Design of an electric servo rudder pedal system “Servo-motoren aansturen vanuit een virtuele realiteit”

Alwin Damman

Presentation overview

• Introduction • Faculties and Research facilities • HMI-laboratory

• Flight Control System • Performed solution • Performance analytical models • Evaluation experiment

• Control Strategy • Performance evaluation experiment

• Conclusions • Questions • New projects!

Introduction Flight Control System Performed solution Analytical models Evaluation experiment Conclusions Questions

Faculties

Technology Policy & Mgmt Architecture

Civil Engineering

& Geosciences

Electrical Engineering, Mathematics

and Computer Sciences

Industrial Design

Engineering

Aerospace Engineering

Applied Sciences

Mechanical, Maritime

and Materials

Engineering

Delft Research Based Initiatives

Research institutes

Supervisory Board

Executive Board

Operational Comm. support boards

faculty faculty faculty faculty faculty faculty faculty faculty

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Research Facilities

High-voltage engineering laboratory

Clean room (DIMES)

Wind tunnels

Water basins for coastal and marine research

Experimental Nuclear Reactor

Aerospace facilities (e.g. jet plane, flight simulator)

Radar and telecommunication test facilities

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Human-Machine Laboratory (HMILAB)

• fixed base simulator for either cars or aircraft • platform for experiments with control tasks or visual perception

research

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Simulation network HMI-lab

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Introduction • (previous) Hydraulic control loading

+ Perfect performance bandwidth

+ Excellent force/volume ratio

- Less safe

- High maintenance workload

- Much energy consumption

- Expensive

• (new) Design electrical control loading

• meet the same characteristics

• Velocity 1.3 m/s

• Force 667 N

• Sinusoidal cycling at 2 Hz max velocity

• Meet the requirements in bandwidth 25 Hz or higher (hard end stop

simulation)

• Durable/Sustainable software (open source or analogue system)

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Flight Control System • Flight Control System

• Primary controls • Secondary controls Rudder pedal system

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Rudder pedal system

• General force / displacement characteristics

• Dynamic characteristics • Typical airplane model, human model, wind model

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Selection size electric servo motor

• When excellent performance is required:

• Torque (select in the continuous area) • Velocity (select gear ratio as small as possible) • Load inertia ratio (select lowest load inertia Ri=Jm/Jl)

• Planetary gearbox

• Gear ratio is 1 to 30

• Reduced backless 3 arc min at the motor side

• Reduced inertia Jr = Jl / Rg2

• Preferred load factor max 5, realised is 1.08

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Performed solution

• Yaskawa 1.3 kW motor with gearbox 1:30

Introduction Flight Control System Performed solution Analytical models Evaluation experiment Conclusions Questions

Select drive communication

• Compax 3 => max 1 kHz DC cycle • (analog version is faster)

• Sigma 5 => max 8 kHz DC cycle

• (settling time drive 1.6 kHz)

• Actual system => runs on 2 kHz DC cycle

EtherCAT communication option (www.EtherCAT.org)

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Analytical models

• FCS simulated as a mass-spring-damper system

• M = Msim + Momd

• Msim = 68.04 kg

• Momd = 15 kg

• csim = 8900 N/m

• bsim = 886 Ns/m

• ζ = 0.7

• x = displacement of the rudder pedal in m

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Analysis of 3 hydraulic models

• Position loop

• Velocity loop

• Force loop

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Analysis of an electrical synchronous motor model

• Velocity loop

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Control Strategy

• Cyclic position

• Cyclic velocity

• Cyclic torque

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Control Strategy

• Which type of control loop is useful for the electric servo motor?

• accuracy torque servo pack > 3.0 % • accuracy additional torque sensor > 0.5 % • noise on torque signal • torque open loop

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Control Stategy

• Servo pack velocity loop closed loop • Servo pack torque loop low accurate (more useful to prevent

overload)

• Controller: • Calculate the reference velocity and feed to the servo pack • Measure the actual torque and feedback to the control loop as a

torque error

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Validation • Mechatronics control loop

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Software implementation

• DUECA middle layer software • Etherlab master, real-time linux kernel 2.6 • EtherCAT protocol

• Cyclic communication via PDO • DC 4 kHz industrial EtherCAT bus

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Ethercat Master

• Commercial Master solutions: • http://beckhoff.com/ • http://koenig-pa.com/

• Open source Master solutions: • Berlin University with TUE Project http://developer.berlios.de/ • KU Leuven http://git.mech.kuleuven.be/robotics/soem.git • Orocos and Ros http://www.orocos.org/ • Etherlab http://www.etherlab.org/

Several Master solutions, please check: http://en.wikipedia.org/wiki/EtherCAT

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Etherlab

• http://www.igh-essen.com/

• Ingenieurgemeinschaft IgH Gesellschaft für Ingenieurleistungen mbH Heinz-Bäcker-Str. 34 D-45356 Essen

• http://www.etherlab.org/ • IgH EtherCAT Master for Linux • Lifting Kursk

Relative easy, well documented

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Etherlab

• Open Source • Hard Real Time (RT kernel or PREEMT • Simulink/RTW® Code Generation • EtherCAT® Blockset • Multi-Client, -User, -Server, -Tasking • Flexibility • Windows® and Linux® Frontend • Documented examples e.g.

• EtherCAT mini.cpp

Features

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Validation

• Impression installation

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Validation

• Velocity at 2 Hz sinusoidal cycling with added mass

Disturbance at the peak

as a result of the pedal brake

rotation including added mass

(2x7,50 kg)

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System Identification

• 1 block 10 blocks with fade-in fade-out added

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• Preparation velocity bandwidth input signal

Validation

• Velocity bandwidth plot

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Validation

• Safety Rudder Pedal System

• Hardware layer • mechanical stop

• safety contactor emergency

• Servo pack layer • Hardware Base Block

• Limited proximity switches

• state flow and enable signal

• Software environment layer • Limitation on position, velocity, torque and energy

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Validation

Movie link local • normal video • HD quality video online • normal video

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Conclusions

• Acceptable bandwidth results • Choice of velocity control loop over low accurate torque

signal • Meet all the requirements • Improved safety environment

• More accurate torque sensor could improve the control loop • Specific motor properties are necessary to improve the

synchronous model

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Questions?

Introduction Flight Control System Performed solution Analytical models Evaluation experiment Conclusions Questions

New projects coming up! • New projects coming up:

• Electrical direct drive steering wheel • Electrical rudder pedals SIMONA • Electrical control column

Please don't hesitate to contact me if you have any further questions: a.damman@tudelft.nl

slideshare.net (search for: design of an electric servo rudder pedal system)

Introduction Flight Control System Performed solution Analytical models Evaluation experiment Conclusions Questions

Electrical direct drive steering wheel

• 45 Nm continuous torque • 200 Nm holding brake

• Low load inertia factor • Compact motor (z-direction)

Please don't hesitate to contact me if you have any further questions: a.damman@tudelft.nl

slideshare.net (search for: design of an electric servo rudder pedal)

Introduction Flight Control System Performed solution Analytical models Evaluation experiment Conclusions Questions