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A Direct-Drive Rotary Actuator Based on Modular FSPM Topology for Large-Inertia Payload Transfer

Author

Listed:
  • Jianlong Zhu

    (School of Mechanical Engineering, Nanjing University of Science & Technology, Nanjing 210094, China)

  • Zhe Wang

    (School of Mechanical Engineering, Nanjing University of Science & Technology, Nanjing 210094, China)

  • Minghao Tong

    (School of Mechanical Engineering, Nanjing University of Science & Technology, Nanjing 210094, China)

  • Longmiao Chen

    (School of Mechanical Engineering, Nanjing University of Science & Technology, Nanjing 210094, China)

  • Linfang Qian

    (School of Mechanical Engineering, Nanjing University of Science & Technology, Nanjing 210094, China)

Abstract

This paper proposes a novel direct-drive rotary actuator based on a modular five-phase outer-rotor flux-switching permanent magnet (FSPM) machine to overcome the limitations of conventional actuators with gear reducers, such as mechanical complexity and low reliability. The research focused on a synergistic design of a lightweight, high-torque-density motor and a precise control strategy. The methodology involved a structured topology evolution to create a modular stator architecture, followed by finite element analysis-based electromagnetic optimization. To achieve precision control, a multi-vector model predictive current control (MPCC) scheme was developed. This optimization process contributed to a significant performance improvement, increasing the average torque to 13.33 Nm, reducing torque ripple from 9.81% to 2.36% and obtaining a maximum position error under 1 mil. The key result was experimentally validated using an 8 kg inertial load, confirming the actuator’s feasibility for industrial deployment.

Suggested Citation

  • Jianlong Zhu & Zhe Wang & Minghao Tong & Longmiao Chen & Linfang Qian, 2025. "A Direct-Drive Rotary Actuator Based on Modular FSPM Topology for Large-Inertia Payload Transfer," Energies, MDPI, vol. 18(19), pages 1-18, October.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:19:p:5272-:d:1764835
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