Space-constrained hybrid linear actuator

Abstract

An electric motor-driven, rolling element screw linear actuator is presented which work in cooperation with an hydraulic actuator and share several components. This is achieved through the integration of a screw-driven integrated nut piston assembly. Combining the use of an electric screw driven actuator can also reduce the need for a redundant hydraulic system, resulting in the elimination of 50% of connections, valves, piping, pumps, filters etc., while still being 100% redundant. An additional advantage is that the two drive systems are technologically independent, and therefore will not both fail because of an identical component flaw or failure point. The systems may also be used at the same time if conditions require force in excess of that generated by the hydraulic actuator alone.

Claims

1. An hybrid linear actuator comprising: a first drive assembly comprising: an electric drive motor having an output shaft; a drive screw attached to the output shaft; a drive nut threaded to the drive screw; and an output rod having two ends, a first end attached to the drive nut so that rotation of the drive screw advances or retracts the output rod, and the second end capable of attachment to a linear actuated valve; a second drive assembly comprising: an hydraulic cylinder, a piston disposed in the hydraulic cylinder and linked to the output rod, and a hydraulic pump fluidly connected to the hydraulic cylinder and operable to selectively pressurize the hydraulic cylinder on either side of the piston to thereby vary a position of the piston within the hydraulic cylinder to thereby extend and retract the output rod; wherein the drive screw is disposed at least partially within the hydraulic cylinder and is of unitary construction; and wherein the actuator has a third drive assembly comprising first and second hydraulic accumulators fluidly connected to the hydraulic cylinder and operable to selectively pressurize the hydraulic cylinder on at least one side of the piston and wherein the first and second hydraulic accumulators are configured to be charged by the electric motor.

2. The linear actuator of claim 1, wherein the piston within the hydraulic cylinder is operable to rotate the drive screw.

3. The linear actuator of claim 1, further comprising a shaft alignment coupling mechanism interposed between the drive screw and the output shaft of the electric drive motor, said shaft alignment coupling mechanism operable to selectively couple and decouple the drive screw and the output shaft.

4. The linear actuator of claim 1, wherein the drive screw and the output rod are coaxial.

5. The linear actuator of claim 1, wherein the output rod comprises a hollow interior, and wherein the drive screw extends into the hollow interior of the output rod.

6. The linear actuator of claim 1, wherein the drive nut is disposed in the hollow interior of the output rod.

7. A compact hybrid linear actuator comprising: an hydraulic cylinder having an inner chamber, a proximal end and a distal end; an output rod extending from the distal end the hydraulic cylinder, the output rod having a proximal end and a distal end; a piston on the proximal end of the output rod, the piston being disposed within the inner chamber of the hydraulic cylinder; the piston dividing the inner chamber of the hydraulic cylinder into a first pressure chamber and a second pressure chamber; a nut disposed in the first pressure chamber of the hydraulic cylinder; the nut disposed in a fixed, non-rotatable relationship with respect to the output rod; a drive screw disposed in the first pressure chamber and installed into the nut such that rotation of the drive screw moves the output rod; and wherein the actuator comprises a third drive assembly comprising a first accumulator fluidly connected to the hydraulic cylinder and operable to selectively pressurize the hydraulic cylinder on a first side of the piston and a second accumulator fluidly connected to the hydraulic cylinder and operable to selectively pressurize the hydraulic cylinder on a second side of the piston and wherein the electric motor driven screw pushes the integrated nut piston, to create fluid flow and pressure into at least one of the first accumulator and the second accumulator configured to charge at least one of said first or second accumulator.

8. The linear actuator of claim 7, wherein the output rod further comprises a hollow interior, wherein a distal end of the drive screw extends into the hollow interior of the output rod.

9. The linear actuator of claim 7, wherein a proximal end of the drive screw extends from the proximal end of the hydraulic cylinder.

10. The linear actuator of claim 7, further comprising an electric motor having an output shaft linked to the proximal end of the drive screw by a drive system.

11. The linear actuator of claim 7, wherein the drive system comprises one of a belt, chain, and gear.

12. The linear actuator of claim 7, wherein the drive system comprises shaft alignment coupling mechanism operable to selectively couple and decouple the output shaft and the drive screw.

13. The linear actuator of claim 7, further comprising: a first valve fluidly connected to the first chamber, the first valve being operable between an open position and a closed position; a second valve fluidly connected to the second chamber, the second valve being operable between an open position and a closed position.

14. The linear actuator of claim 13, further comprising a hydraulic pump fluidly connected to the first valve and the second valve.

15. A linear actuator having redundant power sources for use in space constrained areas comprising: an output rod having a proximal end and a distal end; the output rod having a hollow passage way extending from its proximal end toward its distal end; a first drive assembly comprising: a drive nut disposed in a non-rotatable and fixed position with respect to the output rod, a drive screw installed into the drive nut such that the drive screw extends into the hollow passage way of the output rod, and an electric drive motor having an output shaft linked to the drive screw such that rotation of the output shaft rotates the drive screw to thereby extend and retract the output rod; a second drive assembly comprising: a hydraulic cylinder, a piston disposed in the hydraulic cylinder and linked to the output rod, and an hydraulic pump fluidly connected to the hydraulic cylinder and operable to selectively pressurize the hydraulic cylinder on either side of the piston to thereby vary a position of the piston within the hydraulic cylinder to thereby extend and retract the output rod; and a third drive assembly comprising: a first accumulator fluidly connected to the hydraulic cylinder and operable to selectively pressurize the hydraulic cylinder on a first side of the piston; and a second accumulator fluidly connected to the hydraulic cylinder and operable to selectively pressurize the hydraulic cylinder on a second side of the piston; and wherein at least one of the first accumulator and second accumulator is configured to be charged by the electric motor.

16. The third drive assembly configured to charge the accumulator of claim 15 wherein the actuator comprises the actuator on a coking drum valve wherein the first or second accumulator is charged while the fluidic coking valve is positioned.

17. A compact hybrid linear actuator comprising: an output rod; a first drive assembly comprising: a drive nut linked to the output rod, a drive screw installed into the drive nut, an electric drive motor having an output shaft linked to the drive screw such that rotation of the output shaft rotates the drive screw to thereby extend and retract the output rod, and a second drive assembly comprising: an hydraulic cylinder, a piston disposed in the hydraulic cylinder and linked to the output rod, and an hydraulic pump fluidly connected to the hydraulic cylinder and operable to selectively pressurize the hydraulic cylinder on either side of the piston to thereby vary a position of the piston within the hydraulic cylinder to thereby extend and retract the output rod, wherein the first drive assembly and the second drive assembly are individually capable of extending and retracting the output rod if the other drive assembly fails; and wherein the output rod comprises a hollow interior, and wherein the drive screw extends into the hollow interior of the output rod; and a third drive assembly comprising: a first accumulator fluidly connected to the hydraulic cylinder and operable to selectively pressurize the hydraulic cylinder on a first side of the piston; and a second accumulator fluidly connected to the hydraulic cylinder and operable to selectively pressurize the hydraulic cylinder on a second side of the piston.

18. A compact hybrid linear actuator as recited in claim 17, further comprising a housing wherein the hydraulic fluid and the driving screw are in the same housing.

19. A compact linear actuator as recited in claim 17, wherein the first drive assembly and the second drive assembly may be operated at the same time to increase the thrust on the output rod.

20. A compact linear actuator as recited in claim 17, wherein when the second drive assembly is used to create a thrust force to move the piston during either extension or retraction of the rod, the thrust force generated by the hydraulic pressure against the piston is allowed to passively back drive the screw in the first drive assembly.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) The objects and features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

(2) FIG. 1 shows a perspective view of an embodiment combining electric and hydraulic linear actuators to individually or jointly provide a linear force output to a single rod connected to a linear actuated valve;

(3) FIG. 2 shows an elevational view of a fully integrated embodiment combining both a traditional screw driven linear actuator with that of an hydraulic actuator; and

(4) FIG. 3 shows an enlarged cut-away view of an hybrid electric/hydraulic linear actuator.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(5) A linear electric actuator system that combines the features of an electric motor, screw driven, linear actuator with an hydraulic linear actuator is presented. The benefit of combining the two types of linear actuators is to provide a means for an independently redundant system for applications that require redundancy to prevent shutdowns and process interruptions.

(6) In addition to the benefit of a truly independent redundant system several new and novel control options can be realized. By combining the unique and independent operational characteristics only available with an electric motor screw driven actuator with the unique and independent operational characteristics only found with the hydraulic linear actuator, new novel control features can be executed.

(7) There are two embodiments for combining the electric and hydraulic actuators into a system that works jointly to create a redundant integrated system. The embodiment in FIG. 1 depicts the combination of individual elements, including an hydraulic cylinder, with a linear electric actuator, connecting the two via a common mounting plate, as well as a coupling assembly to tie each of the ends of the actuating rods together.

(8) The integrated embodiment shown in FIG. 2, integrates electric and hydraulic technologies together by designing an hydraulic piston, including guides/bearings and seals to be physically integrated into and/or capture the nut of the electric actuator screw driven actuator. In this approach the hydraulic fluid and the driving screw would occupy the same space. This embodiment minimizes failure points in the system, as well as minimizes the physical size of the system.

(9) Referring now to the embodiment in FIG. 1, an embodiment is depicted having an hydraulic linear actuator 10 and an electric linear actuator 12, both mounted to a bearing mounting guide frame assembly 14. Components such as mounting a plate 16, a rod tie block linear guide bearing 20, linear guide bearing rail 21, a rod tie block 22, and a rod guide bearing 18, are all mounted to frame assembly 14. Frame assembly 14 is made up of end mounting plates attached by rails 24. Mounted to the rails are linear guide bearings 20 and liner guide bearing rail 21. Rod guide bearing 18 is mounted into end plate 16, also part of frame assembly 14. Rod end tie block 22 ties both hydraulic actuator rod 26 and electric actuator rod 28 together. Rod tie block 22 is guided by linear rails 21 and linear guide bearings 20. Hydraulic actuator rod 26 and electric actuator rod 28 are connected to rod tie block 22 which is also connected to a single centrally mounted rod 30 that provides a single linear output.

(10) Actuation of either or both of hydraulic actuator rod 26 or electric actuator rod 28 move rod tie block 22 which then moves single central rod 30 through rod guide bearing 18. Rod guide bearing 18 provides low friction guidance to the single central rod 30 and reacts to forces imparted that are not in the direction of travel of the single central rod 30. Single central rod 30 is attached to a liner actuated valve.

(11) By connecting extension/retract rods 26, 28 together, OR by designing the electric and hydraulic actuators into a single unit physically occupying the same space as in other embodiments, a redundant system is realized. The unit may be operated under various conditions to utilize the unique control capabilities of both systems simultaneously.

(12) In a second embodiment, this one shown in FIG. 2 utilizes a linear electric actuator system that combines the features of an electric motor, screw driven, linear actuator with a hydraulic linear actuator. The benefit of combining the two types of linear actuators is to provide a means for independently redundant system for applications that require redundancy to prevent shutdowns and process interruptions.

(13) In addition to the benefit of a truly independent redundant system several new and novel control options can be realized. By combining the unique and independent operational characteristics, only available with an electric motor screw driven actuator, with the unique and independent operational characteristics, only found with the hydraulic linear actuator, new novel control features can be executed. In this embodiment, the two technologies are integrated together by designing a hydraulic piston, including guides/bearings and seals to be physically integrated into and/or capture the nut of the electric actuator screw driven actuator. In this embodiment, the hydraulic fluid and the driving screw occupy the same space. This embodiment minimizes failure points, but also minimizes the space and in particular, the length of the system. The unit may also be operated under various conditions to utilize the unique control capabilities of both systems simultaneously.

(14) When hydraulic fluid power is used to create a thrust force to move the nut piston assembly during either extension or retraction of the rod, the thrust force generated by the hydraulic pressure against the piston is allowed to passively back drive the screw and power train. There is no torque applied via operation of the electric motor. The use of a high efficiency screw limits the forces required to back drive the screw to a minimum.

(15) When power is supplied to the electric motor to create a thrust force in the extension/retract rod, the hydraulic system is allowed to pass hydraulic fluid from one side of the piston to the other with minimal losses. The thrust loss due to pushing hydraulic fluid through the control valve is determined by the sizing of the control valves and hydraulic lines. Alternatively, hydraulic pressure in conjunction with the application of torque from the electric motor, is applied to either side of the piston, to match the speed and direction of the drive screw nut, to account for fluid losses (which would equate to a loss in thrust generation). This would be useful in situations where a maximum speed is required for the movement of the extend/retract rod.

(16) Referring now to FIG. 2, a fully integrated unit is shown which combines a screw-driven linear electric actuator with a hydraulic actuator. An electric motor 44 drives a gear reducer 46 through a shaft alignment coupling 48. A standoff 50 creates space between motor 44 and gear reducer 46 and the shafts that connect them. 1st stage gear reducer 46 drives a drive belt/chain/gear 52 inside of gear housing 54. It will be understood that a belt, chain or gears by be used for this purpose. Belt 56 drives a system attached to an output shaft of the 2nd stage gear set 59, made up of the drive gears/pullies in the belt/chain assembly, and the drive end of the screw 58. It will be appreciated that gears of varying sizes may be used to alter the speed and or thrust per the requirements of the applications. The gear set 46, 52, 59 in combination with the motor specification define the speed and thrust of the screw/nut 60. A drive screw retention nut 62 captures drive screw 58 and is pre-tensioned to provide the correct alignment/thrust bearing pre-load as well as to prevent fatigue of the screw end from changes in direction of the applied force. A thrust bearing housing 64 and drive screw thrust and alignment bearing set 66 keep drive screw 58 aligned. A piston 69 is moved by hydraulic pressure to push or pull an actuator rod 76. Hydraulic fluid is provided through hydraulic fluid supply line 68. Surrounding drive screw 58 is a piston/nut guide housing 70. This forms one part of the pressure boundary for the hydraulic system and provides alignment of the piston/nut assembly so it is concentric with bearing housing 64 and drive screw 58. A hydraulic fluid return line 72 allows hydraulic fluid to enter or exit the forward (rod side) of the hydraulic chamber which forms the rod side hydraulic volume. A rod guide seal assembly 74 provides guidance and acts as a bearing for the sliding rod. This assembly also provides sealing of the rod and the forward hydraulic volume. Actuator rod 76 is directly connected and sealed to a piston/nut carrier 78 and therefore to piston 69). A hollow portion of rod 76 is exposed to hydraulic pressure from the screw side only of piston 69. The hydraulic piston seal on the piston/nut carrier seals one side of the assembly in the housing from the other side. To create an additional layer of redundancy, the hydraulic circuit includes an hydraulic pump 94, 96, which could, when required, cycle on and off to recharge the accumulators 92, 96, with a backup method as described above, using the motor screw drive to move the piston. In such a configured system, there are three layers of redundancy.

(17) This is done using a hollow push rod that is sealed on the clevis end. The push tube is attached and sealed to the nut carrier/piston. The assembly 81 seals hydraulic fluid pressure from one side of piston 69 to the other side.

(18) Referring now to FIG. 3, a drive screw retention ring 80 is shown capturing and retaining drive screw nut 69 in the piston/rod assembly 81 A piston/nut wear guide 86 guides the piston/nut assembly 81. A hydraulic piston seal 88 separates the forward or outer diameter rod side hydraulic volume from the rear or inner diameter of the rod hydraulic volume. A piston/nut wear guide 90 guides the piston/nut assembly 81.

(19) The electric motor screw drive system takes rotary and torque output from motor 44, through the gear/power 52, and 46 transfer system and into the drive screw 58. The nut/piston assembly 81 is prevented from rotating. Because the main drive screw 58 is rotating, and the nut 60 is not allowed to rotate, nut 60 changes linear position coincident with the centerline of the screw 58 shaft. The nut carrier/piston assembly 81 is connected to the rod 76 and can linearly translate rod 76 when moved by the applied load. The thrust output is a function of motor output torque, subtracting the inertial and frictional losses (and in the case of this invention the fluid losses) in the system.

(20) Traditional hydraulic systems designed with redundancy utilize a hydraulic power unit with redundant pump and valve control systems to minimize the impact of failures of individual components. The space requirements, complexity and cost of such a system is significant. In the present invention, the redundancy created by multiplying these components can be re-created in a space efficient system, utilizing an efficient electric operated screw driven linear actuator. Additionally the redundancy of the system utilizes two different technologies, which prevents weaknesses inherent in one system from being multiplied, thus creating a truly independently redundant system.

(21) The hybrid electric-hydraulic actuator system utilizes typical hydraulic system valves for controlling a traditional hydraulic cylinder with additional valves for allowing the cylinder to passively move hydraulic fluid from one side of the piston to the other in the cylinder/s or combined electric hydraulic cylinder. This allows for the piston to be moved with the torque input from an electric motor drive system to the screw/drive independent of the hydraulic system.

(22) When hydraulic fluid power is used to create a thrust force to move the nut piston assembly 81 during either extension or retraction of rod 76, the thrust force generated by the hydraulic pressure against piston 69 is allowed to passively back drive the screw 58 and power train. There is no torque applied via operation of the electric motor. The use of a high efficiency screw 58 limits the forces required to back drive screw 58 to a minimum.

(23) When power is supplied to the electric motor 44 to create a thrust force in extension/retract rod 76, the hydraulic system is allowed to pass hydraulic fluid from one side of the piston to the other with minimal losses. The thrust loss due to pushing hydraulic fluid through the control valve would be determined by the sizing of the control valves and hydraulic lines.

(24) Alternatively, hydraulic pressure in conjunction with the application of torque from electric motor 44 could be applied to either side of piston 69, to match the speed and direction of the drive screw nut 60, to account for fluid losses (which would equate to a loss in thrust generation). This would be useful in situations where a maximum speed is required for the movement of extend/retract rod 76.

(25) This embodiment combines the functionality of both an electric screw driven linear actuator with that of a traditional hydraulic linear actuator system. Because the system is designed to work as an independent electric actuator or an independent hydraulic actuator system that are linked together, the control of the combined system under basic operation are not affected by a failure of the other system. The function of the combined system is to be managed by a high-level control system such as a micro controller or PLC, to manage the logic required to operate. Inputs are numerous and include redundant position encoders, pressure sensors, servo and control valves, VFD, and soft starters. The positions possible include: electric operation with hydraulic system bypassretract; electric operation with hydraulic system bypassextend; hydraulic system operation with passively back driven screwextend; and hydraulic system operation with passively back driven screwretract. Clearly, all positions between these positions are also achievable. Also available are: electric operation with hydraulic deceleration and positioning assist; electric operation with hydraulic hard stop final positioning; hydraulic operation with electric final positioning; and electric operation with pumpless changing of the accumulators. Accumulators are used to store pressurized hydraulic fluid to be used to hydraulically actuate rod 76 even when the hydraulic power system has failed. The accumulators may also provide hydraulic assist to the electric actuation of rod 76.

(26) In the foregoing Detailed Description, various features of the present disclosure are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present disclosure. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present disclosure and the appended claims are intended to cover such modifications and arrangements. Thus, while the present disclosure has been shown in the drawings and described above with particularity and detail, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made without departing from the principles and concepts set forth herein.