SBIR-STTR Award

The proposed SBIR effort will employ a systems approach to develop motor/controller/screw element systems adequate for demanding launch thrust vector control and control surface actuator applications. This approach will utilize high bandwidth, high efficiency, redundant motor systems coupled with appropriately paired motor controls. The actuator system will consist of a high efficiency permanent magnet motor with a high number of current channels for system redundancy, an H-bridge based controller with a high number of parallel current channels and sufficient current capability to enable high system response, and conventional screw-based linear actuator elements. The linear actuation elements will be designed with corrosion resistance, increased resistance to nut jamming, and inherent features preventing incorrect installation of the device. These innovations are necessary to overcome the inherent limitations of today's actuator systems, which were developed based on the limitations of traditional motors, power electronics, and available actuator hardware. Phase I of this project will focus on the design requirements, key features, and suggested solutions for thrust vector control actuator systems. The Phase II portion of the project will deliver a working prototype actuator.

There is a need to develop electromechanical actuators to improve performance beyond that of hydraulic devices currently being used in numerous aerospace and industrial applications. Beginning with NASA-provided performance specifications, this Phase I SBIR effort has employed a systems approach to develop and optimize the design of an electromechanical linear actuator appropriate for demanding launch vehicle thrust vector and control surface applications. The actuator system design consists of a high-efficiency permanent magnet motor with redundant current channels for system fault tolerance, multiple high-bandwidth controllers that are matched to motor characteristics, and a compact roller-screw mechanism, along with housing and supporting elements. A system of innovations was necessary to overcome the inherent limitations of today's electromechanical actuators, which were developed based on the limitations of traditional motors, power electronics, and available actuator hardware. The projected weight of the actuator prototype to be built in Phase II is less than the existing hydraulic systems currently in use by NASA, and half of previous electric prototypes having the same performance specification. Working with a major aerospace company partner, the Phase II Team will deliver a tested prototype actuator system as a basis for future advanced commercial products.