Design and characteristic research of a novel electromechanical-hydraulic hybrid actuator with two transmission mechanisms

doi:10.1007/s11465-022-0735-x

Front. Mech. Eng.

2023, Vol. 18

Issue (2) : 19 https://doi.org/10.1007/s11465-022-0735-x

RESEARCH ARTICLE

Design and characteristic research of a novel electromechanical-hydraulic hybrid actuator with two transmission mechanisms

Shufei QIAO, Long QUAN(

), Yunxiao HAO, Lei GE, Lianpeng XIA

Key Laboratory of Advanced Transducers and Intelligent Control System of Ministry of Education, Taiyuan University of Technology, Taiyuan 030024, China

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Abstract

Servo-hydraulic actuators (SHAs) are widely used in mechanical equipment to drive heavy-duty mechanisms. However, their energy efficiency is low, and their motion characteristics are inevitably affected by uncertain nonlinearities. Electromechanical actuators (EMAs) possess superior energy efficiency and motion characteristics. However, they cannot easily drive heavy-duty mechanisms because of weak bearing capacity. This study proposes and designs a novel electromechanical-hydraulic hybrid actuator (EMHA) that integrates the advantages of EMA and SHA. EMHA mainly features two transmission mechanisms. The piston of the hydraulic transmission mechanism and the ball screw pair of the electromechanical transmission mechanism are mechanically fixed together through screw bolts, realizing the integration of two types of transmission mechanisms. The control scheme of the electromechanical transmission mechanism is used for motion control, and the hydraulic transmission mechanism is used for power assistance. Then, the mathematical model, structure, and parameter design of the new EMHA are studied. Finally, the EMHA prototype and test platform are manufactured. The test results prove that the EMHA has good working characteristics and high energy efficiency. Compared with the valve-controlled hydraulic cylinder system, EMHA exhibits a velocity tracking error and energy consumption reduced by 49.7% and 54%, respectively, under the same working conditions.

Keywords electromechanical-hydraulic hybrid actuator (EMHA) integration transmission mechanisms power assistance energy efficiency working characteristics

Corresponding Author(s): Long QUAN

About author: *These authors equally shared correspondence to this manuscript.

Just Accepted Date: 15 September 2022 Issue Date: 04 May 2023

Cite this article:

Shufei QIAO,Long QUAN,Yunxiao HAO, et al. Design and characteristic research of a novel electromechanical-hydraulic hybrid actuator with two transmission mechanisms[J]. Front. Mech. Eng., 2023, 18(2): 19.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-022-0735-x
https://academic.hep.com.cn/fme/EN/Y2023/V18/I2/19

Fig.1 Distributed electromechanical-hydraulic hybrid linear drive system: (a) double-actuator coupling drive mechanism and (b) symmetrical coupling drive mechanism with multiple actuators. EMA: electromechanical actuator, SHA: servo-hydraulic actuator.

Fig.2 Schematic diagram of electromechanical-hydraulic hybrid actuator. 1?servo motor, 2?reducer, 3?bearing, 4?lead screw, 5?nut, 6?piston, 7?piston rod, 8?rodless chamber, 9?sealing ring, 10?rod chamber.

Fig.3 Power flow diagram of electromechanical-hydraulic hybrid actuator (EMHA).

Fig.4 Control strategy of electromechanical-hydraulic hybrid actuator.

Fig.5 Simplified structure diagram of electromechanical-hydraulic hybrid actuator.

Fig.6 Three-dimensional structure diagram of electromechanical-hydraulic hybrid actuator.

Tab.1 Parameters of the ball screw pair

Tab.2 Parameters of the servo motor

Tab.3 Parameters of EMHA

Fig.7 Dimension diagram of electromechanical-hydraulic hybrid actuator.

Fig.8 Stress nephogram of the ball screw component: (a) electromechanical actuator with no hydraulic assistance and (b) electromechanical-hydraulic hybrid actuator with hydraulic assistance.

Fig.9 Schematic diagram of the test system.

Fig.10 Photograph of the test platform for linear actuator. EMHA: electromechanical-hydraulic hybrid actuator, SHA: servo-hydraulic actuator.

Fig.11 Motion control characteristic curves: (a) velocity step characteristic and (b) position step characteristic. EMA: electromechanical actuator, EMHA: electromechanical-hydraulic hybrid actuator.

Fig.12 Velocity and displacement tracking characteristic curves of actuators: (a) velocity and displacement tracking characteristic curves of servo-hydraulic actuator (SHA), (b) velocity and displacement tracking characteristic curves of electromechanical-hydraulic hybrid actuator (EMHA), and (c) velocity error characteristic curves.

Fig.13 Pressure characteristic curves of actuators: (a) pressure characteristic curves of servo-hydraulic actuator (SHA) and (b) pressure characteristic curves of electromechanical-hydraulic hybrid actuator (EMHA).

Fig.14 Energy consumption characteristic curves. SHA: servo-hydraulic actuator, EMHA: electromechanical-hydraulic hybrid actuator.

Fig.15 Force curves of the electromechanical-hydraulic hybrid actuator transmission mechanisms.

Fig.16 Dynamic test characteristic curves of electromechanical-hydraulic hybrid actuator.

Tab.4 Performance values of EMHA

Abbreviations
EHA	Electro-hydrostatic actuator
EMA	Electromechanical actuator
EMHA	Electromechanical-hydraulic hybrid actuator
SHA	Servo-hydraulic actuator
Variables
A₁, A₂	Effective action areas of the EMHA rodless and rod chamber pressure, respectively
B	Rotational viscous friction coefficient
c	System viscous damping coefficient
d	Outer diameter of the piston rod
d_c	Outer diameter of the cylinder barrel
d_s	Diameter of the lead screw
d₁, d₂	Diameters of the piston and piston rod, respectively
D_e	Servo motor width
D_z1	Wheelbase between the servo motor and the lead screw
D_z2	Wheelbase between the driving gear and the driven gear
F_e	Electromechanical transmission mechanism force
F_E	Output force of EMA
F_ER	Radial force of the driving rod of EMA
F_f	Interference force including friction
F_h	Hydraulic transmission mechanism force
F_H	Output force of SHA
F_HR	Radial force of the driving rod of SHA
F_L	Load force
F_sum	Total output force
i_d	Stator current of the d axis
i_q	Stator current of the q axis
I	Current of the electrical unit
J₁, J₂	Moments of inertia of the servo motor rotor and reducer, respectively
J_e	Moment of inertia driven by the electrical unit
J_L	Equivalent moment of inertia of the load
J_s	Moment of inertia of the lead screw
k	Reducer reduction ratio
l	Lead of the screw transmission pair
L_E	Arm distance of the EMA output force
L_H	Arm distance of the SHA output force
L_s	Equivalent inductance
m	Gear module
m_h	Hydraulic oil mass
m_l	Load mass
m_s	Lead screw mass
n	Rotation speed of the servo motor
n_s	Rotation speed of the lead screw
N	Number of the pole pairs
p₁, p₂	Pressures of the EMHA rodless and rod chamber, respectively
P_h	Driving power of the hydraulic cylinder
R	Stator resistance
T	Torque amplified through the reducer
T_add	Additional torque of the distributed linear drive system
T_L	Equivalent load torque of the servo motor
u_d	Stator voltage of the d axis
u_q	Stator voltage of the q axis
U	Voltage of electrical unit
v	Velocity of EMHA
v_s	Linear speed of the lead screw rotation
x	Displacement of EMHA
z₁, z₂, z₃	Numbers of the driving teeth, transition teeth, and driven teeth, respectively
α	Rotation angle of the servo motor
ψ	Flux linkage amplitude of the rotor permanent magnet
η₁, η₂	Efficiency of the mechanical and hydraulic transmission mechanism, respectively
θ	A certain angle
θ_E	Angle between the load force of the EMA driving rod and axis
θ_H	Angle between the load force of the SHA driving rod and axis

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