The vision of a more electric aerospace drives the pursuit of novel actuation technologies, capable of replacing the conventional fueldraulic actuators while delivering large stroke, speed, and load, within compact and robust designs. Piezoelectric-based actuators emerge as strong candidates due to their high specific power, broad operational temperature range, and miniaturization capability. However, their adoption in aerospace remains challenging due to performance and spatial integration constraints with existing actuators. This thesis advances the stick-slip stepping actuator, identified as a particularly promising topology for its high-speed and control simplicity. A key research gap identified is the need for comprehensive dynamic modeling and a system-level, interdisciplinary approach to capture the complex interactions among the design and operational parameters, that is, electrical driving signals, frictional contact mechanics, inertia, and mechanical design. Firstly, a transient finite element model of a linear actuator configuration is developed to reveal the complete phenomenon of stick-slip motion. A parametric study examined the impact of driving signals, with results verified through experimental prototyping. Secondly, with these insights into the actuator’s motion modes, the interactions between frictional contact and the driving signal’s operating frequency are investigated. By tailoring contact dynamics using different material combinations, the actuator’s performance is enhanced without requiring additional structures. For instance, increasing the friction coefficient from 0.4 to 0.7 would improve the actuator’s load capacity by 42%, while maintaining comparable stepping displacements at frequencies above 100 Hz - particularly suitable for the intended high speed, load, and compact applications. However, limited stepping displacement at lower operating frequencies is observed due to the passive nature of the stick-slip cycle. Therefore, a novel concept of a morphable actuator is developed, which enables active control of the stick and slip stages, allowing complete disengagement of the end-effector from the bearing to significantly enhance motion, including that at low operating frequencies. A compact, single-unit rotary actuator is designed by integrating a macro-fibre composite piezoelectric element within the compliant structure, and a transient numerical model is developed to analyze the dynamic interactions between its mechanical structure and operating signals. Findings indicated that at 1 Hz, more than fivefold improvement in the bearing stepping angle could be achieved as compared to without its morphing ability. Furthermore, the actuator demonstrated a vertical load capacity exceeding 3 kg, which is more than ten times the mass of the bearing itself. In conclusion, these design strategies and contributions establish the foundation for more-electric actuator technologies in the future, opening avenues for their applications in domains such as aerospace, where performance, compactness, and durability are crucial.
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