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NDIA-6240 - 2006 Stephen Smith
Slide 1
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Joint Undersea Warfare Technology Fall ConferenceUS Naval Submarine Base New London
Groton, ConnecticutSeptember 14, 2006
Electro Hydrostatic ActuatorsFor Control of Undersea Vehicles
Presented by: Jerry IrvingWritten by: Stephen Smith, P.E.
NDIA-6240 - 2006 Stephen Smith
Slide 2
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Introduction
• This presentation will cover– Principals of Electro Hydrostatic Actuator (EHA)
operation– History of EHA’s– EHA Advantages– EHA Disadvantages– Two Fault Tolerant EHA System– Conclusions– Recommendations for Future Studies
NDIA-6240 - 2006 Stephen Smith
Slide 3
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Introduction
• The Navy desires to convert from hydraulic actuation to electric actuation
• Submarines are in the early stages of converting the ship’s hydraulic actuators to electric
• Full benefits of the conversion can only be realized when the hydraulic plant is eliminated.
• Some applications may not lend themselves to conversion due to envelope, force or other operating restrictions
• In these cases, electro-hydrostatic actuation (EHA) could provide a “more electric” approach.
NDIA-6240 - 2006 Stephen Smith
Slide 4
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Typical Hydraulic System
Reservior
Motion Controller
Motor Starter
ServovalvesCheck valves
Hydraulic Motor
Linear Actuator
Manifold
ChillerRetrun Filter
High Pressure Filter
Pump motor & pump
Generic Hydraulic System
Reservior vent
NDIA-6240 - 2006 Stephen Smith
Slide 5
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Electro Hydraulic Features
•Mature technology with skilled technicians
•Low to high pressure systems
–Allows matching of pressure/flow to address envelop and output force
•“Battle”/emergency conditions
–Allows operation of critical functions
–Moves to safe position on power loss
NDIA-6240 - 2006 Stephen Smith
Slide 6
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Electro-Mechanical Actuation System
• Actuator– Brushless DC Motor
– Gear Set
– Ball or Roller-Screw Output– LVDT Position Feedback
• Controller– Servo Control Board
• Closed Loop Control
• Command and Telemetry Interface
• Signal conditioning
– Gate Drive Board• Output Stage to drive electric motor
– Power Supply Board• Low voltage power supply• EMI Power Filter
• Electrical Cables
NDIA-6240 - 2006 Stephen Smith
Slide 7
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Electro-Hydrostatic Actuation System
• Actuator– Brushless DC Motor– Fixed Displacement Hydraulic Pump– Hydraulic Piston-Cylinder Assembly– LVDT Position Feedback
• Controller– Servo Control Board
• Closed Loop Control• Command and Telemetry Interface • Signal conditioning
– Gate Drive Board• Output Stage to drive electric motor
– Power Supply Board• Low voltage power supply• EMI Power Filter
• Electrical Cables
NDIA-6240 - 2006 Stephen Smith
Slide 8
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Actuation System Heritage
1951 Moog FoundedHydraulic Servovalve
• Minuteman• Polaris• Atlas• Saturn• Terrier Tartar• Pershing• Titan II, III
• Space Shuttle
SRB & Orbiter
• Trident C4
• Peacekeeper
• Titan
• Jupiter
• Atlas
1982 Entered Electro-mechanical Actuation Market
• Ariane 4
• Ariane 5 (EM)
• Trident D5
• SM2 (EM)
• SRAM II (EM)
• Titan IV• Atlas III/V (EM)• Delta 4 (EM)• Delta IV SRB• Pegasus (EM)• Kistler K-1 (EM)• GMD (EM)• X-38 CRV (2FT EM)
1999 – Developed Two-Fault Tolerant Electro-mechanical Actuation.
2000 – Developed Electro-hydrostatic Actuation
2002 – Develop Two-Fault Tolerant Electro-hydrostatic Actuation
1950’s 1960’s 1970’s 1980’s 1990’s
• NGLT
• 2GRLV (2FT EHA)
• X-43A (EM)
• Next Gen ICBM
2000’s
1951 Moog FoundedHydraulic Servovalve
• Minuteman• Polaris• Atlas• Saturn• Terrier Tartar• Pershing• Titan II, III
• Space Shuttle
SRB & Orbiter
• Trident C4
• Peacekeeper
• Titan
• Jupiter
• Atlas
1982 Entered Electro-mechanical Actuation Market
• Ariane 4
• Ariane 5 (EM)
• Trident D5
• SM2 (EM)
• SRAM II (EM)
• Titan IV• Atlas III/V (EM)• Delta 4 (EM)• Delta IV SRB• Pegasus (EM)• Kistler K-1 (EM)• GMD (EM)• X-38 CRV (2FT EM)
1999 – Developed Two-Fault Tolerant Electro-mechanical Actuation.
2000 – Developed Electro-hydrostatic Actuation
2002 – Develop Two-Fault Tolerant Electro-hydrostatic Actuation
1950’s 1960’s 1970’s 1980’s 1990’s
• NGLT
• 2GRLV (2FT EHA)
• X-43A (EM)
• Next Gen ICBM
2000’s
NDIA-6240 - 2006 Stephen Smith
Slide 9
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
F18 Stabilator EHA
• 30,000 lbs nominal stall force
• 400 in/sec2 maximum no-load acceleration
• 8.5 in/sec maximum no-load velocity
• 7.12 in total stroke (34.0 in pin-to-pin mid-stroke)
• 23 hp maximum output power (39 hp corner)
• Easily met 5 Hz response requirement (capable of much higher)
• >225,000 lbs/in infinite-frequency stiffness (one actuator piston bypassed)
NDIA-6240 - 2006 Stephen Smith
Slide 10
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
EHA Advantages
• Power on Demand – No power required when unit is not in use. Improves
system level efficiency. – Pressure is only developed in response to static loads
or accelerations
• Independent of the ships hydraulic system.– Self-contained hydraulic supply & return porting– Limited fluid contamination & leakage concerns– Capable of operating at higher internal pressures
• No backlash, lost motion as with geared systems
• Heritage hydraulic piston cylinder assembly
NDIA-6240 - 2006 Stephen Smith
Slide 11
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
EHA Advantages
• “Gear reduction” is obtained by reducing the size of the
pump, facilitating the use of small, low-torque servomotors.
• Snubbing is easily handled with relief valves.
• Mechanical packaging is more flexible.
– Facilitates a distributed control surface arrangement
• Can be made to be Fault Tolerant
– Allows depth control to be triple redundant
NDIA-6240 - 2006 Stephen Smith
Slide 12
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
EHA Advantages
• Redundancy and fail-safe features have minimal impact on
cost, weight, envelope, and reliability.
– Float and Lock of control surface
• PM Motor allows variable speed operation of fixed
displacement pump.
• Lower maintenance
• Improved reliability
– Greater control authority under fault conditions
• Lower cost of ownership
NDIA-6240 - 2006 Stephen Smith
Slide 13
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
EHA Disadvantages
• Lower efficiency due to multiple power conversions
• Pump sizing may result in undesirable weight and envelope.
• Reservoir sizing critical.• Hydraulic fluid is not completely removed from
the ship. • Varying pump/motor operating conditions (i.e.
varying speed and pressure).
NDIA-6240 - 2006 Stephen Smith
Slide 14
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Two-Fault Tolerant EHA System
Thrust Vector Control
NDIA-6240 - 2006 Stephen Smith
Slide 15
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Two-Fault Tolerant EHA System
• Quad Bi-Directional Electric Motor-Hydraulic Pump Control– Flow summed from fixed displacement
hydraulic pumps– Full performance produced after two faults
(two active channels)
• Quad Channel LVDT for Actuator Position
Control Electronics UnitMotor Control Unit
Quadruplex EH Actuator
NDIA-6240 - 2006 Stephen Smith
Slide 16
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Two-Fault Tolerant EHA System
Controller Architecture• 4 Independent Motor Control Units (one per channel)• 4 Independent Control Electronics Units (one per
channel)• Independent Channel Pressure Transducers
– Load resonance damping
• Independent Resolver Commutation– Closed loop motor velocity control
• Quad LVDT Provides Independent Position Loop Closure• Cross-Port Load Relief Valves for Transient Motor Start• Blocking Valves Isolate Failed Channels
– Eliminating potential drag torque from failed channel– Can be used to maintain the last commanded position
NDIA-6240 - 2006 Stephen Smith
Slide 17
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Two-Fault Tolerant EHA System
RESERVOIRRESERVOIR RESERVOIR RESERVOIR
MANIFOLD
MCU
CEUChannel 1
3
BLOCKING VALVE
PUMP MOTOR R
PCASEDRAIN
1553
DISCRETESHUTDOWN
BC
RT
1553FCC
MCU
CEUChannel 2
3
BLOCKING VALVE
PUMP MOTOR R
PCASEDRAIN
1553
DISCRETESHUTDOWN
BC
RT
MCU
CEUChannel 3
3
BLOCKING VALVE
PUMP MOTOR R
PCASEDRAIN
1553
DISCRETESHUTDOWN
BC
RT
MCU
CEUChannel 4
3
BLOCKING VALVE
P
PUMP MOTOR R
PCASEDRAIN
1553
DISCRETESHUTDOWN
BC
RT
QUADLVDT
270 Va
28 Vd28 Vc28 Vb28 Va
EMIFilter
270 Vb
EMIFilter
270 Vc
EMIFilter
270 Vd
EMIFilter
RT RTRTRT
BC
CCDL CCDL
CCDLCCDLCCDL
P
TELEMETRY
CYLINDERPRESSURE
CYLINDERPRESSURE
LEVELSENSE
LEVELSENSE
LEVELSENSE
LEVELSENSE
CCDL
RTD RTD RTD RTD
RTD RTD RTD RTD
IVHM IVHM IVHM IVHM
PPPPPPP
P
TELEMETRY
NDIA-6240 - 2006 Stephen Smith
Slide 18
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Two-Fault Tolerant EHA System• Flow output summed
equally over active channel quantity
• FDIR Step Response (4 to 3 to 2 Channel)– Motor-Pump Assembly
rotor speed as channel faults are detected and isolated
– Motor Current Draw also due to higher winding losses
– Position command maintained
– Actuator output load maintained
Actuator Step Position Command
0-Fault, 4-Channel Motor-Pump Velocity Feedback
1-Fault, 3-Channel Motor-Pump Velocity Feedback
2-Fault, 2-Channel Motor-Pump Velocity Feedback
2ndC
hann
el F
ailu
re
1stC
hann
el F
ailu
re
Actuator Step Position Command
0-Fault, 4-Channel Motor-Pump Velocity Feedback
1-Fault, 3-Channel Motor-Pump Velocity Feedback
2-Fault, 2-Channel Motor-Pump Velocity Feedback
2ndC
hann
el F
ailu
re
1stC
hann
el F
ailu
re
NDIA-6240 - 2006 Stephen Smith
Slide 19
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Two-Fault Tolerant EHA System
1-Fault, 3-Channel Motor-Pump Velocity Feedback
2-Fault, 2-Channel Motor-Pump Velocity Feedback
2ndC
hann
el D
ropp
ed
Cross-Channel Velocity Mis-Match Identified
1-Fault, 3-Channel Motor-Pump Velocity Feedback
2-Fault, 2-Channel Motor-Pump Velocity Feedback
2ndC
hann
el D
ropp
ed
Cross-Channel Velocity Mis-Match Identified
NDIA-6240 - 2006 Stephen Smith
Slide 20
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Two-Fault Tolerant EHA SystemParameter TVC System Capability
Actuator Null Length 51.37 in Total Stroke >10 in Stall Force 75,000 lbf Power Point Slew Rate 5 in/sec Power Point Force Output 66,000 lbf Peak Power Output 50 HP Impulse Load (for 50 msec) 160,000 lbf Supply Voltage <270 VDC TVC Duty Cycle Duration per Mission ( > 100 Flight Missions)
500 sec
Frequency Response (@ p-p cmd) 0.42 in Frequency Response (-3db amplitude) 6 Hz Hydraulic Piston Area 24.6 in² Hydraulic Pump Displacement (per unit) 0.410 in3/rev Hydraulic Pump Mechanical Efficiency 0.85 @ power point Hydraulic Pump Volumetric Efficiency 0.88 @ power point Motor Current Limit 140 Amps rms (200 Amps peak) Electrical Interface Mil-Std 1553 Serial
NDIA-6240 - 2006 Stephen Smith
Slide 21
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Two-Fault Tolerant EHA System
Parameter NormalOperation 2-Failure Operation Power Point Operation
• Slew Rate • Force Output • Pressure Differential @ Pump • Motor Shaft Torque • Motor Speed • Motor Peak Current
• 5.0 in/sec • 66,000 lbf • 2798 psid • 205 in-lbf • 5343 rpm • 148 Amps peak
• 5.0 in/sec • 66,000 lbf • 3098 psid • 236 in-lbf • 10229 rpm • 178 Amps peak
NDIA-6240 - 2006 Stephen Smith
Slide 22
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Conclusions
• “More” Electric Actuation is a viable alternative to mechanical feedback and servo-valve commanded hydraulic actuation.
• Aerospace industry has moved to “more” electric actuation systems– Simplify integration and support– Reduce life cycle cost
• Technology development efforts have demonstrated capability to Technology Readiness Level (TRL) of 6
• Decision to implement “more” electric actuation will be a system-level trade including power systems
NDIA-6240 - 2006 Stephen Smith
Slide 23
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Future Studies
• Noise Evaluation– Pump Configurations– Motors– Controllers
NDIA-6240 - 2006 Stephen Smith
Slide 24
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Future Studies
• Pump Configurations– Slower Speeds– Piston Pump
• Tend to be noisy
– Screw Pump • Typically unidirectional
– Gear Pump – Vane Pump
• Inherently quiet and bi-directional
NDIA-6240 - 2006 Stephen Smith
Slide 25
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Motor Design
• High Torque Density
• Slow Speed– Six step Trapezoidal BEMF – relatively noisy– Sinusoidal BEMF – smooth commutation
-1.5
-1
-0 .5
0
0 .5
1
1.5
Classical Sine WaveSix Step Sine Wave
NDIA-6240 - 2006 Stephen Smith
Slide 26
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Controller Design
• Sine Motor Drive• Compliant to Mil-Std-1399 Class 1 Power
– Harmonic Requirements– Mil-Std-461 Compliance
• High Fidelity Output Current Control– Designed to meet harmonic, distortion, offset, and imbalance
requirements that are required to provide submarine level acoustic requirements
• Small Size and Weight– Allows for remote or integral packaging approach
• Rugged Design Suitable for Shipboard– Shock, Environments (MIL-S-901D) – Designed with Naval requirements in mind rather than upgraded
from an industrial design
NDIA-6240 - 2006 Stephen Smith
Slide 27
Joint Undersea Warfare Technology Fall ConferenceSeptember 11-14, 2006 US Naval Submarine Base New London
Electro Hydrostatic Actuators
Thank You
Questions
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