Wed 16 Nov 2005 Electric Motors in Robot Transmissions and Arms 2

Presentation Contents
Background
Electric Motors
Electricity
Mechanical Motion
Construction and Types of Electric Motors
Brush-Type DC Motor Example

Wed 16 Nov 2005 Electric Motors in Robot Transmissions and Arms 3
Presentation Contents
Background
Electric Motors
Electricity
Mechanical Motion
Construction and Types of Electric Motors
Brush-Type DC Motor Example

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Electric Motors Introduction
Electric motors convert energy and power
Electrical power to mechanical power
Electricity (electron motion)
Voltage V
Current i
Mechanical motion
Rotary
Torque T around a point
Speed N (or ) around a point
Linear
Force F in a straight line
Speed v in a straight line
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Electricity: Basic Ideas
Electricity is a flow of electrons
Voltage V measured in volts
Force of each electron
Voltage can push electrons through things
48V or more can be hazardous
Current i measured in amps
Amount of electron flow
Current can do useful work
Current causes heating
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Electricity different types:
DCDirect Currentbatteries
Electricity flows in one direction
Positive (+ red) and negative ( black)
Comes from battery or DC generator
12V is used in cars (and robots)
ACAlternating Currentwall outlet
Electricity flows back and forth (sine wave)
+/- (black, red) and 0 (white, green)
Comes from inverter or AC generator
110V-120V used in homes (in America)
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Electrical Power
Power = voltage x current
Example: high voltage and low current
240W = 120V x 2A
Small wires but shock danger to humans
Short circuits are a burn hazard!
Example: low voltage and high current
240W = 12V x 20A
Minimal shock hazard but larger wires
Short circuits are a burn hazard!
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Mechanical Motion
Rotary torque (T) and speed (N)
Linear force (F) and speed (v)
Torque
Twisting around a point or shaft
Same as a force acting at some distance
Torque = force x distance
Examples:
1 pound-inch = 1 lb x 1 in
pound-inch or inch-pound
1 newton-meter = 1 N x 1 m

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Rotary Mechanical Units
Torque = force x distance
Foot-pounds (1/12)
Inch-pounds (1)
Inch-ounces (16)
Newton-meters (0.113)
Newton-millimeters (113)
Speed
RPM revolutions per minute (1000)
Radians per second 2 x pi / 60 (104.7)

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Rotary Mechanical Power
Power = torque x speed
Horsepower (in-lb torque x rpm / 63025.)
Watt (Nm x rad/s)
Example: high torque and low speed
0.1 hp = 630 in-lb x 10 rpm / 63025
75 W = 71.2 Nm x 1.047 rad/s
Example: low torque and high speed
0.1 hp = 6.3 in-lb x 1000 rpm / 63025
75 W = 0.712 Nm x 104.7 rad/s

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Linear Mechanical Power
Power = force x speed
horsepower (lb x in/s / 6600)
watts (N x m/s)
Example: high force and low speed
0.1 hp = 55 lb x 12 in/s / 6600
75 W = 245 N x 0.3048 m/s
Example: low force and high speed
0.1 hp = 0.55 lb x 1200 in/s / 6600
75 W = 2.45 N x 30.48 m/s

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Electrical to Mechanical Conversion
Electric Motor converts power
Electricity IN
Voltage (V)
Current (i)
Electrical power = V x i
Rotary Motion OUT
Torque (T)
Speed (N)
Mechanical power = T x N
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Rotary to Linear Transformation
Wheel, Pulley, Sprocket or Arm
Rotary Motion IN
Torque (T)
Speed (N)
Mechanical power = T x N
Linear Motion OUT
Force (F)
Speed (v)
Mechanical power = F x v
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Presentation Contents
Background
Electric Motors
Electricity
Mechanical Motion
Construction and Types of Electric Motors
Brush-Type DC Motor Example

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Construction of Electric Motors
Stator: main stationary part, in housing
Iron core and copper windings OR
Permanent magnets
Rotor: main rotating part, on shaft
Iron core and copper windings OR
Iron core and aluminum bars OR
Permanent magnets OR
Permanent magnets in iron core OR
Iron core alone

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Example of Motor Construction
Brush DC Motor
Stator in housing
permanent magnets
Rotor on shaft
iron core with copper windings
Commutator
Copper bars on end of shaft
Carbon brushes in end of housing

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Operation of Electric Motors
Most run by action of two magnetic fields:
Stator
Rotor
One magnetic field is stationary
Permanent magnets OR
Constant flow of current through coil or coils
One magnetic field is rotating or changing
AC through coil or coils OR
Switched current flow through coil or coils
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Switching for DC Electric Motors
Commutator
Switches DC current and magnetic field
Brush commutator
Carbon brushes attached to housing
Copper bars attached to rotor
Easy to make but brushes eventually wear out
Most small DC motors
Electronic commutator
Switching circuit, usually with sensor
Used with permanent magnets on rotor
Computer fan motors, run from internal DC supply
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Common Types of Electric Motors
Brush DC
~99% of DC motors are brush-type.
Some AC motors are brush-type AC/DC motors.
Brushless DC (Electronic Commutation)
DC motors needing long life or high efficiency
AC Induction
~90% of AC motors are induction-type.
Construction (FYI):
Stator with windings
Rotor with iron core and aluminum bars
Bars look like a squirrel cage / hamster wheel
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Presentation Contents
Background
Electric Motors
Electricity
Mechanical Motion
Construction and Types of Electric Motors
Brush-Type DC Motor Example

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Brush-Type DC Motor Example
Motor performance chart or curves and specs
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Brush DC Motor Example: CIM Motor from Robot Kits
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Brush DC Motor Operation
Output speed N varies with motor voltage V
In CIM motor performance chart, voltage is always 12 V.
Speed control can be done by varying the voltage with PWM.
PWM is pulse width modulation done with electronic switching.
Input current i varies with output torque T
In CIM motor performance chart, i(T) is a straight line
Current is proportional to total torque
Some friction torque in motor, so line has an i intercept
Power = torque x speed
Goes up with increasing torque
Goes down with decreasing speed
Maximum with best combination of torque and speed
Efficiency is 59% at rated power
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Brush DC Motor Example: CIM Motor from Robot Kits
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Brush DC Motor Summary
Power
Maximum Output Power = 286 watts mechanical power
Rated Output Power = 204 watts
Rated at speed of 4,300 rpm (at 12 V)
Rated at torque of 64 oz-in (in-oz) = 4 in lb
Rated at current of 28.7 amps (12 V x 28.7 A = 344 W electrical input)
Torque
Maximum torque (stall torque) = 276 oz-in = 17.25 in-lb
Maximum torque requires 112.4 amps!
Torque at 40 A ~ 90 oz-in = 5.6 in-lb
Speed
Maximum (12 V) No-load speed of motor alone = 5,600 rpm
Maximum (12 V) speed of motor at 40 A ~ 3,600 rpm