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Design Realization: John Canny 10/30/03

This document discusses physics concepts related to motion and motors. It explains Newton's laws of motion, kinetic energy, momentum, and torque. It then describes different types of motors including DC motors, stepper motors, AC induction motors, and linear actuators. DC motors provide controllable options for speed and torque control applications, while AC motors are good for inexpensive high-power uses with less precision needs. Stepper motors and direct-drive torque motors offer additional options.

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muserahmat
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33 views

Design Realization: John Canny 10/30/03

This document discusses physics concepts related to motion and motors. It explains Newton's laws of motion, kinetic energy, momentum, and torque. It then describes different types of motors including DC motors, stepper motors, AC induction motors, and linear actuators. DC motors provide controllable options for speed and torque control applications, while AC motors are good for inexpensive high-power uses with less precision needs. Stepper motors and direct-drive torque motors offer additional options.

Uploaded by

muserahmat
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Design Realization

lecture 20

John Canny
10/30/03
Last time
 Real-time programming
This time
 Mechanics – Physics and Motors
Review of physics
 Newton’s law for translation:
F=ma
F in Newtons, m in kg, a in m/s2.

 Acceleration a = dv / dt

 Kinetic energy E = ½ m v2
E in Joules, m in kg, v in m/s.
Physics of translation
 Momentum p = m v and so F = dp / dt

 In the absence of force, momentum is


conserved.

 Momentum conservation implies energy


conservation.
Physics of rotation
 Rotation is more complex; Euler’s equation:
T=I + xI
T (torque) in N-m,  in radians/sec,  in
radians/sec2, I in kg-m2,  = d / dt

 I is a 3x3 matrix, not necessarily diagonal.

 If T = 0, then I  = -  x I  which is usually


non-zero. So  is non-zero,  changes with
time, and the object wobbles.
Physics of rotation
 Angular momentum is q = I 

 The rotation equation simplifies to T = dq / dt


because

dq/dt = I d/dt + dI/dt  = I  +  x I 

 So even though an object wobbles when there is


no external force, the angular momentum is
conserved: q = I 
Physics of rotation
 Kinetic energy of rotation is ½ T I 

 In the absence of external torque, kinetic energy


of rotation is conserved.

 But angular momentum conservation does not


imply energy conservation.
Work
 Work done by a force = F x (Joules) where x is
the distance (m) through which the force acts.

 Work done by a torque = T  (Joules)


Power
 Power is rate of doing work.

 Power of a force = F v (Watts).

 Power of a torque = T  (Watts).

 Power often expressed in horsepower = 746


Watts
Motors
 Motors come in several flavors:
 DC motors
 Stepper motors
 (AC) induction motors
 (AC) Single-phase motors
 (AC) Synchronous motors

 The first two are highly controllable, and usually


what you would use in an application. But we
quickly review the others.
3-phase AC
 Three or four wires that carry the same voltage
at 3 equally-spaced phases:

 Single phase AC requires two wires (only 1/3 the


current or power of 3-phase).
AC induction Motors
 Induction motors – simple, cheap, high-power,
high torque, simplest are 3-phase.

 Speed up to 7200 rpm: speed ~ 7200 / # “poles”


of the motor.

 Induction motors are brushless (no contacts


between moving and fixed parts). Hi reliability.

 Efficiency high: 50-95 %


Single-phase AC Motors
 Single-phase (induction) motors – operate from
normal AC current (one phase). Household
appliances.

 Single-phase motors use a variety of tricks to


start, then transition to induction motor behavior.

 Efficiency lower: 25-60%

 Often very low starting torque.


Synchronous AC Motors
 Designed to turn in synchronization with the AC
frequency. E.g. turntable motors.

 Low to very high power.

 Efficiency ??
DC Motors
 DC motor types:
 DC Brush motor
 “DC” Brushless motor
 Stepper motor
DC Brush Motors
 A “commutator” brings current to the moving
element (the rotor).

 As the rotor moves, the polarity changes, which


keeps the magnets pulling the right way. DEMO

 Highly controllable, most common DC motor.


DC Brush Motors
 At fixed load, speed of rotation is proportional to
applied voltage.
 Changing polarity reverses rotation.
 To first order, torque is proportional to current.
 Load curve:
 Motors which
approximate this
ideal well are
called DC servo
motors.
DC Brushless Motors
 Really an AC motor with electronic commutation.

 Permanent magnet rotor, stator coils are


controlled by electronic switching. DEMO

 Speed can be controlled accurately by the


electronics.

 Torque is often constant over the speed range.


Stepper Motors
 Sequence of (3 or more) poles is activated in
turn, moving the stator in small “steps”.
 Very low speed / high angular precision is
possible without reduction gearing by using
many rotor teeth.
 Can also “micro-
step” by activating
both coils at once.
Driving Stepper Motors
 Note: signals to the stepper motor are binary,
on-off values (not PWM).

 In principle easy: activate poles as A B C D A…


or A D C B A…Steps are fixed size, so no need
to sense the angle! (open loop control).
Driving Stepper Motors
 But in practice, acceleration and possibly jerk
must be bounded, otherwise motor will not keep
up and will start missing steps (causing position
errors).

 i.e. driver electronics must simulate inertia of the


motor.
Stepper Motor example
 From Sherline CNC milling machine:
 Step angle: 1.8°
 Voltage: 3.2 V
 Holding torque: 0.97 N-m
 Rotor inertia: 250 g-cm2
 Weight: 1.32 lb (0.6 Kg.)
 Length: 2.13" (54 mm)
 Power output = 3W

 Precision stepper motor: 0.02° /step, 1 rpm, 3W


DC Motor example
 V = 12 volts
 Max Current = 4 A
 Max Power Out = 25 W
 Max efficiency = 74%
 Max speed = 3500 rpm
 Max torque = 1.4 N-m
 Weight = 1.4 lbs
 Forward or reverse (brushed)
 Many DC motors of all sizes available new and
surplus for < $10
DC Motors – micro sizes
 From Micromo:
 Conventional (brush)
DC motor: 6mm x 15mm
 13,000 rpm
 0.11 m Nm
 Power 0.15 W
 V from 1.5 to 4.5 V
Brushless DC Motors
 From Micromo:
 Brushless DC motor:
16mm x 28mm
 65,000 rpm
 50 m Nm
 Power 11 W
 V = 12 V
DC Motors – gearing
 Gearing allows you to trade off speed vs. torque.

 An n:1 reduction gearing decreases speed by n,


but increases torque by n.

 Ratios from 10:1 to many 1000s :1 are available


in compact “gearheads” that attach to motors.
DC Motors – gearing
 But gears cost efficiency (20% - 50%)

 Gears decrease precision (due to backlash).

 Reduction gear train is normally not


backdriveable (can’t use for “force control”).
DC torque motors
 Some high-end motors are available for direct
drive servo or force applications (no gears).
 They have low speed (a few rpm), high precision
(with servo-ing), and moderate torque.
 Typically have large diameter vs. length, and
use rare-earth magnetic material.
 Cost $100’s (but maybe
less as surplus).
Sensors
 Shaft encoders can be fitted to almost any DC
motor. They provide position sensing.

 Many motor families offer integrated encoders.

 Strain gauges can be used to sense force


directly. Or DC brush motor current can be used
to estimate force.
Linear movement
 There are several ways to produce linear
movement from rotation:
 Rotary to linear gearing:
Linear movement
 Ball screws: low linear speed, good precision
 Motor drives shaft, stages move (must be
attached to linear bearing to stop from rotating).
Linear movement
 Belt drive: attach moving stage to a toothed belt:

 Used in inkjet printers and some large XY


robots.
True Linear movement
 There are some true linear magnetic drives.
 BEI-Kimco voice coils:
 Up to 1” travel
 100 lbf
 > 10 g acceleration
 6 lbs weight
 500 Hz corner
frequency.

 Used for precision vibration control.


Summary
 AC motors are good for inexpensive high-power
applications where fine control isnt needed.

 DC motors provide a range of performance:


 DC brush: versatile, “servo” motor, high speed, torque
 DC brushless: speed/toque depend on electronics
 Stepper: simple control signals, variable
speed/accuracy without gearing, lower power
 Direct-drive (torque) motors, expensive, lower torque

 Linear actuation via drives, or voice coils.

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