EG2570 Engineering Design and Practice

ELECTROMECHANICAL DRIVE SYSTEM - GEAR RATIO SELECTION USING THE MATLAB SOFTWARE PACKAGE Location: Monday, Thursday, Friday G012 1. INTRODUCTION
In its simplest form, a drive system will consist of something to be driven - a load - and something to do the driving - a source of motive power or prime mover. In an electromechanical drive system the prime mover will usually be an electric motor of some kind. This design exercise is concerned with an examination of the factors which might affect the determination of a suitable gear ratio to enable a selected prime mover to meet the demands imposed by a predefined load. The exercise comprises three parts: i) firstly, a check that the selected prime mover is suitable for the proposed application. This will be done by checking to see that the prime mover can deliver sufficient POWER to meet the demands of the load. Note that the gearbox does not alter the POWER available, only the TORQUE. ii) secondly, the determination of a suitable gear ratio. This will be done by solving the problem algebraically and be verified and graphically displayed by a MATLAB programme. iii) thirdly, a check to ensure that, over the complete range of load speeds, the drive torque available exceeds the maximum load torque demand. The three main objectives of these exercises are: 1) to provide experience in forming quadratic equations, their solution and their use to produce characteristic curves suitable for component matching; 2) to give awareness of the communication requirements of the graphical presentation of results; 3) to develop skills in using the MATLAB programme to solve engineering problems. Reporting The reporting of this exercise will be IMMEDIATE. Keep a note in your logbook of your algebraic solution and the MATLAB programme you write to verify your solution and to portray it graphically. Either sketch or print out the key figures your programme produces. Include your FINAL SELECTION and the reasoning you used to justify it. ASSESSMENT The exercise will be ASSESSED DURING THE SECOND SESSION on the basis of your logbook and your groups oral report on your selection decision (This will take place at the end of the second session). Therefore you must keep notes in your logbook as the exercise proceeds.

2.

GENERAL ARRANGEMENT

A schematic diagram of the proposed drive arrangement is shown in Figure 1.

JM
Motor

JL
Gearbox
Figure 1 Proposed Drive Arrangement

Load

3. ANALYSIS OF THE DRIVE SYSTEM

3.1 General Definitions and Relationships

We are concerned here only with the mechanical aspects of the drive system, essentially the relationships between the various torques and the resulting angular motions. We begin by noting the various torques acting on the drive system. Firstly we have the torque developed by the motor motor torque, Tm and the torque imposed by the load - load torque, T l The load torque is made up of several components, a static friction torque, TS and a viscous friction torque, TV . The variables of interest to describe the angular motion of the drive system are the angular displacement, angular velocity and angular acceleration of the motor (gearbox input) and the load (gearbox output) shafts. For the motor shaft we denote these by m, m and m respectively. For the load shaft the corresponding variables are l ,l and l , respectively. Note that m = m and m = m and that l = l and l = l . From these it also follows that m = m and that l = l. Also, because of the kinematic relationship for the gearbox, m = Nl ,m = Nl , m = Nl

3.2

Load Torque and Power

With these basic definitions and relationships established we can now begin to derive the equations of motion for the drive system. We shall do this by considering the two shafts independently. Thus the equation which gives the torque, Tl, required to drive the load can be expressed as:

& & Tl = J l + N 2 J m &l + f l + Ts

Equation 3.2.1

The term (J1 + N2Jm ) is called the effective inertia, referred, in this case, to the gearbox output - or driven - shaft. If the corresponding analysis is carried out referring everything to the gearbox input - or driving - shaft then the effective inertia would be (J1 /N 2 + Jm ), referred to the gearbox input shaft. The power absorbed by the load, Pl , can be calculated by multiplying the load torque by the angular velocity of the load. Thus Pl = Tl l Equation 3.2.2

3.3

Motor Torque and Power

The torque available from the motor is obtained from the motor torque-speed characteristics given in Figure 2. The characteristics are given for a series of different values of excitation voltage, EC . Note the graph is of the form T= mm + C where m is the line gradient and C is the crossover point on the y-axis. Thus for any value of motor speed, m, and any value of excitation voltage, EC , the corresponding value of the motor torque Tm, can be obtained. Note that the x-axis of Figure 1 can be used to denote values of the gear ratio N by dividing the range of m through by lmax since under worst operating conditions m = Nlmax. The power developed by the motor, Pm at this speed is given by: Pm = Tmm Pm = Tm Nl, expressed in terms of the load speed, l . Equation 3.2.3 or Equation 3.2.4

3.4

Compatibility Requirements

If the motor is to be capable of driving the load then two conditions must be satisfied: (i) the motor must be capable of delivering sufficient power to meet the power demand of the load, i.e. Pmmax > Plmax where Pmmax is the maximum motor output power and Plmax is the maximum power demand of the load; and (ii) the motor must be capable of providing a driving torque in excess of that required by the load, i.e. NTm > Tl , A failure to meet either of these conditions would mean that the motor was unsuitable for the intended application and that a different motor would have to be selected.

4. COMPONENT DATA 4.1 Motor Data

Motor inertia, Jm Motor torque, Tm 0.004 EC = 115V (max) 0.003 Motor Torque (Nm) 0.002 1.3 x 10-7 see Figure 2. kgm 2

0.001 EC = 0V 150 300 450 600

Motor speed (rad/s)

Figure 2 Torque-Speed Characteristics for AC Servomotor 4.2 Load Data

Load inertia, Jl Static friction torque, Ts Viscous friction coefficient, f, Maximum output shaft velocity, lmax Maximum output shaft acceleration, lmax 1.3 x 10-3 2.12 x 10-2 9.55 X 10-9 100 10 kgm2 Nm Nms/rad rpm rad/s2

5. DESIGN PROCEDURE
The exercise is a MATLAB exercise as well as an analysis of an electromechanical drive system. In the design procedure that follows a variety of tasks are to be accomplished. In addition to producing an algebraic solution the lab requires m-files (batch files for MATLAB) to be written to solve the problems and make the appropriate plots. The mfiles and plots should be included as part of your logbook. Remember to comment the m-files to indicate what is happening.

Necessary steps to prepare an initial MATLAB file for EG2570 gearing system First program 1- Drive the equation of a line which gives the Tm motor torque versus lm motor angular velocity only in maximum voltage 115 V by using the parameters in figure 2. 2- Since lmax is 100 rpm consider l between 0.5 rad/sec and 11 rad/sec and define a vector with 0.5 spacing between elements. 3- Consider gear ratio N between 0.5 to 11 define a vector with 0.2 spacing between elements. 4- Calculate the lm via gear ratio N. 5- Calculate Tm from equation you have derived in step 1. 6- Calculate the drive torque Td via gear ration N. & 7- Since in steady state &l = 0 then according to equation 3.2.1 calculate the load torque from the

& equation Tl = f l + Ts use the load data in 4.2 8- By using the commands for and end in MATLAB store the Td and TL in all 1050 cases that are created in steps 2 and 3. 9- By using the command mesh in MATLAB plot the Td and TL you have stored in step 8. 10- Since it may be difficult to designate the region in which Td>TL by this plot you can write second program which is similar with the first such as:
Second program Drive the equation of a line which gives the Tm motor torque versus lm motor angular velocity only in maximum voltage 115 V by using the parameters in figure 2. Since lmax is 100 rpm consider l between 0.5 rad/sec and 11 rad/sec and define a vector with 0.5 spacing between elements. Consider gear ratio N between 0.5 to 11 define a vector with 0.2 spacing between elements. Calculate the lm via gear ratio N. Calculate Tm from equation you have derived in step 1. Calculate the drive torque Td via gear ration N. & Since in steady state &l = 0 then according to equation 3.2.1 calculate the load torque from the

1) 2) 3) 4) 5) 6) 7)

& equation Tl = f l + Ts use the load data in 4.2 8) By using the commands for and end in MATLAB store the Td and TL in all 1050 cases that are created in steps 2 and 3. 9) By using the commands if and else and end in MATLAB create a confirmation matrix conf so that if Td > TL returns 1 otherwise returns 0. 10) By using the command mesh in MATLAB plot the conf you have created in step 9. 11) This is an easy stair type 3D plot so that feasible gear ratios N could be designated, by looking at ones or top stair. 12) Discuss in your group about, how these feasible gear ratios could be explained and justified via the equations in pages 1-3 and record your ideas it in your log books. 13) Discuss in your group about the implementation of the constraint in page 3 which quotes Maximum output shaft acceleration, lmax 10 rad/s2 and suggest the feasible gear ratios in this case and record all your ideas in your log books.
Note: Apart from the two program above , your efforts in responding to the bolded instructions 12 and 13 determines quality of your report. .