The ball-screw actuator's motion profile was designed using cubic polynomial modeling to achieve smooth and controlled movement over a 450mm range within 8 seconds. The profile was divided into an acceleration phase, a constant velocity phase, and a deceleration phase, each modelled mathematically to prevent sudden changes in velocity and minimise strain on the components. This method allowed for a smooth transition between phases, optimising the system’s performance. The simulation results showed that cubic polynomial modeling provided a predictable and reliable motion curve, meeting precision requirements in aerospace testing environments without placing excessive stress on the actuator components.
The simulation validated the design, confirming that the actuator could achieve the required precision in the motion profile with minimal positional error. Under load conditions, the system maintained stability and demonstrated a maximum deviation of less than 1.2% from the desired position. Stress analysis showed that the ball-screw mechanism could operate under the given load without significant wear, supporting long-term durability. These results suggest that the design can reliably meet the demands of aerospace testing environments.
One of the primary challenges was designing within the constraints of simulation without real-world testing, limiting the ability to account for variables such as thermal effects or unforeseen material stress under continuous operation. In future iterations, integrating more advanced sensors and real-time feedback mechanisms could enhance system accuracy. Further refinement of the control algorithms would help mitigate minor deviations in performance, and testing with different materials for the ball-screw could improve long-term durability and reduce wear.
