Preliminary design and sizing of actuation systems

250 Pages·2017·25.84 MB·English

by  Marc Budinger

Preliminary design and sizing of actuation systems
Marc Budinger
To cite this version:
Marc Budinger. Preliminary design and sizing of actuation systems. Mechanical engineering
[physics.class-ph]. UPS Toulouse, 2014. ￿tel-01112448￿
HAL Id: tel-01112448
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Habilitation à Diriger des Recherches
Délivrée par : Université Toulouse 3 – Paul Sabatier
Discipline : Génie Mécanique
Présentée par :
Marc BUDINGER
Docteur en Génie Electrique
Agrégé de Physique Appliquée
Titre :
Preliminary design and sizing of actuation systems
Soutenue le 22 septembre 2014 devant le jury composé de :
Willy CHARON Professeur à l’UT de Belfort-Montbéliard Rapporteur
Laurent GERBAUD Professeur à l’INP de Grenoble Rapporteur
Giovanni JACAZIO Professeur au POLITECNICO de Turin Rapporteur
Alain BERLIOZ Professeur à l’UPS Toulouse Examinateur
Eric BIDEAUX Professeur à l’INSA de Lyon Examinateur
Jean-Charles MARE Professeur à l’INSA de Toulouse Examinateur
Ecole Doctorale : MEGEP
Unité de Recherche : Institut Clément Ader (EA 814)
Établissement de rattachement : Institut National des Sciences Appliquées de Toulouse,
Université de Toulouse

Remerciements
Les travaux présentés dans ce mémoire ont été réalisés au sein de l’Institut Clément Ader de Toulouse
dirigé par M. Marc SARTOR et M. Philippe OLIVIER. Je tiens à les remercier pour leur dévouement pour le
bien commun et pour les discussions et échanges scientifiques que j’ai pu avoir avec eux.
J’exprime ma profonde reconnaissance à M. Jean-Charles MARE qui m’a accueilli dans son équipe et
ouvert les portes de la conception préliminaire des actionneurs dans le monde aéronautique.
J'adresse ma reconnaissance à M. Willy CHARON, M. Laurent GERBAUD et M. Giovanni
JACAZIO et M. Eric BIDEAUX qui m'ont fait l'honneur d'être rapporteurs ou examinateur et pour le
temps, les remarques judicieuses et le retour qu’ils ont pu me faire dans leur rapport, leurs questions ou nos
discussions.
Mes plus chaleureux remerciements vont à M. Alain BERLIOZ qui m’a fait l’honneur de présider mon
jury.
Je remercie M. Xavier ROBOAM et M. Bernard MULTON pour les travaux et réflexions que nous
avons pu mener ensemble ainsi que M. Frank THIELECKE et l’ensemble des membres de l’institut FST à
TUHH pour l’accueil et leur disponibilité pendant les quelques mois passés en Allemagne.
Je tiens également à remercier l’ensemble du personnel du département de Génie Mécanique de l’INSA
et des autres départements de l’INSA auprès duquel j’ai pu travailler et pour l’ambiance générale positive et
constructive qui y règne.
Je tiens à remercier également les doctorants que j’ai eu la chance d’encadrer, Jonathan LISCOUET,
Toufic El HALABI, Fabien HOSPITAL, Amine FRAJ, Xavier GIRAUD et Aurélien REYSSET et à
l’ensemble des chercheurs, ingénieurs et stagiaires que j’ai pu côtoyer ces dernières années.
Enfin, je réserve une place toute particulière à mes enfants et à ma femme, qui ont su m’apporter amour
et complicité pendant toutes ces années.
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Table of contents
Preface
Introduction to preliminary design and sizing

Chapters and papers
Chapter 1 - Estimation models with scaling laws
Paper 1 - Estimation models for the preliminary design of electromechanical actuators
Chapter 2 - Simulation models for preliminary design
Paper 2 - Modelling approach for the Simulation-Based Preliminary Design of Power
Transmissions
Chapter 3 - Evaluation models and sizing for lifetime and reliability
Paper 3 - An integrated methodology for the preliminary design of highly reliable
electromechanical actuators: Search for architecture solutions
Chapter 4 - Metamodels for model-based-design of mechatronic systems
Paper 4 - Scaling-law-based metamodels for the sizing of mechatronic systems
Chapter 5 - Design graphs for sizing procedures and optimization problems definition
Paper 5 - Optimal preliminary design of electromechanical actuators
Postface and perspectives
Annexes
Annex 1 - Curriculum Vitae, version détaillée (French)
Annex 2 - Curriculum Vitae, short version (English)
Annex 3 - Publications
The synthesis report is written so that included publications can be read as a continuation or a
deepening of each chapter. It is recommended that the reader read each paper numbered from 1 to 5 after
the chapter bearing the corresponding number.

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Preface
Since my recruitment at INSA in September 2006, I have worked at research level in the Clément Ader
Institute (ICA), mainly with J-Ch Maré on the preliminary design of power systems with electromechanical
actuators in the aerospace field. This theme of research has been developed around three areas:
• Technologies: mechatronic systems and their actuation systems include power transmission
elements from different fields, which are usually treated independently. The goal of my research
is to synthesize them in a coupled manner;
• Models: the models to set up in order to design a system are of different natures. Simulation
models are used to calculate all quantities that influence the choice of the components.
Evaluation models enable lifetime or reliability to be calculated. Estimation models give rapid
access to component characteristics, generally obtained after detailed design.
• Methods: to optimize a design, it is advantageous to develop meta-models to replace time
consuming simulations, to analyse the uncertainty of results, and to help the implementation of
the design procedures.
Figure 1 synthetizes these research areas and how the PhD students, whom I co-supervised, were able to
participate.
Figure 1 – Research areas, PhD students and teaching activities
The PhD thesis of Jonathan Liscouet (2007-2010), funded by and structured around the European project
DRESS and the French ANR project SIMPA2 C6E2, laid the foundations methodologies, such as inverse
simulation , scaling laws, and equivalent sizing variables, to reduce the complexity and the size of design
loops. The simulation models suitable for preliminary design (e.g. considering the dimensioning thermal
effects for an electric motor) have been developed and implemented in the Modelica (Figure 2a) language.
To facilitate design exploration, the parameters needed for the simulation are based on scaling laws models.
The designer thus handles a reduced set of parameters: the technological reality is considered with reference
to an industrial component, both of which contribute to the deriving of parameters (such as mass, inertia, the
thermal time constant) from a reduced number of design parameters (such as the equivalent thermal torque).
These research activities were carried out in collaboration with the LAPLACE laboratory (C6E2) and the
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LMS-Imagine (C6E2) and Messier Bugatti Dowty (DRESS) companies. They led to the creation of the
steering actuator prototype for a nose landing gear shown in Figure 2b.
b) Distributed and Redondant
Electrical nose gear Steering
a) Modelica predesign library System (DRESS) actuator
Figure 2 – Jonathan Liscouet PhD - French ANR project SIMPA2-C6E2 and European project DRESS
The PhD thesis of Toufic El Halabi (2008-2012), funded by the FUI project CISACS of the ASTECH
cluster, applied these models to the optimization of the design of landing gear actuation systems. To reduce
the calculation time associated with the simulation of transient mission profiles, response surfaces were used
to optimize of the geometrical and kinematic integration of the actuators (Figure 3a). These research
activities were conducted in collaboration with Messier-Bugatti-Dowty and Sagem companies. The project
led to the realization a prototype for a landing gear extension/retraction actuator as shown in Figure 3b.
b) Extension/retraction nose landing
gear actuator
a) Geometrical integration
Figure 3 – Toufic El Halabi PhD - French FUI project CISACS (Concept Innovant de Système
d'Actionnement de Commandes de vol secondaires et de Servitudes)
The PhD thesis of Fabien Hospital (2009-2012), funded by an AMN ministerial scholarship, mainly
treated the mechanical aspect of component selection and control synthesis. The Figure 4 illustrates the work
performed on the sizing of housings of long actuators, e.g. of a slanding actuator, in severe vibratory
environment. The models studied showed that vibrations were a key sizing criterion for long EMA (Electro
Mechanical Actuator) housing but not for SHA (Servo Hydraulic Actuator) housing (mostly sized by the
internal pressure strength). Some exploratory studies were performed on the housing geometry to highlight
the compromise between diameter, thickness and extended length in vibration design.
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a) Modal and stress analysis of long
a) Optimal diameter of linear actuator
actuator
Figure 4 – Fabien Hospital PhD - AMN funding
The PhD thesis of Xavier Giraud (2011-2014), funded by Airbus, deals with the preliminary design of
the embedded electrical network and associated modular power electronics bay (Figure 5a). The work
addressed the optimization (Figure 5b) of multi-physics problem (power electronics) with large
combinatorial aspects (allocation of loads, operational scenarios). The thesis was prepared in collaboration
with Marc Sartor of the ICA laboratory and Xavier Roboam and Hubert Piquet of the LAPLACE laboratory.

a) Modular power electronic bay
b) Mass optimization :
complexity/sizing compromise
Figure 5 – Xavier Giraud PhD - Airbus Cifre
The PhD thesis of Amine Fraj (2010-2014), funded by the FUI project SYRENA, has the aim of
quantifying the effects of uncertainties in mission profiles and the estimation models and of building bridges
between 1D and 3D design using scaling laws as shown in Figure 6. Further projects are underway including
the European project Actuation 2015 which began in late 2011 and deals with the standardization of
electromechanical actuators for aerospace. I am responsible for the Model Based Design Tools work
package. In this context, PhD student Aurélien Reysset is working on mission profiles analysis, automatic
generation of sizing procedures and analysis of the effects of standardization.
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b) Scaling laws based meta models
a) 3D CAD link with scaling laws (SLAWMM)
Figure 6 – Amine Fraj PhD - French FUI project SYRENA
The following synthesis of this research period is written so that included publications can be read as a
continuation or a deepening of each chapter. This research work had also many interactions with my
teachings made primarily on System Engineering aspects of the Mechanical Engineering Department in
INSA Toulouse. Students are between bachelor 2 and master 2 levels. Table 1 describes briefly these courses
and Figure 1 illustrates the links between my research and teaching activities. Over the past two last R3ASC
conferences (2012 & 2014), I also made a tutorial of one day on the preliminary design of electromechanical
actuators. The public of thirty participant was predominantly industrial and from varied geographical and
institutional origins as illustrated in Figure 7.

Figure 7 – R3ASC tutorial
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