Hybrid design optimization methodology for electromechanical linear actuators in automotive LED headlights

Đurić, Mario (avtor), Selak, Luka (avtor), Bračun, Drago (avtor)

The development of electromechanical linear actuators (EMLAs) aims at compactness, energy efficiency, and high reliability. Conventional design methods often rely on costly prototypes and individual considerations of mechanics, electromagnetics, and control dynamics. This leads to long development cycles, inadequate treatment of nonlinear effects, and suboptimal performance. To address these challenges, our paper introduces a novel hybrid design methodology, integrating Analytical Modeling, Finite Element Analysis (FEA), Genetic Algorithms (GAs), and targeted experiments. Analytical Modeling provides rapid sizing, FEA combined with a GA refines geometry, and targeted experiments quantify nonlinear effects (friction, wear, thermal variability, and dynamic resonances). Unlike conventional methods, the integration is performed within iterative loops, using empirical data to refine simulation assumptions. As a result, development time is reduced by 30% and nonlinear effects are precisely addressed. The method is demonstrated on an automotive-grade EMLA. Its design is based on a claw-pole Permanent Magnet Stepper Motor, a trapezoidal lead screw, and an open-loop control with Hall effect end-position detection. After applying the method, the EMLA delivers more than 40 N of push force and achieves 600,000 actuations under the required conditions, making it suitable for various applications.

• Jezik: Angleški jezik
• Ključne besede: hybrid design methodology, actuator, electromechanical linear actuator, EMLA, system optimization, automotive LED headlights, targeted experiments for nonlinear effects
• Vrsta gradiva: Članek v reviji
• Tipologija: 1.01 - Izvirni znanstveni članek
• Organizacija: FS - Fakulteta za strojništvo
• Status publikacije: Objavljeno
• Različica publikacije: Objavljena publikacija
• Leto izida: 2025
• Št. strani: 30 str.
• Številčenje: Vol. 14, issue 10, art. 465
• PID: 20.500.12556/RUL-174055
• UDK: 621
• ISSN pri članku: 2076-0825
• DOI: 10.3390/act14100465
• COBISS.SI-ID: 250585859
• Datum objave v RUL: 26.09.2025

Gradivo je del revije

• Naslov: Actuators
• Skrajšan naslov: Actuators
• Založnik: MDPI
• ISSN: 2076-0825
• COBISS.SI-ID: 522943513

Licence

• Licenca: CC BY 4.0, Creative Commons Priznanje avtorstva 4.0 Mednarodna
• Povezava: http://creativecommons.org/licenses/by/4.0/deed.sl
• Opis: To je standardna licenca Creative Commons, ki daje uporabnikom največ možnosti za nadaljnjo uporabo dela, pri čemer morajo navesti avtorja.

Projekti

• Financer: ARIS - Javna agencija za znanstvenoraziskovalno in inovacijsko dejavnost Republike Slovenije
• Številka projekta: P2-0270
• Naslov: Proizvodni sistemi, laserske tehnologije in spajanje materialov