ................................................................ 62
2.7 Conclusion of Chapter 2 ............................................................................................................................ 71
References ........................................................................................................................................................................ 72
Chapter 3 Power Drive Electronics and Motor .................................................... 73
3.1 Physical Effects in Power Drive Electronics (PDE) .................................................................... 73
3.2 Physical Effects at Electric Motor (EM) ........................................................................................ 85
3.3 Incremental Virtual Prototyping ......................................................................................................... 95
3.4 Numerical Simulation and Analysis ................................................................................................ 104
3.5 Conclusion of Chapter 3 ......................................................................................................................... 111
References ..................................................................................................................................................................... 112
Chapter 4 Mechanical Power Transmission ........................................................ 115
4.1 Power Screw Mechanism ...................................................................................................................... 116
4.2 1-DoF Integrated Model ......................................................................................................................... 119
4.3 2-DoF Decomposition Model .............................................................................................................. 131
4.4 Model Implementation .......................................................................................................................... 148
4.5 Numerical Simulation and Analysis ............................................................................................... 156
4.5 Conclusion of Chapter 4 ......................................................................................................................... 167
References .................................................................................................................................................................... 168
Chapter 5 Test Bench and Preliminary Study of Position
Synchronization ........................................................................................................................ 171
5.1 Description of the Test Bench ............................................................................................................ 171
5.2 Preliminary Study of Position Synchronization ...................................................................... 181
5.3 Validation of Overall Twin-Parallel EMAs Virtual Prototype ........................................... 191
5.4 Conclusion of Chapter 5 ......................................................................................................................... 201
References .................................................................................................................................................................... 202
Conclusion ..................................................................................................................................... 205
List of Publications ................................................................................................................. 209
Appendix ........................................................................................................................................ 211
Appendix A BLDC vs.PMSM Used for EMAs ..................................................................................................... 21
Appendix B SKF Bearing Loss Model .................................................................................................................. 21
1
7
Résumé ........................................................................................................................................... 221