Marine Steering Actuator with Dual-Sensor Position Calibration
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Solution Overview
Problem
Existing marine steering systems face challenges in efficiently and reliably steering marine vessels due to limitations in actuator design, particularly in handling varying loads and preventing engine collisions, which can lead to inefficiencies and potential safety issues.
Innovation Solution
The development of an electric actuator with an integrated steering control unit, featuring a stator, rotor assembly, and brake system, which includes Hall Effect sensors and a roller screw assembly, allows for precise control of the steering force and torque, reducing the risk of engine collisions through advanced control logic and redundancy in position sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional actuator design is used, then the structure is simpler, but the precision and reliability of steering control deteriorates
Solution Approach 1:
The actuator is divided into distinct functional modules: motor assembly, roller screw assembly, brake assembly, and housing. Each module performs a specific function and can be independently manufactured and assembled, achieving high steering precision through modular design while maintaining manufacturing efficiency.
Solution Approach 2:
The roller screw assembly is nested within the motor assembly, with the output shaft coupled to the motor shaft. The brake assembly is integrated into the housing structure. This nested arrangement achieves compact, precise steering control without proportionally increasing overall device complexity.
2Reliability
If basic position sensing is used, then the device complexity is lower, but the ability to prevent engine collisions deteriorates
Solution Approach 1:
Hall effect sensors provide continuous feedback on the angular position of the output shaft and the linear position of the housing. The control system processes this feedback to detect potential engine collision conditions and automatically adjusts steering commands to prevent collisions, achieving high reliability through intelligent control rather than mechanical complexity.
Solution Approach 2:
Electronic sensing and control systems replace mechanical collision prevention mechanisms. Hall effect sensors and microcontroller-based control logic detect and prevent engine collisions through software algorithms, reducing mechanical complexity while improving reliability and adaptability.
3Adaptability or versatility
If simple load handling is implemented, then the device complexity is reduced, but the adaptability to varying loads deteriorates
Solution Approach 1:
The actuator employs dynamic control through the roller screw mechanism, which converts rotational motor motion into linear housing displacement with variable force characteristics. The system adapts to varying loads through electronic control of motor torque and speed, allowing the same hardware to handle different steering forces required for various vessel sizes and operating conditions.
Solution Approach 2:
The control system adjusts operational parameters such as motor voltage, current, and rotational speed based on detected load conditions. Hall effect sensor feedback enables real-time parameter modification to optimize performance across different load scenarios, achieving versatility through software-based parameter tuning rather than mechanical reconfiguration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the precision and reliability of marine vessel steering by minimizing backlash, adapting to varying loads, and preventing engine collisions, thereby improving steering performance and safety.
Implementation Method 1
The brake system includes Hall Effect sensors
Implementation Method 2
There is a screw assembly disposed within the housing and coupled to the output shaft. The screw assembly includes a plurality of annular rollers and a central screw received by the annular rollers. Rotation of the rotor causes the central screw to translate axially relative to the rotor and the output shaft to reciprocate relative to the housing.
Data Source
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AI summary
An actuator for imparting steering movement to a tiller of a propulsion unit of a marine vessel comprises an absolute position sensor which senses a steering position and a relative position sensor which senses a position of the motor. A steering control unit calibrates the relative position sensor based on a signal of the absolute position sensor. Calibration of the relative position sensor based on a signal of the absolute positon sensor initializes an accumulative position which accumulates a relative position as the actuator moves over time.