Feasibility study of electromechanical cylinder drivetrain for offshore mechatronic systems

Currently, there is an increasing focus on the environmental impact and energy consumption of the oil and gas industry. In offshore drilling equipment, electric motors tend to replace traditionally used hydraulic motors, especially in rotational motion control applications. However, force densities available from linear hydraulic actuators are still typically higher than those of electric actuators. Therefore, usually the remaining source of hydraulic power is thereby the hydraulic cylinder. This paper presents a feasibility study on the implementation of an electromechanical cylinder drivetrain on an offshore vertical pipe handling machine. The scope of this paper is to investigate the feasibility of a commercial off-the-shelf drivetrain. With a focus on the motion performance, numerical modeling and simulation are used when sizing and selecting the components of the considered electromechanical cylinder drivetrain. The simulation results are analyzed and discussed together with a literature study regarding advantages and disadvantages of the proposed solution considering the design criteria of offshore drilling equipment. It is concluded that the selected drivetrain can only satisfy the static motion requirements since the required transmitted power is higher than the recommended permissible power of the transmission screw. Consequently, based on the recommendation of the manufacturer, avoidance of overheating cannot be guaranteed for the drivetrain combinations considered for the case study presented in this paper. Hence, to avoid overheating, the average speed of the motion cycle must be decreased. Alternatively, external cooling or temperature monitoring and control system that prevents overheating could be implemented

Design and application of electromechanical actuators for deep space missions

The annual report Design and Application of Electromechanical Actuators for Deep Space Missions is presented. The reporting period is 16 Aug. 1992 to 15 Aug. 1993. However, the primary focus will be work performed since submission of our semi-annual progress report in Feb. 1993. Substantial progress was made. We currently feel confident in providing guidelines for motor and control strategy selection in electromechanical actuators to be used in thrust vector control (TVC) applications. A small portion was presented in the semi-annual report. At this point, we have implemented highly detailed simulations of various motor/drive systems. The primary motor candidates were the brushless dc machine, permanent magnet synchronous machine, and the induction machine. The primary control implementations were pulse width modulation and hysteresis current control. Each of the two control strategies were applied to each of the three motor choices. With either pulse width modulation or hysteresis current control, the induction machine was always vector controlled. A standard test position command sequence for system performance evaluation is defined. Currently, we are gathering all of the necessary data for formal presentation of the results. Briefly stated for TVC application, we feel that the brushless dc machine operating under PWM current control is the best option. Substantial details on the topic, with supporting simulation results, will be provided later, in the form of a technical paper prepared for submission and also in the next progress report with more detail than allowed for paper publication

Design and application of electromechanical actuators for deep space missions

This progress report documents research and development efforts performed from August 16, 1993 through February 15, 1994 on NASA Grant NAG8-240, 'Design and Application of Electromechanical Actuators for Deep Space Missions.' Following the executive summary are four report sections: Motor Selection, Tests Stand Development, Health Monitoring and Fault Management, and Experiment Planning. Three specific motor types have been considered as prime movers for TVC EMA applications: the brushless dc motor, the permanent magnet synchronous motor, and the induction motor. The fundamental finding was that, in general, the primary performance issues were energy efficiency and thermal dissipation (rotor heating). In terms of all other issues, the three motor types were found to compare quite equally. Among the design changes made to the test stand since the last progress report is the addition of more mounting holes in the side beams. These additional holes allow the movable end beam to be attached in a greater number of positions than previously. With this change the movable end beam can move from full forward to full back in three inch increments. Specific mathematical details on the approach that have been employed for health monitoring and fault management (HMFM) have been reported previously. This approach is based on and adaptive Kalman filter strategy. In general, a bank of filters can be implemented for each primary fault type. Presently under consideration for the brushless dc machine are the following faults: armature winding open-circuits, armature winding short-circuits (phase-to-phase and phase-to-ground), bearing degradation, and rotor flux weakening. The mechanically oriented experiments include transient loading experiments, transverse loading experiment, friction experiment, motor performance experiment, and HMFM experiment

Windings fault detection and prognosis in electro-mechanical flight control actuators operating in active-active configuration

One of the most significant research trends in the last decades of the aeronautic industry is the effort to move towards the design and the production of “more electric aircraft”. Within this framework, the application of the electrical technology to flight control systems has seen a progressive, although slow, increase: starting with the introduction of fly-by-wire and proceeding with the partial replacement of the traditional hydraulic/electro-hydraulic actuators with purely electro-mechanical ones. This evolution allowed to obtain more flexible solutions, reduced installation issues and enhanced aircraft control capability.Electro-Mechanical Actuators (EMAs) are however far from being a mature technology and still suffer from several safety issues, which can be partially limited by increasing the complexity of their design and hence their production costs. The development of a robust Prognostics and Health Management (PHM) system could provide a way to prevent the occurrence of a critical failure without resorting to complex device design. This paper deals with the first part of the study of a comprehensive PHM system for EMAs employed as primary flight control actuators; the peculiarities of the application are presented and discussed, while a novel approach, based on short pre-flight/post-flight health monitoring tests, is proposed. Turn-to-turn short in the electric motor windings is identified as the most common electrical degradation and a particle filtering framework for anomaly detection and prognosis featuring a self-tuning non-linear model is proposed. Features, anomaly detection and a prognostic algorithm are hence evaluated through state-of-the art performance metrics and their results discussed

Electromechanical actuators affected by multiple failures: a simulated-annealing-based fault identification algorithm

The identification of early evidences on monitored parameters allows preventing incoming faults. Early alerts can avoid rate of the failures and trigger proper out-of-schedule maintenance activities. For this purpose, there are many prognostic approaches. This paper takes into account a primary flight command electromechanical actuator (EMA) with multiple failures originating from progressive wear and proposes a fault detection approach that identifies symptoms of EMA degradation through a simulated annealing (SA) optimization algorithm; in particular, the present work analyses the functioning of this prognostic tool in three different fault configurations and it focuses on the consequences of multiple failures. For this purpose, we developed a test bench and obtained experimental data necessary to validate the results originated from the model. Such comparison demonstrates that this method is affordable and able to detect failures before they occur, thus reducing the occurrence of false alarms or unexpected failures. © 2016, North Atlantic University Union. All rights reserved

Proposal of a model based fault identification neural technique for more-electric aircraft flight control EM actuators

There are many different ways to detect incipient failures of electromechanical actuators (EMA) of primary flight command provoked by progressive wear. With the development of a prognostic algorithm it’s possible to identify the precursors of an electromechanical actuator failure, to gain an early alert and so get a proper maintenance and a servomechanism replacement. The present work aims to go beyond prognostic algorithms strictly technology-oriented and based on accurate analysis of the cause and effect relationships because if on one hand they show great effectiveness for some specific applications, instead they mostly fail for different applications and technologies. Through the development of a simulation test bench the authors have demonstrated a robust method to early identify incoming failures and reduce the possibility of false alarms or non-predicted problems. Authors took into account friction, backlash, coil short circuit and rotor static eccentricity failures and defined a model-based fault detection neural technique to assess data gained through Fast Fourier Transform (FFT) analysis of the components under normal stress conditions

Linear Electromechanical Actuators Affected by Mechanical Backlash: a Fault Identification Method Based on Simulated Annealing Algorithm

Several approaches can be employed in prognostics, to detect incipient failures of primary flight command electromechanical actuators (EMA), caused by progressive wear. The development of a prognostic algorithm capable of identifying the precursors of an electromechanical actuator failure is beneficial for the anticipation of the incoming faults: a correct interpretation of the fault degradation pattern, in fact, can trig an early alert of the maintenance crew, who can properly schedule the servomechanism replacement. The research presented in this paper proposes a fault detection / identification technique, based on approaches derived from optimization methods, able to identify symptoms of EMA degradation before the actual exhibition of the anomalous behavior; in particular, the authors’ work analyses the effects due to progressive backlashes acting on the mechanical transmission and evaluates the effectiveness of the proposed approach to correctly identify these faults. An experimental test bench was developed: results show that the method exhibit adequate robustness and a high degree of confidence in the ability to early identify an eventual fault, minimizing the risk of false alarms or not annunciated failures

Data Driven Approach to Non-stationary EMA Fault Detection and Investigation Into Remaining Useful Life

Growing interest in using Electromechanical Actuators (EMAs) to replace current hydraulic actuation methods on aircraft control surfaces has driven significant research in the area of prognostics and health management. Non- stationary speeds and loads in the course of controlling an aircraft surface make fault identification in EMAs difficult. This work presents a time- frequency analysis of EMA thrust bearing vibration signals using wavelet transforms. A relatively small EMA system is designed and built to allow for simple, quick, and repeatable component replacement. A simulated signal is developed to test four potential faults in the system. Classification is performed using an artificial neural network (ANN), which yields over 99% accuracy. Indentation faults from moderate and heavy loads are seeded in thrust bearings, which are then tested to generate data. The ANN achieves 95% classification accuracy in a two class scenario using healthy and moderately indented bearings. A three class test is executed using thrust bearings at each level of damage to perform preliminary remaining useful life (RUL) testing, where an ANN is able to identify the fault severity with an accuracy of 88%

A review of diagnostic methods for hydraulically powered flight control actuation systems

Aircraft systems are designed to perform functions that will aid the various missions of the aircraft. Their performance, when subjected to an unfamiliar condition of operation, imposes stress on them. The system components experience degradation due to fault which ultimately results in failure. Maintenance and monitoring mechanisms are put in place to ensure these systems are readily available when required. Thus, the sensing of parameters assists in providing conditions under which healthy and faulty scenarios can be indicated. To obtain parameter values, sensor data is processed, and the results are displayed so that the presence of faults may be known. Some faults are intermittent and incipient in nature. These are not discovered easily and can only be known through a display of unusual system performance by error code indication. Therefore, the assessed faults are transmitted to a maintenance crew by error codes. The results may be fault found (FF), no fault found (NFF), or cannot display (CND). However, the main classification of the faults and their origins may not be known in the system. This continues throughout the life cycle of the system or equipment. This paper reviews the diagnostic methods used for the hydraulically powered flight control actuation system (HPFCAS) of an aircraft and its interaction with other aircraft systems. The complexities of the subsystem’s integration are discussed, and different subsystems are identified. Approaches used for the diagnostics of faults, such as model-based, statistical mapping and classification, the use of algorithms, as well as parity checks are reviewed. These are integrated vehicle health management (IVHM) tools for systems diagnostics. The review shows that when a system is made up of several subsystems on the aircraft with dissimilar functions, the probability of fault existing in the system increases, as the subsystems are interconnected for resource sharing, space, and weight savings. Additionally, this review demonstrates that data-driven approaches for the fault diagnostics of components are good. However, they require large amounts of data for feature extraction. For a system such as the HPFCAS, flight-management data or aircraft maintenance records hold information on performance, health monitoring, diagnostics, and time scales during operation. These are needed for analysis. Here, a knowledge of training algorithms is used to interpret different fault scenarios from the record. Thus, such specific data are not readily available for use in a data-driven approach, since manufacturers, producers, and the end users of the system components or equipment do not readily distribute these verifiable data. This makes it difficult to perform diagnostics using a data-driven approach. In conclusion, this paper exposes the areas of interest, which constitute opportunities and challenges in the diagnostics and health monitoring of flight-control actuation systems on aircraft

Improving Energy Efficiency and Motion Control in Load-Carrying Applications using Self-Contained Cylinders

Because of an increasing focus on environmental impact, including CO2 emissions and fluid spill pollution, inefficient hydraulic systems are being replaced by more environmentally friendly alternatives in several industries. For instance, in some offshore applications that have multiple diesel generators continuously running to produce electricity, all hydraulic rotating actuators supplied from a central hydraulic power unit have been replaced with AC induction motors containing a variable frequency drive and gearbox. However, hydraulic linear actuators are still needed in most load-carrying applications mainly because of their high reliability associated with external impact shocks. Moreover, their force capacity is higher than that of their linear electromechanical counterparts. Valve-controlled linear actuators (cylinders) supplied from a centralized hydraulic power unit are standard in offshore load-carrying applications. In addition to the advantages mentioned above of hydraulic linear actuators, they have, nevertheless, a number of important drawbacks, which include: 1) a high level of energy consumption due to significant power losses caused by flow throttling in both the pipelines and valves, 2) reduced motion performance due to the influence of load-holding valves, 3) high CO2 emissions and fuel costs related to the diesel generator that supplies electricity to the hydraulic power unit, 4) significant potential for hydraulic fluid leakage because of many leakage points, 5) demanding efforts with respect to installation and maintenance, as well as 6) costly piping due to the centralized hydraulic power supply. The work presented in this dissertation and the appended papers are devoted to replacing inefficient hydraulic linear actuation systems traditionally used in offshore load-carrying applications with more environmentally friendly solutions. Two alternative technologies are identified, namely electro-mechanical and electro-hydraulic self-contained cylinders. The feasibility of replacing conventional valve-controlled cylinders with self-contained cylinder concepts is investigated in two relevant case studies.publishedVersio