Abstract
The development and validation of prognostic algorithms and digital twins for Electromechanical Actuators (EMAs) requires datasets of operating parameters that are not commonly available. In this context, we are assembling a test bench able to simulate different operating scenarios and environmental conditions for an EMA in order to collect the operating parameters of the actuator both in nominal conditions and under the effect of incipient progressive faults. This paper presents the design and manufacturing of a planetary gearbox for the EMA test bench. Mechanical components were conceived making extensive use of Fused Deposition Modelling (FDM) additive manufacturing and off-the-shelf hardware in order to limit the costs and time involved in prototyping. Given the poor mechanical properties of the materials commonly employed for FDM, the gears were not sized for the maximum torque of the electric motor, and a secondary torque path was placed in parallel of the planetary gearbox to load the motor through a disc brake. The architecture of the gearbox allowed a high gear ratio within a small form factor, and a bearingless construction with a very low number of moving parts.
Highlights
Electromechanical Actuators (EMAs) are devices intended to convert electrical power into mechanical power to achieve closed-loop control of the position of a mechanical component
EMAs are employed for secondary flight controls of last-generation commercial and fighter aircraft, according to the all-electric and more-electric aircraft paradigms [8,9,10,11], as well as for primary flight controls of small Unmanned Aerial Vehicles (UAVs)
In this paper, we propose the design of an electromechanical test bench intended to simulate the operation of an actuator in different conditions, and under the effect of different fault modes
Summary
Electromechanical Actuators (EMAs) are devices intended to convert electrical power into mechanical power to achieve closed-loop control of the position of a mechanical component. The same risk is virtually inexistent in hydraulic systems [12,13,14] To address this issue and ease the diffusion of EMAs for aerospace applications, advanced risk mitigation strategies are needed. Wang et al [19] propose a review of condition monitoring techniques applied to planetary gearboxes Such tools rely either on data acquired from the operation of systems, or on detailed simulation models. As highlighted by Djeziri et al [20], large experimental datasets on operating parameters of EMAs are not commonly available, and databases would be required, including both the effects of faults on system operation and the propagation of damages For this reason, in this paper, we propose the design of an electromechanical test bench intended to simulate the operation of an actuator in different conditions, and under the effect of different fault modes. The rate of propagation of damages can be measured as well, it may be not completely representative of real operating scenarios due to different materials, manufacturing technologies and environmental conditions (e.g., externally induced vibrations and load factors) that are difficult to quantify or to reproduce on a static test bench
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