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

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

2. 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

3. Faculties
Supervisory Board
boards
faculty
faculty
faculty
Architecture
Civil
Engineering
&
Geosciences
Electrical
Engineering,
Mathematics
and
Computer
Sciences
Executive Board
Operational Comm.
faculty
support
faculty
faculty
faculty
Aerospace
Engineering
Technology
Policy &
Mgmt
Applied
Sciences
faculty
Delft Research
Based Initiatives
Industrial
Design
Engineering
Research
institutes
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions
Mechanical,
Maritime
and
Materials
Engineering

4. 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
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

5. Human-Machine Laboratory
(HMILAB)
• fixed base simulator for either cars or aircraft
• platform for experiments with control tasks or visual perception
research
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

6. Simulation network HMI-lab
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

7. 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)
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

8. Flight Control System
• Flight Control System
• Primary controls
• Secondary controls
Rudder pedal system
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

9. Rudder pedal system
• General force / displacement characteristics
• Dynamic characteristics
• Typical airplane model, human model, wind model
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

10. 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
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

11. Performed solution
• Yaskawa 1.3 kW motor with gearbox 1:30
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

12. Select drive communication
EtherCAT communication option (www.EtherCAT.org)
• 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
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

13. 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
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

14. Analysis of 3 hydraulic models
• Position loop
• Velocity loop
• Force loop
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

15. Analysis of an electrical
synchronous motor model
• Velocity loop
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

16. Control Strategy
• Cyclic position
• Cyclic velocity
• Cyclic torque
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

17. 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
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

18. 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
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

19. Validation
• Mechatronics control loop
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

20. 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
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

21. Ethercat Master
Several Master solutions, please check:
http://en.wikipedia.org/wiki/EtherCAT
• 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/
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

22. Etherlab
Relative easy, well documented
• 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
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

23. Etherlab
Features
•
•
•
•
•
•
•
•
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
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

24. Validation
• Impression installation
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

25. 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)
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

26. System Identification
• Preparation velocity bandwidth input signal
• 1 block
10 blocks with fade-in fade-out added
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

27. Validation
• Velocity bandwidth plot
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

28. 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
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

29. Validation
Movie link
local
• normal video
• HD quality video
online
• normal video
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

30. 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
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

31. Questions?
Introduction  Flight Control System  Performed solution  Analytical models  Evaluation experiment  Conclusions  Questions

32. 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

33. 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