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

Jianlong Zhu, Zhe Wang, Minghao Tong (), Longmiao Chen and Linfang Qian
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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

Energies, 2025, vol. 18, issue 19, 1-18

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.

Keywords: direct-drive; rotary actuator; large-inertia payload; FSPM; MPCC (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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