Design, modelling and experimental validation of bipenniform shape memory alloy-based linear actuator integrable with hydraulic stroke amplification mechanism
🤖 AI Summary
Conventional electromagnetic actuators suffer from low efficiency, large volume, high cost, and structural complexity. Method: This study proposes a biomimetic linear actuator based on shape memory alloy (SMA) wires featuring a dual-pinnate architecture integrated with a hydraulic stroke-amplification mechanism. A novel multi-layer dual-pinnate SMA coil configuration is developed, supported by mathematical modeling, design failure mode and effects analysis (DFMEA), and experimental validation—all while retaining standard mounting dimensions. Contribution/Results: Under 15 V input, the prototype delivers a thrust of 257 N. Compared to conventional electromagnetic actuators, it achieves a 67% mass reduction, 80% fewer components, 32% lower manufacturing cost, and 19% reduced energy consumption. The design offers advantages in lightweighting, component minimization, high energy efficiency, and fault robustness, making it suitable for highly integrated applications such as building automation, space robotics, and prosthetic devices.
Application Category
📝 Abstract
The increasing industrial demand for alternative actuators over conventional electromagnetism-based systems having limited efficiency, bulky size, complex design due to in-built gear-train mechanisms, and high production and amortization costs necessitates the innovation in new actuator development. Integrating bio-inspired design principles into linear actuators could bring forth the next generation of adaptive and energy efficient smart material-based actuation systems. The present study amalgamates the advantages of bipenniform architecture, which generates high force in the given physiological region and a high power-to-weight ratio of shape memory alloy (SMA), into a novel bio-inspired SMA-based linear actuator. A mathematical model of a multi-layered bipenniform configuration-based SMA actuator was developed and validated experimentally. The current research also caters to the incorporation of failure mitigation strategies using design failure mode and effects analysis along with the experimental assessment of the performance of the developed actuator. The system has been benchmarked against an industry-developed stepper motor-driven actuator. It has shown promising results generating an actuation force of 257 N with 15 V input voltage, meeting the acceptable range for actuation operation. It further exhibits about 67% reduction in the weight of the drive mechanism, with 80% lesser component, 32% cost reduction, and 19% energy savings and similar envelope dimensions for assembly compatibility with dampers and louvers for easy onsite deployment. The study introduces SMA coil-based actuator as an advanced design that can be deployed for high force-high stroke applications. The bio-inspired SMA-based linear actuator has applications ranging from building automation controls to lightweight actuation systems for space robotics and medical prosthesis.
Problem
Research questions and friction points this paper is trying to address.
Developing a bio-inspired linear actuator using shape memory alloys to replace inefficient electromagnetic systems
Creating a lightweight high-force actuator with failure mitigation strategies and experimental validation
Addressing industrial need for compact, cost-effective actuators with high power-to-weight ratio
Innovation
Methods, ideas, or system contributions that make the work stand out.
Bio-inspired bipenniform shape memory alloy actuator
Hydraulic stroke amplification mechanism integration
Multi-layered mathematical modeling with experimental validation
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