# Patent

## Title
Stepper motor driven proportional actuator

## Abstract

A stepper motor driven actuator that eliminates the need for a position sensor is provided. The stepper motor rotates a cam in a control piston valve. In a single nozzle embodiment, pressure balance is maintained by a spring preload on one end of the piston in one embodiment, and by hydraulic pressure acting on a double diameter end portion of the piston in another embodiment. As the cam is rotated, the change in the gap between the nozzle and the cam changes the pressures on the control piston ends, which forces the piston in the direction that will re-equalize the pressure based on the cam-nozzle gap. As a result, the head or rod of the actuator piston receives high pressure flow, thereby moving the actuator. Movement of the actuator rod provides mechanical feedback to the cam, causing the cam to move back to its mechanical null position.

## Background
CROSS-REFERENCE TO RELATED PATENT APPLICATION
This patent application is a continuation-in-part of co-pending U.S. patent application Ser. No. 11/234,019, filed Sep. 23, 2005, the entire teachings and disclosure of which are incorporated herein by reference thereto.


FIELD OF THE INVENTION
This invention pertains to actuators, and more particularly to sensorless actuators.
BACKGROUND OF THE INVENTION
Conventional actuator systems employ a closed loop position control system. These systems include a position sensor for actuator position feedback and either an integrating controller or proportional controller used for control. The integrating controller assures that the steady state sensed position matches the commanded position. However, the actual position versus commanded position is still susceptible to inaccuracies of the position sensor gain and position (i.e., calibration of the position sensor to the valve position), the position sensor demodulator accuracy, channel-channel tracking and digital resolution. The proportional controller is susceptible to the above inaccuracies as well as an allowed steady state error that is a function of disturbance magnitudes and the proportional gain of the controller.
Regardless of the controller type, the accuracy of the system is very highly dependent on the position sensor accuracy. For precise metering applications such as in aircraft systems, the position sensors need to be very accurate and have high resolution. While very accurate, the position sensors are typically very expensive, both in terms of time and cost. They are relatively difficult to interface with due to the mechanical interface, the hydraulic interface, the number of small gauge wires, complicated demodulation circuitry, etc. Position sensors are also prone to failure due to the reliability of small gauge wires. This failure mode leads to dual channel requirements (i.e., two separate position sensors, drivers, and motor control) and additional cost in order to meet reliability requirements.
Elimination of the position feedback sensor will save money and weight. However, the lack of position feedback and the closed loop controller means that the effects of disturbances and/or the variations in forward path gain that are sensed and/or compensated in the closed loop controller will no longer be sensed and/or compensated. To negate these adverse effects, the magnitude of the disturbances should be minimized, the inherent disturbance rejection characteristics of the forward path should be maximized and the gain accuracy of the forward path should be made insensitive to the environment. In other words, the forward path must be “robust.” The forward path must also be strictly proportional since there is no feedback to prevent the divergence that would occur with an integrating forward path.
Open loop, proportional electro-hydraulic servo valve (EHSV) based actuator systems use a low energy torque motor that controls hydraulics that drive the actuator. The motor used has high speed but very low torque. The low torque levels result in the motor (and thus the actuator) being substantially affected by relatively small DC torque disturbances. For example, isolation seals, relaxation of torsion spring preload, magnet MMF (magnetomotive force) variations, variations in flux path reluctance, discrete steps in nozzle pressure feedback forces, thermal induced movement of parts, etc. can affect the torque motor. The relatively undamped torque motor also does not support good dynamic torque disturbance rejection (e.g., current transient, vibration, etc.) and creates resonance issues. The actuator position is fed back to the motor via springs. This indirect position feedback technique does not provide adequate load disturbance rejection for most applications.
What is needed is a system that overcomes the problems of sensorless actuators as discussed above. The invention provides a system with such features. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.
BRIEF SUMMARY OF THE INVENTION
The invention provides a stepper motor driven proportional actuator that eliminates the need for a position feedback sensor. The stepper motor is used to drive a cam that is designed such that the cross-cam distance on the nozzle-nozzle centerline of the fuel metering valve in a two nozzle embodiment is a constant for any operational cam angle. Additionally, the tangent to the cam surface is perpendicular to the nozzle-nozzle centerline, thereby allowing the cam to contact and push on the nozzles if needed.
In a one nozzle embodiment, a constant fluid gap between the cam surface and the nozzle is maintained by a constant Pc-Pb pressure. A spring provides a preload that is balanced by a Pz1 induced force. This ensures that the piston position is a function of the cam position. In an alternate one nozzle embodiment, the spring preload is replaced by a hydraulic load via a double diameter end portion. The double diameter end portion is desirable in that its hydraulic force varies with Ps-Pb in the same manner that the Pz1 force does. This trait assures that the cam-nozzle gap stays constant in the presence of a varying Ps-Pb. This ensures that the piston position is a function of the cam.
The stepper motor drives a gearbox connected to the cam. The gearbox in one embodiment is a planetary gear system having an outer ring gear connected in mesh relationship to planet gears, which are connected together with a planet frame and are in mesh relationship with a pinion gear. The outer ring gear is rotatably connected to a rack that is integrated to the actuator piston. The pinion gear is integral to the stepper motor rotor. When the stepper motor turns, the resultant pinion gear rotation cause the planet gears and planet frame to rotate. An output shaft that is attached to the planet frame and cam rotates with it. The cam rotation opens (or closes) cam/nozzle gaps causing the control piston to translate, thereby opening the head and rod ports to supply or drain causing the actuator piston and rack to stroke. The rack provides direct actuator position feedback to the outer ring gear and causes the outer ring gear to rotate. The rotation of the ring gear causes the planet gears and the planet frame to rotate back to their original position, thereby rotating the cam and translating the control valve to its mechanical null position.
Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the actuator system in accordance with the teachings of the present invention;
FIG. 2 is a partial cross-sectional view of the actuator system of FIG. 1 with the stepper motor shown as a separate component for clarity and the valve piston at a centered position;
FIG. 3 is a schematic view of the actuator system of FIG. 2 illustrating the cam-rack interaction;
FIG. 4 is a partial cross-sectional view of the actuator system of FIG. 2 with the control piston at a position such that flow drives the actuator in the retract direction with the actuator against the retract stop;
FIG. 5 is a partial cross-sectional view of the actuator system of FIG. 2 with the control piston at a position such that flow drives the actuator in the extend direction with the actuator against the extend stop;
FIG. 6 is a partial cross-sectional view of a single nozzle embodiment of the actuator system constructed in accordance with the teachings of the present invention; and
FIG. 7 is a partial cross-sectional view of another single nozzle embodiment of the actuator system constructed in accordance with the teachings of the present invention.



While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides a stepper motor driven actuator system that eliminates the need for a position sensor and position feedback. The hydraulic amplification that is typically provided by an EHSV flapper valve is eliminated and replaced with a constant gain cam-nozzle amplification-tracking system. The combination of the cam-nozzle, stepper motor, and a gearbox in communication with the rack of the actuator piston provides an accurate and robust actuation positioning system. One feature of the invention is that it can provide a “fail-fixed” system, that is, a system that maintains it's last commanded position in the event of electrical power failure.
Turning to the drawings, wherein like reference numerals refer to like elements, the invention provides a stepper motor driven robust proportional actuator. With reference to FIGS. 1 to 3, a stepper motor 100 is used to drive cam 102. The stepper motor drives a planetary gear system 104 where the ring gear 106 is in mesh relation to rack 108. The pinion gear 110 is integral to the stepper motor rotor 112. When the stepper motor 100 is rotated, the pinion gear 110 rotates. The pinion gear 110 rotation caused the planet gears 114 and planet frame 116 to rotate. The output shaft 118 is attached to the planet frame 116 and rotates with it. Similarly, the cam 102 that is attached to the output shaft 118 rotates with the output shaft 118.
The cam rotation increases the gap between the cam 102 and nozzle 120 on one side of the cam 102 and decreases the gap between the cam 102 and nozzle 120 on the other side. The differences in the gaps affect the Pz1 and Pz2 pressures on the ends 124 of the control piston 122 so as to force the control piston 122 in the direction that will re-equalize the cam-nozzle gaps. The control piston translation opens the head port 126 and rod port 128 to supply or drain, thereby causing the actuator piston 130 and rack 108 to stroke. The rack 108 provides direct actuator position feedback to the ring gear 106, causing the ring gear 106 to rotate. The ring gear rotation causes the planet gears 114 and planet frame 116 to rotate back to their original position, thereby rotating the cam and translating the control piston 122 to the mechanical null position (i.e., the center position).
When the cam 102 is in the center position, the hydraulic flow will enter port 134, pass through the cam-nozzle-orifice system (i.e., around cam 102 and through nozzles 120 and corresponding orifices), enter line 136, and then drain out through Pb port 138 due to the lower pressure in the Pb drain. It should be noted that the direction of flow is from line 134 and into the nozzles 120 via the cam-nozzle gap (i.e., “flow in”) as compared to conventional valves where flow is from the piston ends 124 out of the nozzle 120 (i.e., “flow out”).
Note that when the cam 102 is positioned such that the control piston 122 is towards the left-most position 140 in the control valve body 132, the supply port 134 is opened to the head port 126 (see FIG. 5). When this occurs, the hydraulic flow passes through port 134, out head port 126 and returns through rod port 128 and discharges out Pb port 138. When the cam 102 is positioned such that the control piston 122 is towards the right-most position 142 in the control valve body 132, the supply port 134 is opened to the rod port 128 (see FIG. 4). The hydraulic flow passes through port 134, out rod port 128 and returns through head port 126 and discharges out Pb port 144.
During normal operation with a properly sized hydraulic and electromechanical system, it is unlikely that the control piston 122 will be at either its left-most position 140 or its right-most position 142 (as respectively shown in FIGS. 5 and 4) due to the response of the system. In FIG. 4, the hydraulics are driving the actuator in the retract direction but it is against the retract stop. FIG. 5 depicts the hydraulics driving the actuator in the extend direction but the actuator is against the extend stop. Generally, as the stepper motor 100 rotates the cam 102, the control piston 122 begins to move and flow enters one of the head port 126 or rod port 128. As the control piston 122 continues to move as the cam 102 is rotated, the port through which flow enters (i.e., head port 126 or rod port 128) opens wider, thus increasing flow. As the flow pushes actuator piston 130, rod 108 moves, thus rotating ring gear 106 as described above. The rotation of ring gear 106 by rod 108 results in the cam 102 and control piston 122 translating to the mechanical null position, thus preventing further flow to the actuator. The result is a proportional tracking of the actuator 130 to the motor rotor 112. As long as the dynamics of the system are sufficient fast so as to keep up with the input from the motor 100, the actuator 130 will track the motor 100 commands with relatively small transient rotations of shaft 118, cam 102 and translations of control piston 122.
The primary disturbance to the system is the force input to the actuator. Any movement of the actuator piston 130 will cause rack 108 translation and ring gear 106 rotation. Any ring gear movement results in cam 102 rotation due to the precision gearbox system 104. The high pressure gain of the system assures control piston 122 movement for any cam 102 rotation. The high pressure gain of the control valve ports 126 & 128 coupled with the large head/rod areas will result in the required resistive force with minimal position error.
An example of the stiffness of the system is provided below. Assume for purposes of discussion that there are 103 gear teeth on the inner diameter of the ring gear 106 (approximately 130 teeth on the outer diameter), 45 gear teeth on each planet gear 114, 13 gear teeth on the pinion gear 110, 33 teeth per inch on rack 108 and the motor pinion rotating approximately 1.73 degrees per step of the stepper motor 100. With the proper cam sizing as described in U.S. application Ser. No. 11/094,099, filed Apr. 27, 2005, hereby incorporated by reference in its entirety, there is 418 steps per inch of actuator stroke. A 0.001 inch actuator stroke error is equivalent to 0.091 degrees of ring rotation. 0.091 degrees of ring rotation leads to 0.081 degrees of cam rotation (neglecting gearbox slop). The cam rise of 0.004 in/degree yields 0.000324 inches of control valve stroke. Assuming a control port pressure gain of approximately 125000 psid/in, the actuator stroke error equates to a dP of 40 psid. Assuming an actuator with a 5 in2 head area and a 4.25 in2 rod area, Pb=100 and Ps=600 psid, the resulting change in force is approximately 185 lbs. The resulting disturbance rejection is approximately 185,000 lbs/in (neglecting any rack and gearbox backlash). A 500 lb external force would move the actuator 0.0027 inches or 0.09% stk. As can be seen from the foregoing, the actuator system of the invention is very stiff.
The stepper motor system is a relatively low energy motor coupled to relatively high energy hydraulics. The stepper motor in combination with a gearbox provides the capability to decrease stepper motor speed and increase its torque while staying at the same energy level. This is accomplished by proper selection of the motor stator and rotor tooth count and the gearbox ratio. This can be used to increase the motor torque, decrease it's susceptibility to torque disturbances and still keep the motor fast enough to handle dynamic operation. The stepper motor has nearly perfect gain and is essentially unaffected by torque disturbances due to higher torque capability, the gear box torque amplification and the inherent detent feature of the stepper motor. The round, symmetrical, balanced construction of the stepper motor is in essence unaffected by vibration and temperature variations.
The precision machined placement of stator and rotor teeth provide the inherent baseline position and gain accuracy of the stepper motor. If an accurate calibration is made, and the effects of disturbances are negated, the need for a sensor is eliminated. This accuracy does not change with life, is essentially constant from unit to unit, and is not a function of any calibration procedure. The round, symmetric construction of the stepper motor maintains this accuracy in the presence of environment variations (e.g., temperature). Torque disturbances at the output shaft such as dynamic seal friction, nozzle hydraulic loads, unbalanced cam mass, etc. are minimal and are essentially rejected by the precision gearbox 140 (comprising pinion gear 110, ring gear 106, planet gears 114 and planet frame 116) and the high detent torque of the motor. The detent torque prevents disturbances from having any appreciable effect until they reach such a magnitude that they completely overpower the stepper motor. The stepper motor rotor rides on precision ball bearings and is inherently precision-balanced about its rotation axis in the presence of translational accelerations (i.e., vibration), so the torque disturbances at the motor rotor are negligible. The stepper motor 100 has no channel-channel tracking error due to the fact that both channels share the same rotor-stator-pole flux circuit. Power transients have no effect on steady state operation and the precision gearbox has minimal backlash. In one embodiment, the backlash of the gearbox 140 is approximately two step increments of the stepper motor 100.
With a thorough understanding of the two nozzle embodiment firmly in hand, attention is now directed to FIGS. 6 and 7 which depict single nozzle embodiments of the present invention. Each of these single nozzle embodiments operate similar to the two nozzle embodiments discussed above and reduce cost over the two nozzle embodiments discussed above, albeit at the expense of a reduced force gain and force margin. Each embodiment utilizes a means for applying force on one end of the control piston 122. Specifically, FIG. 6 illustrates an embodiment wherein the means is a spring preload with a constant supply pressure (Pc)-drain pressure (Pb). FIG. 7 depicts a single nozzle embodiment that does not include a spring preload, but instead utilizes a double diameter end portion with an unregulated Pc-Pb as the means.
With regard to the embodiment of FIG. 6, a spring 160 provides a preload on the control piston 122, e.g. a  ̃10 lb preload in one embodiment. Those skilled in the art will recognize that other preload forces may be provided depending on the operating parameters and conditions of the particular installation, and therefore all such preloads are to be included herein. This load is balanced by a Pz1 induced force existing at the opposite end of the control piston 122. Pz1 is regulated between the pressure at port 134 (Pc) and the pressure at port 144 (Pb) as a function of the cam 102 and nozzle 120 gap. In the presence of a constant spring force (spring scale is neglected) and constant Pc-Pb pressure, the fluid gap between the cam 102 and the nozzle 120 is constant. This assures that the piston 122 position is a function of cam 102 position, and only cam 102 position.
Assuming a 66% pressure recovery for purposes of example, a 0.625′′ piston 122 will provide a 20 lb hydraulic force, which provides 10 lbs to resist the spring force and 10 lbs for force margin, with a Pc-Pb=100 psid. The hydraulic force plus cam force, or spring force plus cam force, can provide a total force margin of ±20 lbs.
In the single nozzle embodiment depicted in FIG. 7, the spring 160 preload is replaced by a hydraulic load via a double diameter end portion 162. The double diameter end portion 162 is desirable in that its hydraulic force varies with Ps (at port 134)-Pb (at port 144) in the same manner that the Pz1 force does on the opposite end of the control piston 122. This trait ensures that the cam 102 nozzle 120 gap stays constant in the presence of a varying Ps-Pb, which ensures that the piston position 122 is a function of the cam 102, and only the cam 102.
As can be seen from the foregoing, a robust stepper motor driven proportional actuator has been described. Robustness, as used herein, refers to the ability of a system to remain accurate in the presence of disturbance inputs and environment variations. Disturbances lead to a shift in the entire step versus position plot and gain variations lead to changes in the slope of the plot. Disturbances are due to undesired torques and forces as well as imperfect calibration. Gain variations are due to the change in output/input characteristics due to component life and environment. Robustness is obtained by embodiments of the invention by minimizing the magnitude of disturbances where possible, by isolating the device from disturbances where necessary, maximizing the disturbance rejection characteristics of the device, designing a device with minimal wear and/or whose performance is unaffected by wear, precision calibration, and inherent gain accuracy in the presence of environment variations (e.g., temperature, stray flux, vibration, pressures, etc.).
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. For example, a ball screw can be used where the ball portion is mounted in the actuator with the screw integral to the ring gear. Actuator translation would cause the ring gear to rotate as described above. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

## Claims

1. A stepper motor driven actuator comprising:
a stepper motor;
a cam operatively connected to the stepper motor, the cam rotating position in response to stepping of the stepper motor, the cam positioned within a valve body having an inlet port, a rod port, a head port and at least one drain port;
a control piston positioned within the valve body and having a nozzle positioned on a first side of the cam in close proximity to a surface of the cam and movable between a null position and flow positions, the nozzle having a flow path leading from a first end of the control piston, the control piston further including a means for applying a force on a second end of the control piston, the control piston moving as a result of a pressure imbalance at the ends of the control piston occurring in response to a change in position of the cam; and
an actuator having a piston integral to a rack that is operably coupled to the cam, the piston having a first side and a second side, the first side being in fluid communication with the head port and the second side being in fluid communication with the rod port, the cam moving in response to the rack moving.

2. The actuator of claim 1 wherein the cam is connected to an output shaft, the actuator further comprising a gearbox connected between a rotor of the stepper motor and the output shaft.

3. The actuator of claim 1 wherein translation of the control piston opens one of the head port and rod port to supply and the other of the head port and rod to drain, thereby causing the actuator piston and rack to stroke.

4. The actuator of claim 3 wherein translation of the control piston towards a first end of the valve body opens the head port to supply and the rod port to drain.

5. The actuator of claim 4 wherein translation of the control piston towards a second end of the valve body opens the head port to drain and the rod port to supply.

6. The actuator of claim 3 wherein the actuator rotates the cam and translates the control piston to a mechanical null position in response to the rack stroking.

7. The actuator of claim 1, wherein the means for applying a force on a second end of the control piston comprises a spring in operative contact with the second end of the control piston.

8. The actuator of claim 7, wherein the second end of the control piston is in fluid communication with the drain port.

9. The actuator of claim 1, wherein the means for applying a force on a second end of the control piston comprises a double diameter end portion having an end thereof in fluid communication with the inlet port.

10. The actuator of claim 9, wherein a hydraulic pressure at the end of the double diameter varies in the same manner as a hydraulic pressure at the first end of the control piston.

11. A stepper motor driven actuator system comprising:
a stepper motor;
a gearbox operatively connected to the stepper motor;
a cam operatively connected to the gearbox, the cam rotating position in response to stepping of the stepper motor, the cam positioned within a valve body having an inlet port, a rod port, a head port and at least one drain port;
a control piston positioned within the valve body and having a single nozzle positioned on one side of the cam in close proximity to a surface of the cam so as to define a gap therebetween, the single nozzle having a flow path in communication with a first end of the control piston, the control piston having a spring positioned within the valve body providing a preload on a second end of the control piston, the control piston moving as a result of a pressure imbalance at the ends of the control piston occurring in response to a change in the gap between the surface of the cam and the single nozzle due to a change in the position of the cam; and
an actuator having a piston integral to a rack, the piston having a first side and a second side, the first side in fluid communication with the head port and the second side in fluid communication with the rod port, the rack in mesh relationship to the gearbox, the cam moving in response to the rack moving.

12. The actuator system of claim 11 further comprising an output shaft operatively connected to the cam and the gearbox.

13. The actuator system of claim 11 wherein the actuator rotates the cam and translates the control piston to a mechanical null position in response to the rack stroking.

14. The actuator system of claim 11 wherein translation of the control piston towards a first end of the valve body opens the head port to supply and the rod port to drain.

15. The actuator system of claim 14 wherein translation of the control piston towards a second end of the valve body opens the head port to drain and the rod port to supply.

16. The actuator system of claim 11 wherein the single nozzle has a first end by the cam and a second end opposite the cam, and wherein flow enters the single nozzle in the first end and out the second end.

17. A stepper motor driven actuator system comprising:
a stepper motor;
a gearbox operatively connected to the stepper motor;
a cam operatively connected to the gearbox, the cam rotating position in response to stepping of the stepper motor, the cam positioned within a valve body having an inlet port, a rod port, a head port and at least one drain port;
a control piston positioned within the valve body and having a single nozzle positioned on one side of the cam in close proximity to a surface of the cam so as to define a gap therebetween, the single nozzle having a flow path in communication with a first end of the control piston, the control piston having a double diameter end portion having an end thereof in fluid communication with the inlet port, the control piston moving as a result of a pressure imbalance at the ends of the control piston occurring in response to a change in the gap between the surface of the cam and the single nozzle due to a change in the position of the cam; and
an actuator having a piston integral to a rack, the piston having a first side and a second side, the first side in fluid communication with the head port and the second side in fluid communication with the rod port, the rack in mesh relationship to the gearbox, the cam moving in response to the rack moving.

18. The actuator system of claim 17, further comprising an output shaft operatively connected to the cam and the gearbox.

19. The actuator system of claim 17 wherein the actuator rotates the cam and translates the control piston to a mechanical null position in response to the rack stroking.

20. The actuator system of claim 17 wherein translation of the control piston towards a first end of the valve body opens the head port to supply and the rod port to drain and translation of the control piston towards a second end of the valve body opens the head port to drain and the rod port to supply.