Novel Electric Direct-Drive Actuator for the Universal Modular Mast

Existing submarines rely on hydraulic cylinders to actuate masts. For the next generation Universal Modular Mast (UMM), all-electric actuation is desired to reduce system complexity and weight, and reduce costs. A direct-drive solution is especially desirable to avoid backlash, gear noise, and wear, and to be robust under shock-loading conditions. Under a separate program with the Navy, Foster-Miller has demonstrated a novel motor principle which provides 50 times greater torque or force density than existing state-of-the art motors at comparable levels of power dissipation. For the UMM application, Foster-Miller has already produced a preliminary design of a direct-drive linear motor that meets the UMM thrust and stroke requirements and fits within the size envelope of the current hydraulic mast actuator. In Phase I, Foster-Miller would work with the Navy and Calzoni to optimize electromagnetic design, develop preliminary designs for the brake, sensors, pressure-compensation, power electronic and control systems, and prepare a preliminary manufacturing plan. Also in Phase I, Foster-Miller and Calzoni would demonstrate a critical manufacturing step for one of the actuator's components. In Phase II, Foster-Miller and Calzoni will produce a reduced stroke, full-force prototype, and demonstrate smooth, closed loop control of position and velocity. (P-040114)