I-Corps: Developing servomotor actuators using advances in metallic additive manufacturing

这个I-Corps项目的更广泛的影响/商业潜力是开发用于机器人和工业自动化系统中更高扭矩位置控制执行器的电动机。到2026年，全球位置控制执行器市场预计将达到160亿美元。这种市场增长与向工业4.0方法的过渡有关，工业4.0方法通过开发产品开发和交付技术的简化流程来寻求提高效率和更快地适应可变的市场需求。实现工业4.0实践的好处涉及广泛使用先进的电动机控制和执行器，通过数字通信网络连接制造系统。此外，自动驾驶汽车、电动飞机和铁路等运输系统的电气化进一步增加了对位置控制执行器及其相关控制电子设备的需求。拟议中的技术可能会提高美国工业扩大制造能力的能力。此外，与先进机器人、自动驾驶汽车、飞机和运输电气化等新兴市场相关的经济发展，电动马达执行器可能会带来更大的增长。这个I-Corps项目是基于铜增材制造技术的发展，该技术能够设计新型电机，包括电动机位置控制执行器。这些类型的执行器用于机器人和工业自动化设备的位置，速度和加速度的精确控制。拟议的铜增材制造实现的设计允许传感器和电子控制功能集成到单个模块化设备中。此外，与现有的电动执行器相比，该技术提供了超过40%的扭矩和功率密度，通过将电机执行器和控制电子设备集成到一个组件中，消除了电动机执行器和控制电子设备之间的电缆和布线，并且使用磁性和电气结构消除了单独的位置传感设备，从而提供了扭矩产生和位置和速度传感的双重功能。这些特性可以减小尺寸和重量，同时在极端温度、振动和液体环境中提高可靠性。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

The broader impact/commercial potential of this I-Corps project is the development of electric motors for higher torque position control actuators used in robotic and industrial automation systems. The worldwide market for position control actuators is forecast to reach $16 billion by 2026. This market growth is associated with the transition to Industry 4.0 methods that seek improved efficiency and faster adaptation to variable market demands by developing streamlined processes in product development and delivery technologies. Achieving the benefits of Industry 4.0 practices involves extensive use of advanced electric motor controls and actuators to connect manufacturing systems through digital communication networks. In addition, the electrification of transportation systems such as autonomous vehicles, electric aircraft, and railways are further increasing the demand for position control actuators and their associated control electronics. The proposed technology may increase the ability of industries to expand manufacturing capacity in the US. Further, electric motor actuators may enable a much larger increase in economic development associated with emerging markets for advanced robotics, autonomous vehicles, aircraft, and transportation electrification. This I-Corps project is based on the development of copper additive manufacturing technologies that enable the design of new types of electrical machinery including electric motor position control actuators. These types of actuators are used for precise control of position, velocity and acceleration in robotics and industrial automation equipment. The designs enabled by the proposed copper additive manufacturing allows sensor and electronic control functions to be integrated into a single modular device. In addition, the proposed technology provides greater than 40% more torque and power density compared to existing electrical actuators, eliminates cables and wiring between electric motor actuators and control electronics by integrating these into a single assembly, and eliminates separate position sensing devices using magnetic and electrical structures that provide dual functionality of torque production with position and velocity sensing. These proposed features may result in reduced size and weight while achieving increased reliability in extreme temperature, vibration, and liquid environments.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.