Electrification of Heavy-Duty Robotic Manipulators via PMSM-Driven Electromechanical Linear Actuators

Abstract

This paper presents a unified, actuator-aware framework for the modeling, optimization, planning, and experimental realization of heavy-duty robotic manipulators (HDRMs) actuated by electromechanical linear actuators (EMLAs). The framework preserves the electromechanical energy-conversion chain, integrating the electrical dynamics of the permanent-magnet synchronous motor (PMSM), the mechanical transmission of the gearbox and screw mechanism, and the manipulator-level force-velocity coupling within a consistent system-level model. A multi-objective configuration optimization is formulated to identify the most suitable combination of motor, gear, and screw parameters that satisfy torque-speed, voltage, and current constraints. At the manipulator level, joint-space feasibility maps are constructed that capture actuator limits and payload-dependent dynamics. These maps are extended to payload-adaptive feasibility mapping using learned interpolation and are employed in a constraint-aware trajectory generation and control scheme that maintains feasibility during motion execution. The complete framework is experimentally validated on a one-degree-of-freedom EMLA testbed driven by an 11.6 kW PMSM and coupled to a hydraulic load emulator. The results demonstrate accurate trajectory tracking, preserved feasibility, and close correspondence with simulation, confirming the reliability of the proposed modeling, optimization, and control integration. Overall, the developed framework establishes a consistent digital-to-physical methodology for the electrification of HDRMs, enabling scalable and energy-efficient operation in heavy-duty applications.