Research

14 pages, 8266 KiB

Open AccessArticle

Design and Analysis of Brake-by-Wire Unit Based on Direct Drive Pump–Valve Cooperative

by Peng Yu, Zhaoyue Sun, Haoli Xu, Yunyun Ren and Cao Tan

Actuators 2023, 12(9), 360; https://doi.org/10.3390/act12090360 - 14 Sep 2023

Viewed by 1179

Aiming at the requirements of distributed braking and advanced automatic driving, a brake-by-wire unit based on a direct drive pump–valve cooperative is proposed. To realize the wheel cylinder pressure regulation, the hydraulic pump is directly driven by the electromagnetic linear actuator coordinates with [...] Read more.

Aiming at the requirements of distributed braking and advanced automatic driving, a brake-by-wire unit based on a direct drive pump–valve cooperative is proposed. To realize the wheel cylinder pressure regulation, the hydraulic pump is directly driven by the electromagnetic linear actuator coordinates with the active valve. It has the advantages of rapid response and no deterioration of wheel side space and unsprung mass. Firstly, by analyzing the working characteristics and braking performance requirements of the braking unit, the key parameters of the system are matched. Then, in order to ensure the accuracy of the simulation model, the co-simulation model of the brake unit is established based on the Simulink-AMESim co-simulation platform. Then, the influence law of key parameters on the control performance is analyzed. Finally, the experimental platform of the brake unit is established. The accuracy of the co-simulation model and the feasibility of the brake-by-wire unit based on direct drive pump–valve cooperative are verified through the pressure control experiment and ABS simulation, which shows that the braking unit has good dynamic response and steady-state tracking effect. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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14 pages, 4124 KiB

Open AccessArticle

Research on Stability Control Technology of Hazardous Chemical Tank Vehicles Based on Electromagnetic Semi-Active Suspension

by Jianguo Dai, Youning Qin, Cheng Wang, Jianhui Zhu and Jingxuan Zhu

Actuators 2023, 12(8), 333; https://doi.org/10.3390/act12080333 - 17 Aug 2023

Cited by 1 | Viewed by 1012

Abstract

Liquid sloshing in the tank can seriously affect the stability of hazardous chemical tanker trucks during operation. To this end, this paper proposes a solution based on an electromagnetic semi-active suspension system to prevent chemical spills and ensure safe driving of hazardous chemical [...] Read more.

Liquid sloshing in the tank can seriously affect the stability of hazardous chemical tanker trucks during operation. To this end, this paper proposes a solution based on an electromagnetic semi-active suspension system to prevent chemical spills and ensure safe driving of hazardous chemical tank vehicles. A comprehensive investigation was conducted across four domains: theoretical research, simulation model establishment, co-simulation platform construction, and simulation data analysis. Three fuzzy controllers were used to suppress the vibration of the tank vehicles, and a simulation study of the stability control of the tank vehicles under electromagnetic semi-active suspension was carried out. The results show that the electromagnetic semi-active suspension can significantly reduce the vertical, pitch, and roll vibrations of the tank vehicles by 17.60%, 25.78%, and 27.86%, respectively. The research results of this paper are of great significance for improving the safety and stability of hazardous chemical tanker trucks. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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12 pages, 7826 KiB

Open AccessArticle

Magnetic Poles Position Detection of Permanent Magnet Linear Synchronous Motor Using Four Linear Hall Effect Sensors

by Bin Zhou and Cong Huang

Actuators 2023, 12(7), 269; https://doi.org/10.3390/act12070269 - 30 Jun 2023

Cited by 1 | Viewed by 1442

Abstract

Magnetic pole position detection is the core of the closed-loop control system of the permanent magnet linear synchronous motor (PMLSM), and its position estimation accuracy directly affects control performance and dynamic response speed. In order to solve the problem of the increased estimation [...] Read more.

Magnetic pole position detection is the core of the closed-loop control system of the permanent magnet linear synchronous motor (PMLSM), and its position estimation accuracy directly affects control performance and dynamic response speed. In order to solve the problem of the increased estimation error of magnetic pole position caused by magnetic field distortion at the end of PMLSM while also considering the cost of control hardware, the paper uses four linear Hall sensors as magnetic pole position detection components and adopts an optimized estimation algorithm to improve the dynamic performance of the motor. Firstly, a numerical simulation of the magnetic field of poles was conducted using Ansoft Maxwell software, and combined with theoretical analysis, the optimal installation position range of four linear Hall orthogonal placements relative to the motor was obtained. Meanwhile, based on the existing vector tracking position observer, an improved observer detection model is proposed. The Matlab/Simulink software was used to compare the Hall-based detection model with the Hall-based improved observer detection model, verifying the feasibility of the improved detection algorithm. Finally, the rationality of the spatial layout design of linear Hall and the feasibility of improving the estimation algorithm were verified through experiments. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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14 pages, 5262 KiB

Open AccessArticle

Evaluation and Simulation Analysis of Mixing Performance for Gas Fuel Direct Injection Engine under Multiple Working Conditions

by Hongchen Wang, Tianbo Wang, Jing Chen, Lanchun Zhang, Yan Zheng, Li Li and Yanyun Sun

Actuators 2023, 12(6), 239; https://doi.org/10.3390/act12060239 - 08 Jun 2023

Viewed by 1078

Abstract

Gas fuel direct injection (DI) technology can improve the control precision of the in-cylinder mixing and combustion process and effectively avoid volumetric efficiency reduction in a compressed natural gas (CNG) engine, which has been a tendency. However, compared with the port fuel injection [...] Read more.

Gas fuel direct injection (DI) technology can improve the control precision of the in-cylinder mixing and combustion process and effectively avoid volumetric efficiency reduction in a compressed natural gas (CNG) engine, which has been a tendency. However, compared with the port fuel injection (PFI) method, the former’s mixing path and duration are shortened greatly, which often leads to poor mixing uniformity. What is worse, the in-cylinder mixing performance would be seriously affected by engine working conditions, such as engine speed and load. Based on this situation, the fluid mechanics software FLUENT is used in this article, and the computational fluid dynamics (CFD) model of the injection and mixing process in a gas-fueled direct injection engine is established. A quantitative evaluation mechanism of the in-cylinder mixing performance of the CNG engine is proposed to explore the influencing rule of different engine speeds and loads on the mixing process and performance. The results indicate that phase space analysis can accurately reflect the characteristics of the mixture mixing process. The gas fuel mixture rapidly occupies the cylinder volume in the injection stage. During the transition stage, the gas fuel mixture is in a highly transient state. The diffusion stage is characterized by the continuous homogenization of the mixture. The in-cylinder mixing performance is linearly dependent on the engine’s working condition in the phase space. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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17 pages, 762 KiB

Open AccessArticle

Currents Analysis of a Brushless Motor with Inverter Faults—Part II: Diagnostic Method for Open-Circuit Fault Isolation

by Cristina Morel, Baptiste Le Gueux, Sébastien Rivero and Saad Chahba

Actuators 2023, 12(6), 230; https://doi.org/10.3390/act12060230 - 02 Jun 2023

Cited by 1 | Viewed by 880

Abstract

In this paper, a brushless motor with a three-phase inverter is investigated under healthy and multiple open-circuit faults. The occurrence of faults in an inverter will lead to atypical characteristics in the current measurements. This is why many usual entropies and multiscale entropies [...] Read more.

In this paper, a brushless motor with a three-phase inverter is investigated under healthy and multiple open-circuit faults. The occurrence of faults in an inverter will lead to atypical characteristics in the current measurements. This is why many usual entropies and multiscale entropies have been proposed to evaluate the complexity of the output currents by quantifying such dynamic changes. Among this multitude of entropies, only some are able to differentiate between healthy and faulty open-circuit conditions. In addition, another selection is made between these entropies in order to improve diagnostic speed. After the fault detection based on the mean values, the open-circuit faults are localized based on the fault diagnostic method. The simulation results ensure the ability of these entropies to detect and locate open-circuit faults. Moreover, they are able to achieve fault diagnostics for a single switch, double switches, three switches, and even four switches. The diagnostic time to detect and to isolate faults is between 10.85 ms and 13.67 ms. Then, in order to prove the ability of the fault diagnostic method, a load variation is performed under the rated speed conditions of the brushless motor. The validity of the method is analyzed under different speed values for a constant torque. Finally, the fault diagnostic method is independent from power levels. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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31 pages, 1576 KiB

Open AccessArticle

Currents Analysis of a Brushless Motor with Inverter Faults—Part I: Parameters of Entropy Functions and Open-Circuit Faults Detection

by Cristina Morel, Sébastien Rivero, Baptiste Le Gueux, Julien Portal and Saad Chahba

Actuators 2023, 12(6), 228; https://doi.org/10.3390/act12060228 - 31 May 2023

Cited by 2 | Viewed by 1157

Abstract

In the field of signal processing, it is interesting to explore signal irregularities. Indeed, entropy approaches are efficient to quantify the complexity of a time series; their ability to analyze and provide information related to signal complexity justifies their growing interest. Unfortunately, many [...] Read more.

In the field of signal processing, it is interesting to explore signal irregularities. Indeed, entropy approaches are efficient to quantify the complexity of a time series; their ability to analyze and provide information related to signal complexity justifies their growing interest. Unfortunately, many entropies exist, each requiring setting parameter values, such as the data length N, the embedding dimension m, the time lag

τ

, the tolerance r and the scale s for the entropy calculation. Our aim is to determine a methodology to choose the suitable entropy and the suitable parameter values. Therefore, this paper focuses on the effects of their variation. For illustration purposes, a brushless motor with a three-phase inverter is investigated to discover unique faults, and then multiple permanent open-circuit faults. Starting from the brushless inverter under healthy and faulty conditions, the various possible switching faults are discussed. The occurrence of faults in an inverter leads to atypical characteristics of phase currents, which can increase the complexity in the brushless response. Thus, the performance of many entropies and multiscale entropies is discussed to evaluate the complexity of the phase currents. Herein, we introduce a mathematical model to help select the appropriate entropy functions with proper parameter values, for detecting open-circuit faults. Moreover, this mathematical model enables to pick up many usual entropies and multiscale entropies (bubble, phase, slope and conditional entropy) that can best detect faults, for up to four switches. Simulations are then carried out to select the best entropy functions able to differentiate healthy from open-circuit faulty conditions of the inverter. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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23 pages, 6749 KiB

Open AccessArticle

Multi-Objective Optimal Design of μ–Controller for Active Magnetic Bearing in High-Speed Motor

by Yuanwen Li and Changsheng Zhu

Actuators 2023, 12(5), 206; https://doi.org/10.3390/act12050206 - 17 May 2023

Cited by 2 | Viewed by 1307

Abstract

In this paper, a control strategy based on the inverse system decoupling method and μ-synthesis is proposed to control vibration in a rigid rotor system with active magnetic bearings that are built into high-speed motors. First, the decoupling method is used to [...] Read more.

In this paper, a control strategy based on the inverse system decoupling method and μ-synthesis is proposed to control vibration in a rigid rotor system with active magnetic bearings that are built into high-speed motors. First, the decoupling method is used to decouple the four-degrees-of-freedom state equation of the electromagnetic bearing rigid rotor system; the strongly coupled and nonlinear rotor system is thus decoupled into four independent subsystems, and the eigenvalues of the subsystems are then configured. The uncertain parametric perturbation method is used to model the subsystem, and the multi-objective ant colony algorithm is then used to optimize the sensitivity function and the pole positions to obtain the optimal μ-controller. The closed-loop system thus has the fastest possible response, the strongest internal stability, and the best disturbance rejection capability. Then, the unbalanced force compensation algorithm is used to compensate for the high-frequency eccentric vibration; this algorithm can attenuate the unbalanced eccentric vibration of the rotor to the greatest extent and improve the robust stability of the rotor system. Finally, simulations and experiments show that the proposed control strategy can allow the rotor to be suspended stably and suppress its low-frequency and high-frequency vibrations effectively, providing excellent internal and external stability. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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24 pages, 8056 KiB

Open AccessArticle

Improvements on the Dynamical Behavior of a HiL-Steering System Test Bench

by Alexander Haas, Benedikt Schrage, Gregor Menze, Philipp Maximilian Sieberg and Dieter Schramm

Actuators 2023, 12(5), 186; https://doi.org/10.3390/act12050186 - 25 Apr 2023

Cited by 1 | Viewed by 1723

Abstract

Shorter available development times and fewer available vehicle prototypes have increased the subsystem-based investigation on test rigs within the automotive development process. Steering systems exhibit a direct interface to the driver, therefore, posing high requirements to the control performance of a test bench, [...] Read more.

Shorter available development times and fewer available vehicle prototypes have increased the subsystem-based investigation on test rigs within the automotive development process. Steering systems exhibit a direct interface to the driver, therefore, posing high requirements to the control performance of a test bench, especially for the perception of steering feel. This work proposes three approaches to improve the force control performance of permanent magnet linear motors incorporated on a steering test bench. The first method improves control accuracy when a harmonic force signal is introduced into the steering system by adjusting the reference force signal based on the identified peak values of the measured and reference forces. The second method allows the inclusion of the actuator’s inertia and the occurring ratios between steering wheel angle and rack displacement into the control scheme to reduce performance deterioration due to inertia. The third approach considers delay time in the actuator control and estimates its future position for delay compensation. A validation of the proposed methods is conducted, displaying an improvement for all three applications. The proposed methods extend the applicability of a steering test bench within the automotive development process by enabling more accurate and reproductible control performance. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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18 pages, 6680 KiB

Open AccessArticle

Simulation Study on Direct-Drive Compressor with Electromagnetic Linear Actuator

by Jianhui Zhu, Mengmeng Xue, Jianguo Dai, Zongzheng Yang and Jingnan Yang

Actuators 2023, 12(5), 185; https://doi.org/10.3390/act12050185 - 25 Apr 2023

Viewed by 1437

Abstract

In order to enhance compressor efficiency and meet the requirements of energy conservation and environmental protection, this study designed a direct-drive compressor with an electromagnetic linear actuator. Starting with the structural design and performance analysis of the linear compressor, the working process of [...] Read more.

In order to enhance compressor efficiency and meet the requirements of energy conservation and environmental protection, this study designed a direct-drive compressor with an electromagnetic linear actuator. Starting with the structural design and performance analysis of the linear compressor, the working process of the moving-coil linear compressor was analyzed. The basic performance of the designed moving-coil linear motor was simulated and analyzed using the Maxwell software, while the overall performance of the linear compressor was simulated and analyzed using the Simulink software to verify the feasibility of controlling a linear compressor via the direct drive of a linear motor. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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17 pages, 4562 KiB

Open AccessArticle

Design and Analysis of Electromagnetic Linear Actuation-Energy-Reclaiming Device Applied to a New-Type Energy-Reclaiming Suspension

by Jianguo Dai, Lv Chang, Youning Qin, Cheng Wang, Jianhui Zhu, Jun Zhu and Jingxuan Zhu

Actuators 2023, 12(4), 142; https://doi.org/10.3390/act12040142 - 27 Mar 2023

Viewed by 1500

Abstract

In order to meet the increasing demand for high-performance and high-efficiency vehicles, this paper proposes a novel electromagnetic linear energy-reclaiming suspension technology based on the McPherson independent suspension, and analyzes its core component—ELA-ERD (Electromagnetic Linear Actuation Energy-Reclaiming Device). ELA-ERD, taking a shock absorber [...] Read more.

In order to meet the increasing demand for high-performance and high-efficiency vehicles, this paper proposes a novel electromagnetic linear energy-reclaiming suspension technology based on the McPherson independent suspension, and analyzes its core component—ELA-ERD (Electromagnetic Linear Actuation Energy-Reclaiming Device). ELA-ERD, taking a shock absorber piston rod as the inner yoke, has a compact structure and reasonable layout by integrating the structural features of the suspension. In this paper, the design process of ELA-ERD is elaborated in detail. Aiming at the problem of over-saturation of the inner yoke magnetic density, this paper proposes a method to optimize the magnetic circuit by increasing the size of the inner yoke within the effective working area of the moving coil, thus effectively improving the electromagnetic characteristics of ELA-ERD. Moreover, the effect and potential of energy reclaiming on ELA-ERD were studied by using finite element software. The study on the energy-reclaiming law of ELA-ERD was carried out from the perspective of the changes in vibration frequency and amplitude. In addition, the internal relationship between the energy-reclaiming voltage and the vibration velocity was revealed in this work, and the energy-reclaiming voltage coefficient

K_{e}

was defined. Through calculation of a large amount of model data, the

K_{e}

value applicable to the designed ELA-ERD in this paper was approximately set to 4.5. This study lays an important theoretical foundation for the follow-up studies. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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15 pages, 4512 KiB

Open AccessArticle

A Numerical Study on the Transient Injection Characteristics of Gas Fuel Injection Devices for Direct-Injection Engines

by Tianbo Wang, Hongchen Wang, Lanchun Zhang, Yan Zheng, Li Li, Jing Chen and Wu Gong

Actuators 2023, 12(3), 102; https://doi.org/10.3390/act12030102 - 25 Feb 2023

Cited by 2 | Viewed by 1230

Abstract

Natural gas has emerged as one of the preferred alternative fuels for vehicles owing to its advantages of abundant reserves, cleaner combustion and lower cost. At present, the gas supply methods for natural-gas engines are mainly port fuel injection (PFI) and direct injection [...] Read more.

Natural gas has emerged as one of the preferred alternative fuels for vehicles owing to its advantages of abundant reserves, cleaner combustion and lower cost. At present, the gas supply methods for natural-gas engines are mainly port fuel injection (PFI) and direct injection (DI). The transient injection characteristics of a gas fuel injection device, as the terminal executive component of the PFI or DI mode, will directly affect the key performance of a gas fuel engine. Therefore, gas fuel injection devices have been selected as the research object of this paper, with a focus on the transient injection process. To explore the impacts of valve vibration amplitude, period, frequency and velocity on transient injection characteristics, one transient computational fluid dynamics (CFD) model for gas fuel injection devices was established. The findings thereof demonstrated that there is a linear relationship between the instantaneous mass flow rate and instantaneous lift during the vibration process. However, this relationship is somewhat impacted when the valve speed is high enough. A shorter valve vibration period tends to preclude a shorter period of flow-hysteresis fluctuation. The near-field pressure fluctuation at the throat of an injection device, caused by valve vibration, initiates flow fluctuation. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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20 pages, 6342 KiB

Open AccessArticle

Design of an Improved Active Disturbance Rejection Control Method for a Direct-Drive Gearshift System Equipped with Electromagnetic Linear Actuators in a Motor-Transmission Coupled Drive System

by Shusen Lin, Min Tang, Bo Li and Wenhui Shi

Actuators 2023, 12(1), 40; https://doi.org/10.3390/act12010040 - 12 Jan 2023

Cited by 1 | Viewed by 1677

Abstract

In this study, a type of direct-drive gearshift system integrated into a motor-transmission coupled drive system is introduced. It used two electromagnetic linear actuators (ELAs) to perform gearshift events. The adoption of ELAs simplifies the architecture of the gearshift system and has the [...] Read more.

In this study, a type of direct-drive gearshift system integrated into a motor-transmission coupled drive system is introduced. It used two electromagnetic linear actuators (ELAs) to perform gearshift events. The adoption of ELAs simplifies the architecture of the gearshift system and has the potential to further optimize gearshift performance. However, a number of nonlinearities in the gearshift system should be investigated in order to enhance the performance of the direct-drive gearshift system. An active disturbance rejection control (ADRC) method was selected as the principal shifting control method due to the simple methodology and strong reliability. The nonlinear characteristics of the electromagnetic force produced by the ELA were subsequently reduced using the inverse system method (ISM) technique. The ADRC approach also incorporated an acceleration feedforward module to enhance the precision of displacement control. The extended state observer (ESO) module used a nonlinear function in place of the original function to improve the ability to reject disturbances. Comparative simulations and experiments were carried out between the ADRC method and improved ADRC (IADRC) method. The outcomes demonstrate the effectiveness of the designed control method. The shift force fluctuates less, and the shift jerk decreases noticeably during the synchronization procedure. In conclusion, combined with the optimized IADRC method, the direct-drive gearshift system equipped with ELAs shows remarkable gearshift performance, and it has the potential to be widely used in motor−transmission coupled drive systems for EVs. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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16 pages, 5524 KiB

Open AccessArticle

Design of Valve Seating Buffer for Electromagnetic Variable Valve System

by Qingya Zhou, Liang Liu, Cong Zheng, Zhaoping Xu and Xianhui Wang

Actuators 2023, 12(1), 19; https://doi.org/10.3390/act12010019 - 01 Jan 2023

Viewed by 1979

Abstract

An electromagnetic variable valve (EMVV) system can significantly reduce pumping loss and discharge loss of the engine by enabling variable valve timing and variable valve lift. However, the valve seat easily produces a larger impact collision with the engine cylinder head because of [...] Read more.

An electromagnetic variable valve (EMVV) system can significantly reduce pumping loss and discharge loss of the engine by enabling variable valve timing and variable valve lift. However, the valve seat easily produces a larger impact collision with the engine cylinder head because of fast valve seating velocity, greatly decreasing engine life. Therefore, in this paper, a valve seating buffer (VSB) is designed to solve the problem of large electromagnetic valve seating impact. Firstly, a scheme of an EMVV system with embedded buffer is proposed, the collision model is established to resolve the problem of the soft landing of the valve and the effectiveness of the model is verified by experiment. In addition, the structure, material and dimension parameters of the proposed buffer are designed, and some key parameters of the buffer are optimized by the Nelder–Mead (N–M) algorithm. Finally, a co-simulation model of the actuator and the buffer is built, and the valve seating performance is analyzed. The co-simulation results show that the valve seating velocity and rebound height of the EMVV system with the designed buffer are reduced by 94.8% and 97%, respectively, which verifies the advantages of the designed VSB. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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15 pages, 5789 KiB

Open AccessArticle

Design and Analysis of a High Power Density Permanent Magnet Linear Generator for Direct-Drive Wave Power Generation

by Xinyu Fan, Changkun Wang, Zhibing Zhu and Hao Meng

Actuators 2022, 11(11), 327; https://doi.org/10.3390/act11110327 - 10 Nov 2022

Cited by 2 | Viewed by 1904

Abstract

Wave energy is a new type of clean energy. Aiming at a low wave energy density and small wave height in China’s coastal areas, a tubular permanent magnet linear generator (PMLG) with a short stroke, small volume, and high power density is designed [...] Read more.

Wave energy is a new type of clean energy. Aiming at a low wave energy density and small wave height in China’s coastal areas, a tubular permanent magnet linear generator (PMLG) with a short stroke, small volume, and high power density is designed for wave power generation. Firstly, the generator’s electromagnetic parameters are analyzed by the analytical method, and the magnetic circuit topology and basic structure of the generator are analyzed by the equivalent magnetic circuit method (EMCM). Then, the finite element method (FEM) is used to analyze the influence law of the generator’s basic structural parameters on the output electromotive force (EMF) and its sinusoidal characteristics. The multi-factor and multi-level analysis is carried out based on the orthogonal test method to study the size parameters of the above analysis, and the optimal structure parameter combination for the generator is obtained. Finally, the prototype is trial-produced and tested for steady-state and transient performance to confirm the accuracy of the simulation calculations, and the output performance under no-load and load conditions is examined. The results show that both the optimized prototype’s power density and the output EMF’s sinusoidal properties have been improved under the proposed scheme. Full article

(This article belongs to the Special Issue Linear Motors and Direct-Drive Technology)

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