Principles of Mechatronic

Sheet_2_Actuators
1) The DC motor can be modeled as an inductor with a resistor, write down
the electrical equation of the DC motor permanent magnet, and find the
equation of Maximum power. (at the end of the sheet)

2) Mention the five main considerations for actuator selection and explain
two of them.
Technology: electric, hydraulic, pneumatic, thermal, other

Functional Performance: maximum force possible, extent of the linear range, maximum
speed possible, power, efficiency, dynamic response

Physical properties: weight, size, strength

Quality Factors: reliability, durability, maintainability, accuracy, resolution.

Cost: expense, availability, facilities for testing and maintenance

3) Explain with drawing how an H-Bridge can control the speed and
direction of a motor.

PWM: Rapidly switch between S1-S4 closed and S2-S3 closed

Averages to effective voltage across motor between -V and +V depending

on time spent in S1-S4 and S2-S3 states

Switch control signals are simply digital signals

• The H-Bridge Chip has a “Direction Pin” that can be set using digital logic
High/Low
controls flow through the motor in the forward or reverse configuration.
4) DC motors are classified based on the connection between field coil and
armature coil. Explain the difference between i) Series wound motor, ii)
Shunt wound motor from point of view of starting torque and no load
speed.
 6) You have been assigned to follow up on the design of a former employee.
The only documentation that you can find shows that the motor chosen has
Kt = 9.33 and produces 2.8 Nm at stall when driven at 12V. The design requires
that the motor deliver 0.4 Nm at 1500 rpm. The motor was supposed to be
driven from a 12V supply and switched by a ULN2003 (max. 325 mA).

( Kt = 1.3524 Ke [oz-in/A ; V/krpm])

Your boss has asked you:

a) How can I find out how much current the motor will draw at stall ?
Ts = Kt *Is
Is = Ts/Kt = 2.8/9.33 = 0.3A
b) Can the ULN2003 safely switch the required current?
325 > 300 yes, barely safe

c) How can I find the NL Speed ?

Wnl = V/Ke = (12 * (1.352))/9.33 = 1.739 Krpm
 d) How can I find the coil resistance ?
V = I*R
R = V/I = 12/0.3 = 40 Ω

e) How can I find the torque at a given speed ?

T = ((Kt *V) – (Ke*Kt*W)) / R
T = 2.799 – 1.607 *W
f) Will the design meet the requirements for torque & speed? If not, what
changes could you suggest? 0.4 Nm at 1500 rpm

V K T× Ke× ω
T =K T −
R R

T = 0.38 Nm < 0.4 Nm (required)

Voltage drop = 0.8 V

V = 12 – 0.8 = 11.2 V

T = 0.198 V < 0.4 V

0.4 = ((9.33 *V) – (6.89*9.33*1.5)) / 40

V = 12.05 V
Accounting for the voltage drop: V = 12.05+0.8 =12.85 V required

So,

1- We have to switch to higher voltage source and use PWM to get the
specific requirements.
 2- Use voltage divider but this will take current , it will burn power.
3- Change the motor (change R)

Switching to 15 Volt source and then duty cycle = 12.85/15 *100 = 85%

7) State the different types of actuators.

8) Given a permanent magnet DC motor with a measured stall torque of 28 Nm, a no

load speed of 1160 rpm (both at 12V) and a measured armature resistance of

2.,estimate:

1) The Torque Constant, Kt. 2) The stall current.

In a specific application, the motor will driven from a 15V source and is required to

deliver 10 Nm at 500 rpm,

3) Show that the motor can meet this requirement.

4) Estimate the required drive duty cycle when operating at this

speed-load point.

5) Estimate the motor current when operating at this speed-load

point.

Solution:
Vs = 12 V, R = 2 Ω, 12= I* R => Is = 6 A

T = Kt I, 28 = Kt * 6 => Kt = 4.6 oz.in/A

Desired V = 15 v, T = 10 inoz, w= 500 rpm.

To meet speed requirement , what current is required:

V = I*R + Ke*w
15 = I*2 +Ke* 0.5

Ke = V/Wnl = 12/1.16 = 10.34 (Take note that we used V = 12v because

no load speed was measured at 12 v)

 I = 4.9 A at 15 v and 500 rpm.

 T = Kt * I = 4.6*4.9 = 23 > 10 Here at 4.9 A we can achieve the
required torque at 500 rpm but we desire exactly T = 10 inoz , we
need the required current for this requirement.
 T = Kt * I => 10 =4.6 * I => I = 2.14 A
 V = I *R + Ke * W = 2.14*2+ 10.34 * 0.5 => V = 9.456 v => Duty
Cycle: 9.456/15 * 100 = 63%

DC PM Modeling

KVL : ∑ V = 0

V = I*R + L dI/dt + Ke*W

At steady state : L dI/dt = 0

V = I*R + Ke* W

T α B and B α I

Then T α I

T = Kt * I
Then : V = I*R + Ke* W  (1)

T = Kt * I

I = T/Kt  (2)

Substitute (2) into (1)

V = (( T/Kt) * R) + Ke* W

V = (( T/Kt) * R) + Ke* W

So, At T = 0 No load over the motor

V = Ke * W - W = V / Ke (no load speed)

AND

V = (( T/Kt) * R) + Ke* W

At W = 0 (Stall: enough torque to stop the motor)

Ts = (V/R) * Kt

Ts = Is *Kt
 Where: Ts ….Stall torque

Is …..Stall current

Back to the first equation: V = (( T/Kt) * R) + Ke* W

T×R
V− =K e × ω
KT

V T ×R
ω= −
Ke KT × K e

T×R
ω=ω nl −
K T × Ke

Rearrange:
V K T× Ke× ω
T =K T −
R R

speed-torque curves
for two voltages
w

Problem:
Consider a rotary motion axis driven by an electric servo motor. The rotary load is
directly connected to the motor shaft without any gear reducer (Fig. 1). The rotary
load is a solid cylindrical shape made of steel material, d=75mm, l=50mm,
ρ=7800kg/m3.The desired motion of the load is a periodic motion (Fig. 2). The total
distance to be traveled is 1/4 of a revolution. The period of motion is tcyc=250 msec.,
and dwell portion of it is tdw=100 msec., and the remaining part of the cycle time is
equally divided between acceleration, constant speed and deceleration periods,
ta=tr=td=50 msec. Determine the required motor size for this application.

Fig.(2)
Fig. (1)

Solution:

1) Determine the Net inertia:

J total=J m+J eff

where:

Jtotal=the total inertia reflected on the motor axis.

Jeff=the load inertias reflected on the motor shaft J eff =J L .

Jm=the motor rotor inertia.

The ratio of motor inertia to reflected load inertia should be between one-to-
one and up to one-to-ten.
Jm 1 1
= ~
J eff 1 10

The one-to-one is considered the optimal match (an ideal case), where the motor
drives a purely inertia load and this inertia ratio results in minimum heating of the
motor. Let us assume that we will pick a motor which has a rotor inertia same as
the load so that there is an ideal load and motor inertia match.

J m=J eff =0. 0012 kg . m2

∴ J total =J m +J eff =0 . 0024 kg . m2

2) Determine the Net inertia:

∑ T (t )=T total (t )=T m (t )−T R (t )

where:

Ttotal(t)=the total torque.

Tm(t)=the torque generated by the motor.

TR(t)=the resistive load torques on the system, where TR(t) represent the sum
of all external torques. If the load torque is in the direction of assisting
the motion, it will be negative, and net result will be the addition of
two torques. The TR(t) may include friction (Tf), gravity (Tg), and
process related torque and forces (i.e. an assembly application may
required the mechanism to provide a desired force pressure (TR).
∵ T R (t )=0
∴ T total (t )=T m (t )

3) Fundamental Equations for torque calculation:

The torque and motion relationship is:

J total θ̈=∑ T

(J m +J eff ) θ̈=T m

The required torque to move the load through the desired cyclic motion given
in Fig. 2 can be calculated if the value of θ̈ calculated.

4) Define the desired cyclic motion profile in the form of load (motor) speed
versus time:
From the desired motion profile specification, we can determine the velocity
and acceleration as shown in Fig. 3. of the actuator can be deliver using the
kinematic relations.
250−100
t a =t r =t d = =50 m sec .
3

where:

ta=acceleration mode time.

tr=constant speed mode time.

td=deceleration speed mode time.

5) Calculate the maximum speed θ̈ max required to define this profile from the
motor:
From displacement motion profile:
1 π
θtotal =θa + θr +θd = ×2 π=
4 2
 note that:

θ(t )=∫ θ̇(t )dt

From velocity motion profile:

1 1
θtotal = θ̇ max t a + θ̇max t r + θ̇ max t d
2 2
t a +2 t r +t d
θtotal =θ̇max ( )
2

2 θtotal
θ̇ max =
t a +2t r +t d

π
∴ θ̇max = =15 . 7 rad /sec
200×10−3 (31.14)
60 { θ̇ max
n= =150 rpm ¿
2π (300)

6) Calculate the angular acceleration θ̈ :

Note that:

d θ̇
θ̈=
dt

From velocity motion profile:

d θ̇a θ̇ max −0 θ̇ max 15 . 7
θ̈ a= = = = =314 rad /sec2
dt t a −0 t a 50×10−3

d θ̇r θ̇max −θ̇ max 0

θ̈r = = = =0
dt ( t a +t r )−t a t r
 d θ̇ d 0−θ̇ max −θ̇ max −15 .7
θ̈ d = = = = −3
=−314 rad /sec2
dt (t d +t r +t a )−(t r + t a ) td 50×10

7) Use Fundamental equation for torque calculation at each mode:

(J m +J eff ) θ̈=T m

∴ T m =( J m +J eff ) θ̈ a =0 . 0024×314=0. 754 N . m

a

∴ T m =( J m + J eff ) θ̈r =0
r

∴ T m =(J m +J eff ) θ̈d =0. 0024×−314=−0 . 754 N . m

d

The torque diagram profile is shown in Fig. 3.

8) The Peak torque (maximum torque):

Hence, the peak torque requirement is

T max =0 . 754 N .m

9) Trms= root mean square torque over entire cycle:

√
t cyc

∫ T m (t )2 dt
0
T rms=
t cycle

From torque diagram:

T rms=
√ T m 2 t a +T m t r +T m t d +T H t dw
a
2
r
2
d

t a +t r +t d + t dw
2
where : TH=holding torque required in dwell mode=0

T rms=
√ (1 .0032 )2 ×50×10−3 +0+(−1 . 0032)2 ×50×10−3 +0
250×10−3
= 0 . 6344 N .m

Therefore, a motor which has rotor inertia of about 0.0012 kg.m2, maximum
speed capability of 20.9 rad/sec(199.6 rpm)or better, peak and RMS torque rating
in the range of 1.0032 N.m and 0.6344 N.m range would be sufficient for the task