Electromechanical Actuation For Launch Vehicles - Moog Inc.
ELECTROMECHANICAL ACTUATIONFORLAUNCH VECHICLESPresented By:Mark A. DavisMoog Inc.37th AIAA/ASME/SAE/ASEEJoint Propulsion ConferenceSalt Lake City, UtahJuly 10, 2001
Introduction This paper describes recent developments in Electromechanical Actuationapplied to Launch Vehicles. The following topics are discussed:4 Electromechanical (EM) Actuation System Design4 Comparison of Electromechanical and Electrohydraulic ActuationSystems4 High Power EM Thrust Vector Control (TVC) Systems4 Redundant EM TVC Systems4 Propellant Valve Electromechanical ActuationMOOG
Electromechanical TVC Actuation SystemMOOG
Electromechanical Servoactuator SystemBATTERY VOLTAGEA NCURRENTCONTROLLERPULSEWIDTHMODULATORB C BRUSHLESSMOTORA AB BC CA-GEARREDUCTIONB-BALLSCREWOUTPUTPOSITIONC-MOTOR PHASE CURRENTRESOLVERMOTOR POSITIONMOTOR VELOCITYRESOLVERSIGNALCONVERTERACTUATOR POSITIONACEXCITERLVDTDEMODULATORL5112.DRWPermanent Magnet Brushless MotorSinusoidal Motor DriveMOOG
Comparison of EM and EH Actuation Systems Advantages of Conventional Electrohydraulic Systems4 Mature Technology4 High Reliability4 Can Use Relief Valves to Limit Piston Force Effective to Handle Impulse Load4 Continuous Stall Torque Capability4 High Acceleration Capability4 No EMI Generation4 Simple, Low Power Electronics4 Mature Redundancy ImplementationMOOG
Comparison of EM and EH Actuation Systems Advantages of Electromechanical Systems4 Excellent Long-Term Storability4 Easy Checkout4 Easy Installation4 Low Maintenance4 Minimal Operations Cost4 Low Quiescent Power4 No Fluid Leakage4 No Concern for Fluid Contamination4 High Reliability4 Lower Weight than Hydraulic Blowdown TVC SystemsMOOG
Limitation of EM Actuation SystemsTypical EM System Frequency Response LimitsMOOG
38 HP EM TVC ACTUATOR Dual Torque-Summed MotorsOutput Travel . /- 5.5 inImpulse Load . 100,000 lbStall Force 55,000 lbAcceleration .60 in/sec 2Rated Power .38 HPDuty Cycle 10 minOutput Force .48,000 lbAverage Load 15,000 lbOutput Velocity .5.2 in/sec Supply Voltage .270 VDCFull Performance with one motorMOOG
38 HP EM Actuation SystemForce-Velocity Test Data On SSME Test FixtureMOOG
38 HP EM Actuation SystemFrequency Response Test Data On SSME SimulatorLoad Position Response ( /- 2 % COMMAND)MOOG
38 HP EM Actuation SystemFrequency Response Test Data On SSME SimulatorLoad Position Response ( /- 5 % Command)MOOG
Controller Controller Critical to Performance of EM Systems Breadboard Controller Used to Demonstrate 38 HP EM TVC System Development of Flight Worthy High Power EM ControllerMOOG
Moog DSP-Based Digital Controller Digital Loop ClosureIGBT Power Stage320 VDC Maximum Supply Voltage200 Amps Peak Motor Phase CurrentVector Control / Sinusoidal Motor DriveDemonstrated with a 20 HP EM TVC ActuatorMOOG
EM TVC Actuators For Large Solid Rocket MotorsTwo TVC Actuators Have Been DemonstratedStall Force (lb)Stroke (in)Length (in)Power PointVelocity (in/sec)Force (lb)Weight (lb)Voltage (VDC)12 HP21 HP4600 /- 1.9215.531,000 /- 1.517.0204000165.8524,00075280280--- Brushless PM Motor--- Ballscrew--- LVDTMOOG
Upper Stage Redundant EM TVC Systems Flight Proven Active-Standby Redundancy Full Performance with one motor operating Six-Step Motor DriveMOOG
Upper Stage Redundant EM TVC SystemsTypical Performance SummaryStrokeStall ForceNo-load VelocityOutput PowerFrequency ResponseActuator LengthSupply VoltageElectrical InterfaceActuator WeightController Weight /- 0.75 in2000 lb3.0 in/sec0.4 HP90 deg phase @ 4.3 Hz23.25 in28 VDCMIL-STD-155317 lb each27 lbMOOG
Upper Stage TVC System Block DiagramActive-Standby RedundancyFull Performance With One Motor OperatingMOOG
Propellant Valve EM Actuation Systems Dual Redundant Brushless Motors Harmonic Drive Provides Rotary Output Redundant ControllerTypical PerformanceStroke . /- 70 degOutput Power .0.05 HPVelocity .340 deg/secTorque .60 in-lbActuator Weight .8.2 lbController Weight .21.3 lbVoltage .28 VDCMOOG
Summary Electromechanical Actuation is a Reality for Launch Vehicles4 Flight Proven EM TVC Systems on Upper Stages High Power Applications (Booster TVC Systems)4 EM Actuation is a Viable Alternative to Electrohydraulic Actuation4 High Power EM TVC Systems are Flight Ready4 EM TVC Systems Offer the Potential of: Lower Life Cycle Cost Lower WeightMOOG
4High Power EM Thrust Vector Control (TVC) Systems 4Redundant EM TVC Systems 4Propellant Valve Electromechanical Actuation. . A B C A- B- C-A A-B B-C C-MODULATOR WIDTH PULSE CONTROLLER CURRENT COMMUTATION SERVO ELECTRONIC CONVERTER SIGNAL RESOLVER DEMODULATOR RESOLVER REDUCTION GEAR SCREW BALL EXCITER AC LVDT . 4Mature Redundancy .
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