Design of a Magnetostrictive-Hydraulic Actuator Considering Nonlinear System Dynamics and Fluid-Structure Coupling.

摘要

Smart material electro-hydraulic actuators (EHAs) utilize fluid rectification via one-way check valves to amplify the small, high-frequency vibrations of certain smart materials into large motions of a hydraulic cylinder. Although the concept has been demonstrated in previously, the operating frequency of smart material EHA systems has been limited to a small fraction of the available bandwidth of the driver materials. The focus of this work is to characterize and model the mechanical performance of a magnetostrictive EHA considering key system components: rectification valves, smart material driver, and fluid-system components, leading to an improved actuator design relative to prior work.;The one-way valves were modeled using 3-D finite element analysis, and their behavior was characterized experimentally by static and dynamic experimental measurement. Taking into account the effect of the fluid and mechanical conditions applied to the valves within the pump, the dynamic response of the valve was quantified and applied to determine rectification bandwidth of different valve configurations. A novel miniature reed valve, designed for a frequency response above 10~kHz, was fabricated and tested within a magnetostrictive EHA.;The nonlinear response of the magnetostrictive driver, including saturation and hysteresis effects, was modeled using the Jiles-Atherton approach to calculate the magnetization and the resulting magnetostriction based on the applied field calculated within the rod from Maxwell's equations.;The dynamic pressure response of the fluid system components (pumping chamber, hydraulic cylinder, and connecting passages) was measured over a range of input frequencies. For the magnetostrictive EHA tested, the peak performance frequency was found to be limited by the fluid resonances within the system.;A lumped-parameter modeling approach was applied to model the overall behavior of a magnetostrictive EHA, incorporating models for the reed valve response, nonlinear magnetostrictive behavior, and fluid behavior (including inertia and compliance). This model was validated by experimental study of a magnetostrictive EHA with a reduced volume manifold. The model was subsequently applied to design a compact magnetostrictive EHA for aircraft applications.;Testing of the system shows that the output performance increases with frequency up to a peak unloaded flow rate of 100 cm3/s (6.4 cu in/s) at 1200 Hz, which is a 100% to 500% increase over previous state-of-the-art systems. A blocked differential pressure of 12.1 MPa (1750 psi) was measured, resulting in a power capacity of 310 W, more than 100 W higher than previously reported values. The design and modeling approach used to scale up the performance to create a compact aircraft EHA can also be applied to reduce the size and weight of smart material EHAs for lower power level applications.