More Electric Landing Gear Actuation Study

This report addresses the problem of landing gear actuation system design on more-electric aircraft (MEA). Firstly, information about more-electric aircraft and more-electric actuators was gathered and sorted. Current more-electric landing actuation system applications and researches were also summarized. Then several possible more-electric landing gear actuation concepts were identified. To evaluate these concepts, the case study method has been used. A concept aircraft “MRT7-T”, which has similar maximum takeoff weight to that of Boeing 787, has been chosen as the design case. Systems of different configurations and architectures were designed for this aircraft. In the end of this study, a comparison between different more-electric landing gear actuation systems, and also with traditional central hydraulic system was made. The best concept was proposed. More-electric actuation technology has made considerable progress in the last two decades. However, most of the applications and researches have focused on flight control actuation and brakes. Using more-electric drives for landing gear actuation has been well known to be difficult, for the reason of massive power needs and difficulties in achieving redundancy levels. Famous more-electric research projects like POA and Power-By-Wire only gave recommendation of using electro-hydrostatic actuators (EHA) in landing gear actuation. And no further information is available to the public. In this study, DHS (distributed hydraulic system), EHA (electro-hydrostatic actuator) and EMA (electro-mechanical actuator) were identified as candidate solutions. Design requirements such as retraction time, load and redundancy levels were derived through analysis. As a unique feature, landing gear kinematics concepts were also subject to optimization. Various kinematics concepts were proposed and analyzed in detail, to provide favorable loading and geometrical conditions for the systems. Kinematics design guidelines were built through discussion. Different motors such as AC induction motor, BDCM (brushless DC motor) and PMSM (permanent magnetic synchronous motor) were evaluated for use. Different system architectures were also explored. The multi-discipline optimization method has been extensively used in the design process of the systems. Firstly, each node of the actuation systems was optimized. Then optimizations were made to the systems. Performances of each system were analyzed in several aspects such as weight, power, reliability and maintenance. Comparison of different systems was made through scoring method. The results suggested that DHS, EHA and EMA are all applicable for landing gear actuation. And isolated EHA is the best

Energy Comparison between a Load Sensing System and Electro-Hydraulic Solutions Applied to a 9-Ton Excavator

With the increasingly stringent regulations on air quality and the consequent emission limits for internal combustion engines, researchers are concentrating on studying new solutions for improving efficiency and energy saving even in off-road mobile machines. To achieve this task, pump-controlled or displacement-controlled systems have inspired interest for applications in offroad working machines. Generally, these systems are derived from the union of a hydraulic machine coupled to an electric one to create compact components that could be installed near the actuator. The object of study of this work is a 9-ton excavator, whose hydraulic circuit is grounded on load sensing logic. The validated mathematical model, created previously in the Simcenter Amesim© environment, represents the starting point for developing electro-hydraulic solutions. Electric components have been inserted to create different architectures, both with open-and closed-circuit layouts, in order to compare the energy efficiency of the different configurations with respect to the traditional load sensing system. The simulations of a typical working cycle show the energy benefits of electrohydraulic solutions that allow for drastically reducing the mechanical energy required by the diesel engine and, consequently, the fuel consumption. This is mainly possible because of the elimination of directional valves and pressure compensators, which are necessary in a load sensing circuit, but are also a source of great energy dissipations. The results show that closed-circuit solutions produce the greatest benefits, with higher energy efficiencies than the open-circuit solution. Furthermore, closed-circuit configurations require fewer components, allowing for more compact and lighter solutions, as well as being cheaper

Fuzzy control of the electrohydraulic actuator

Industrial applications increasingly require actuators that offer a combination of high force output, large stroke and high accuracy. The ElectroHydraulic Actuator (EHA) was designed by Drs. Habibi and Goldenberg originally as a high-performance actuator for use in robotics. However, it was determined that the EHA had the potential to achieve high positional accuracy. Little research has been performed in the area of high-accuracy hydraulic positioning systems. Therefore, the objective of this study to achieve nano-scale positional accuracy with the EHA while maintaining large stroke and high force output. It was planned to achieve this objective through modification of the prototype EHA and the use of fuzzy control. During this research project, both hardware and control system modifications to the EHA were performed. A high-precision optical encoder position sensor with a 50 nm resolution was mounted on the inertial load to directly measure the position of the load. A number of device drivers were written to interface the MATLAB real-time control environment with the optical encoder and servo motor amplifier. A Sugeno-inference fuzzy controller was designed and implemented in MATLAB. For comparison purposes, a switched-gain controller and a proportional controller were also implemented in the control environment. The performance of the fuzzy controller was compared to the switched-gain controller and the proportional controller in a number of tests. First, the regulatory and tracking performance of the EHA with an inertial load of 20 kg was examined. It was determined in the regulatory tests that the positional accuracy of the EHA with the fuzzy controller was excellent, achieving a steady state error of 50 ± 25 nm or less for step inputs in the range 5 cm to 200 nm. The positional accuracy during the tracking tests was found to be reduced compared to the regulatory tests since the actuator did not have sufficient time to settle to final accuracy due to the timevarying input signals. In all cases, it was found that the positional accuracy of the EHA with the fuzzy controller was significantly greater than with the switched-gain and proportional controllers for both regulatory and tracking signals. Testing with the inertial load eliminated or changed was not performed because the position sensor was mounted to the load, making it unfeasible to alter the load during the time frame of this study. The regulatory and tracking performance of the EHA with an inertial load of 20 kg plus external resistive loads of 90 to 280 N were investigated. It was found that the positional accuracy of the EHA decreased with the application of an external load to 3.10 ± 0.835 µm for a 1 cm step input (90 N load) and 8.45 ± 0.400 µm for a 3 cm step input (280 N load). Again, the positional accuracy of the EHA decreased during the tracking tests relative to the regulatory tests, for the reason stated above. This implies that the positional accuracy of the EHA with a resistive load is in the microscale, rather than the nano-scale as was put forth as the objective of this study. Nevertheless, the positional accuracy of the EHA with the fuzzy controller was found to be significantly greater than with the switched-gain and proportional controllers. It is postulated that the increase in positional error observed during the external load tests was due to an increase in cross-port leakage, relative to the inertial load tests, caused by the pressure differential induced across the actuator by the external load. Methods of reducing the increase in positional error caused by external loads on the EHA remains an area for future study

Volume 1 – Symposium

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group A: Materials Group B: System design & integration Group C: Novel system solutions Group D: Additive manufacturing Group E: Components Group F: Intelligent control Group G: Fluids Group H | K: Pumps Group I | L: Mobile applications Group J: Fundamental

Volume 2 – Conference: Wednesday, March 9

10. Internationales Fluidtechnisches Kolloquium:Group 1 | 2: Novel System Structures Group 3 | 5: Pumps Group 4: Thermal Behaviour Group 6: Industrial Hydraulic

Actuation technology for flight control system on civil aircraft

This report addresses the author’s Group Design Project (GDP) and Individual Research Project (IRP). The IRP is discussed primarily herein, presenting the actuation technology for the Flight Control System (FCS) on civil aircraft. Actuation technology is one of the key technologies for next generation More Electric Aircraft (MEA) and All Electric Aircraft (AEA); it is also an important input for the preliminary design of the Flying Crane, the aircraft designed in the author’s GDP. Information regarding actuation technologies is investigated firstly. After initial comparison and engineering consideration, Electrohydrostatic Actuation (EHA) and variable area actuation are selected for further research. The tail unit of the Flying Crane is selected as the case study flight control surfaces and is analysed for the requirements. Based on these requirements, an EHA system and a variable area actuation system powered by localised hydraulic systems are designed and sized in terms of power, mass and Thermal Management System (TMS), and thereafter the reliability of each system is estimated and the safety is analysed. These two systems are then compared in fuel penalty, safety, maintenance and installation, cost, risk and certification. A conventional Fly-By-Wire (FBW) actuation system is used as the reference case. The results show that both the EHA system and the variable area actuation system are feasible for the FCS on civil aircraft. The EHA system is proved to be quite efficient in power consumption and mass reduction. However, the reliability of EHA needs to be improved and the TMS of this system may lead to an increase in aircraft drag. The variable area actuation system demonstrates that it can significantly reduce the system design point and system size; while the localised hydraulic system is not as efficient as a centralised hydraulic system. Finally, a variable area actuation system powered by the centralised hydraulic systems is suggested for the FCS on civil aircraft and the Flying Crane. A variable area actuation system powered by localised hydraulic systems is recommended as the first step towards MEA and AEA in the future

Development of Motion Control Systems for Hydraulically Actuated Cranes with Hanging Loads

Automation has been used in industrial processes for several decades to increase efficiency and safety. Tasks that are either dull, dangerous, or dirty can often be performed by machines in a reliable manner. This may provide a reduced risk to human life, and will typically give a lower economic cost. Industrial robots are a prime example of this, and have seen extensive use in the automotive industry and manufacturing plants. While these machines have been employed in a wide variety of industries, heavy duty lifting and handling equipment such as hydraulic cranes have typically been manually operated. This provides an opportunity to investigate and develop control systems to push lifting equipment towards the same level of automation found in the aforementioned industries. The use of winches and hanging loads on cranes give a set of challenges not typically found on robots, which requires careful consideration of both the safety aspect and precision of the pendulum-like motion. Another difference from industrial robots is the type of actuation systems used. While robots use electric motors, the cranes discussed in this thesis use hydraulic cylinders. As such, the dynamics of the machines and the control system designmay differ significantly. In addition, hydraulic cranes may experience significant deflection when lifting heavy loads, arising from both structural flexibility and the compressibility of the hydraulic fluid. The work presented in this thesis focuses on motion control of hydraulically actuated cranes. Motion control is an important topic when developing automation systems, as moving from one position to another is a common requirement for automated lifting operations. A novel path controller operating in actuator space is developed, which takes advantage of the load-independent flow control valves typically found on hydraulically actuated cranes. By operating in actuator space the motion of each cylinder is inherently minimized. To counteract the pendulum-like motion of the hanging payload, a novel anti-swing controller is developed and experimentally verified. The anti-swing controller is able to suppress the motion from the hanging load to increase safety and precision. To tackle the challenges associated with the flexibility of the crane, a deflection compensator is developed and experimentally verified. The deflection compensator is able to counteract both the static deflection due to gravity and dynamic de ection due to motion. Further, the topic of adaptive feedforward control of pressure compensated cylinders has been investigated. A novel adaptive differential controller has been developed and experimentally verified, which adapts to system uncertainties in both directions of motion. Finally, the use of electro-hydrostatic actuators for motion control of cranes has been investigated using numerical time domain simulations. A novel concept is proposed and investigated using simulations.publishedVersio

Volume 3 – Conference

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group 8: Pneumatics Group 9 | 11: Mobile applications Group 10: Special domains Group 12: Novel system architectures Group 13 | 15: Actuators & sensors Group 14: Safety & reliabilit