Introduction to Mechatronics Mech-1540

Actuators
Stefan B. Williams Research Fellow of Mechatronic Engineering

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 1

Schedule of Events
Week 1 2 Date 13/3 20/3 Content Introduction Design Process Q 1 of Assign. 1 Assignment Notes

3
4 5 6

27/3
3/4 10/4 17/4

Actuators
Sensors Assignment 1 Design Exercise Computer Hardware MID SEMESTER BREAK

Q 2 of Assign 1
Q 3 of Assign 1

Due 11/4
Q 1 of Assign 2 Q 2 of Assign 2 Q 3 of Assign 2 Q 4 of Assign 2

7 8 9 10 11 12 13 14

1/5 8/5 15/5 22/5 29/5 5/6 12/6 19/6

Computer Software and Design Tools System Modelling and Control Assignment 2 - Control and Modelling Active Sensor Systems (Graham Brooker) Case Study : Formula SAE Case Study : Unmanned Air/Land/Sea Vehicles Major Assignment Spare

Due 16/5

Due 13/6

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 2

What is an actuator?

a mechanical device for moving or controlling something

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 3

Actuators and Drives

Electric Motors and Drives Hydraulic Drives Pneumatic Drives Internal Combustion hybrids Actuators of the future

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 4

Electric Actuators and Drives

Electrical energy transformed to mechanical energy

DC Motors

AC Motors Linear Motors Stepper Motors

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 5

DC-Motors

Rotary actuators Power range: Fractions of watts to 100s of Kw. Power supply by grid, diesel generator, or batteries Easy to control accurately

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 6

Basic Operating Principle

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 7

DC-Motors
Apply a voltage to armature Armature rotates in magnetic field Speed control by: V

=K.V

Armature voltage Field Strength

Speed proportional to Voltage Torque proportional to current Power=Speed x Torque

1540 Introduction To Mechatronics: Slide 8

Stefan B. Williams

DC Motors: Basic Rules I

Torque proportional to current

T = KT ia
Torque Constant Current flowing in Armature

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 9

DC Motors: Basic Rules II

Voltage Balance in Armature

Ra Raia Va Vb

Ra ia + Vb = Va Ra ia + Kb = Va

Voltage generated by motion of armature in field (like a Generator)

Stefan B. Williams

Back EMF Constant

1540 Introduction To Mechatronics: Slide 10

DC Motors: Basic Rules III

Torque and Speed

T = KT ia

No-load Speed

Ra ia + Kb = Va
Ra 1 = T+ Va K b KT Kb
Stefan B. Williams

T
Stall Torque
1540 Introduction To Mechatronics: Slide 11

DC Motors Behaviour I
Equations of Motion: Torque Drives a Load

B T
J

K TVa K b KT T= Ra Ra

KTVa = Ra

d T=J + B dt

d Kb KT J +B+ dt Ra
Stefan B. Williams

1540 Introduction To Mechatronics: Slide 12

DC Motors: Behaviour II
d K b KT J + B+ dt Ra KT Va = Ra

1 0.9 0.8 0.7 0.6 Output

d (t ) + K1 (t ) = K 2V (t ) dt

0.5 0.4 0.3 0.2 0.1 0

0.5

1.5

2.5 Time (s)

3.5

4.5

(t ) = K 2e K1tV (t )
Stefan B. Williams

Step response of motor speed with varying load

1540 Introduction To Mechatronics: Slide 13

DC Servo Motors

Power range: few W to few kW: for disc drives, X-Y recorders, instruments, robot arms Speed: very low to very high 10000 rpm (use gear boxes) Time-constants (ms): Electrical, Mechanical and thermal Friction: Coulomb, viscous, stiction Often in-built encoders or tachometers

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 14

Permanent Magnet DC Motors

Many DC Servos are now brushless PM-DC motors because of advances in:
1. High energy ceramic and rare earth magnets 2. Development of high power switching semiconductors

No field windings Result is motors which are smaller and linear Motor is inside-out (magnets rotate).

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 15

Digital Control of DC Motors

Pulse-Width-Modulated (PWM)
Output Voltage Sample Period Output is average over sample period

Pulse-Rate-Modulated (PRM)
Output Voltage Constant pulse length
Stefan B. Williams

Output is average Over all periods

1540 Introduction To Mechatronics: Slide 16

When to use a DC Motor

Accurate position or velocity control Low noise, high efficiency Cost not too critical Speed and power payoff (gearing)

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 17

Some Examples
Consumer Products:
CDs, disk drives Fans, drills, etc

Manufacturing
Robots CNC machines

Aerospace
Sensor pointing Fly-by-wire inputs

Cars:
Windscreen wipers Fuel management
Stefan B. Williams 1540 Introduction To Mechatronics: Slide 18

AC-MOTORS: An Introduction

Single or three phase motors 100 Watts MW High power high torque applications Brushless, durable, easy to maintain Now fully digital vector controlled

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 19

AC-MOTORS: Main Features

Brush free full digital control Requires sophisticated algorithms to control speed (hence recent) Frequency control via power converter (field control) Suitable for high speed and/or high power applications Complex structure, heavy weight

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 20

Multi-phase AC servo motors

Drive voltages out of phase Multi-phase induction Better control and power density Transfer function is second order
r k = vc s ( m s + 1)
Stefan B. Williams

vm = Vmcos? t ~

vc = kVm sin t

1540 Introduction To Mechatronics: Slide 21

When to Use an AC Motor

High power required Complex control profiles:
Point to point Velocity

Load Demand
High duty cycle Efficiency Reliable

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 22

Applications of AC Drives

Large Cranes or material handling systems Belts or conveyors High Speed Trains Electric Drive Haul Trucks (930E)

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 23

Stepper Motors

Motors that cause angular shift correspondence to a number of pulses 1st method: providing a fixed number of pulses, motion proportional to number of pulses 2nd method: synchronising rotations with the input pulse frequency

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 24

Stepper Motors
PM type: permanent magnets rotor VR (variable reluctance) type: salient poles rotor, torque is generated from difference of magnetic resistance Applications: Electronic typewriters and printers, magnetic disk drives

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 25

Linear Motors: A Brief Introduction

Slider (rotor), stationary part (stator), and gap are extended in a straight line Linear DC motors, stepping motors, induction motors, etc. Relatively expensive and large for power output

F = iB
1540 Introduction To Mechatronics: Slide 26

Stefan B. Williams

Linear Motors: A Brief Introduction

Miniature & simple structure, low power factor & efficiency Linear DC motors: rare earth PMs, two yokes, moving coil Linear induction motors: eddy current is developed in a good electrical conductor to obtain thrust

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 27

Linear Motors: comparison

Linear Motor Type
Induction: 1. Flat type Single-side 2. Double side Rod type 1.

Advantages
1.

Disadvantages

Examples of use
1. Conveyance of steel plates, tubes, pallets, Separation of non-ferrous metals, High speed (300km/h) railways Tensioning devices 2. Pushers, Automatic doors Head feeding of printers, XY plotters, Copying machines Marking devices Positioning magnetic heads, pen recorders, Needle feed of sewing machines Ultra high speed railways (500km/h)

Easy gap maintenance Thrust is large

Thrust is small

Stepper

2. No need of external bearing mechanisms Open-loop Distance ~ # pulses

Difficult gap maitenance 2. Small stroke motion (max. 2m) Lower speed

DC

High speed, large thrust

Closed loop, small stroke

Synchronous
Stefan B. Williams

Constant feed travel, High efficiency

Need freq. transformer to control speed

1540 Introduction To Mechatronics: Slide 28

Summary of Electric Motors

Servo Motor
DC servo motor:

Advantages
Easy to use, Low priced control device No brush maintenance

Disadvantages
Brush replacement. Has restrictions in respect of operating environment Control device is expensive due to its complexity Detector is necessary

Applicable capacity
0.1 - few 100 Watts

Brushless motor (PM synchronous) Synchronous motor (vector control) Induction motor (vector control) Stepping motor

from few W to few kW

Excellent environment resistivity Durable construction Open loop control, large static torque

Complicated control system Dropped out of step. Large weight/capacity ratio

More than few W Below few 10 W

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 29

Hydraulic Systems and Actuators

Hydraulics: Use of fluids to transmit power:
Pumps are power generators Inverse pumps or cylinders are power drain Valves used for control

Pump or Rotary motor

Linear Actuator (Cylinder)

Traditionally High Power applications Now use integrated electronics and sensing
Stefan B. Williams 1540 Introduction To Mechatronics: Slide 30

HYDRAULIC CIRCUITS

Hydraulic Power Units: Pumps Accumulators (fluid capacitors) Check valves to isolate hydraulic systems Reservoirs Piping and Fittings Proportional/servo valves Hydraulic actuators

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 31

Hydraulic Circuit Components and Symbols

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 32

Rotary Hydraulic Pumps and Motors

General Operating principles:
Fluid is compressed by pump on which mechanical work is done Fluid does work in motor producing mechanical power

Two Types:
Vane/gear pumps Piston/swash-plate

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 33

Hydraulic Motor

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 34

Gear and Vane Actuators

Output shaft rotated by fluid motion (or shaft used to generate fluid flow) Gear motors: The inside of the case is partitioned into 2 with a set of external gears. Vane motors: Torque is generated by the effect of the hydraulic pressure on the sliding vanes fitted on the radially directed slits on the rotor Gear and vane motors are used for small and medium displacements

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 35

Piston and Swash-plate Pumps/Motors

Pistons connected to swash plate Swash plate is angled
Swash plate rotates and pumps fluid Fluid flow rotates swash plate

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 36

Piston and Swash-plate Pumps/Motors

Pistons connected to swash plate Swash plate is angled
Swash plate rotates and pumps fluid Fluid flow rotates swash plate

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 37

Piston and Swash-plate Pumps/Motors

Pistons motors used for medium and high displacement applications Very high power densities available Require an engine (diesel or turbine for example) to drive pump

Variable displacement
Stefan B. Williams

Fixed displacement
1540 Introduction To Mechatronics: Slide 38

Cylinder Actuators
Piston in cylinder acted on by hydraulic pressure Force generated by rod: Single acting Double acting Double cylinder Double rod Efficiency governed by friction, Small internal leakage: hold static load
Stefan B. Williams

Pressure Force

Fc = ?PA c
Friction

Area

1540 Introduction To Mechatronics: Slide 39

Cylinder Construction

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 40

Rod cylinder with swivel clevis mounting

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 41

Hydraulic Valves
Three main valve types:
On/off valves for manual control Proportional valves: Control of volume flow rate Servo valves: Accurate control of flow and pressure

Control Mode: Electric over hydraulic Hydraulic over hydraulic (pilot) Manual

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 42

Electro Hydraulic Servo Valves

Servo: a small input signal produces a large output signal,eg. 0.08W to 100kW. Single stage (pilot control); 2-, 3-stage (with elect. mech. feedback) In the form of an electrically controlled hydraulic amplifier, used in closed loop control position/speed error measured electrically and fed back to correct the flow Typical Applications: Heavy Industry, Rolling Mills, Test Machines, Dynamic Test Cylinder Material Testing

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 43

Servo-Valve Controllers
0-9V Electrical Amplifier 0-1.5A Proportional solenoid with stroke/force to current relationship Force/ Stroke

Machine

Hydraulic actuator

Direction, Proportional Pressure,Flow directional valve, Pressure/flow control valve

Hydraulic flow or pressure proportional to force or travel high force level, permanent magnet linear force motor directly drives spool. A LVDT is attached to the spool to provide spool position feedback. An internal loop is closed around the spool position. Wood Industry, Set Saw Positioning, Basic Metals, Strip Gage Control
Stefan B. Williams 1540 Introduction To Mechatronics: Slide 44

Hydraulic Sensing and Control

Position Sensor

Fully Integrated Control Valve Flow ports

Stefan B. Williams

Selenoid Controller
1540 Introduction To Mechatronics: Slide 45

Digital Flow Control

Integrated Valve

Integrated Manifold Fully Digital Controller

Stefan B. Williams 1540 Introduction To Mechatronics: Slide 46

Electro-hydraulic System Example

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 47

When to use Hydraulics

Large Force, High Power applications High power density Accurate control Rugged environments (explosive, dusty,etc) Now use integrated electronics and sensing Wide range of applications:
www.moog.com www.rexroth-hydraulics.com

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 48

Applications
Heavy Plant
Steel press Large-scale precision motion tables

Mobile Systems
Steering, brakes Propulsion and transmission

Aerospace
Aerolon actuation in aircraft Fin actuation in missiles/rockets

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 49

Pneumatic Systems
Many of the same principles as hydraulics except working fluid is compressed air Compressed air widely available and environmentally friendly, Piping installation and maintenance is easy Explosion proof construction Major disadvantage is compressibility of air, leading to low power densities and poor control properties (usually on/off) Pneumatic systems are suitable for light and medium loads (30N20kN) with temperature -40 to 200 degrees Celsius

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 50

Typical Pneumatic Actuator

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 51

More Pneumatic Actuators

Oscillating actuator (Rack and pinion type)

Air motors (multi-stroke radial piston type)

1540 Introduction To Mechatronics: Slide 52

Stefan B. Williams

Modern Pneumatic Systems

Dual check valves Linear drive

Servovalve offers closed loop control of acceleration, velocity, positioning and force
Stefan B. Williams

Angular Toggle Gripper

Twin cylinder piston vacuum pump or compressor 250 W motor developing 2.8 bar with flow to 8.7 m3/hr

1540 Introduction To Mechatronics: Slide 53

When to use Pneumatics

Low cost and easy to install Clean and easy to maintain Low power densities Only on/off or inaccurate control necessary

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 54

Pneumatic Applications
Manufacturing
Robot grippers Movement of parts Assembly operations

Medical Systems
Drills/cutting tools Suction and clamping

Robotics
Animatronics Grippers Subsea
Stefan B. Williams 1540 Introduction To Mechatronics: Slide 55

Internal Combustion Engine

Fuel energy transformed to mechanical energy

Petrol Engine Diesel Hybrid

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 56

Internal Combustion Engine

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 57

Hybrid Electric Drives - Parallel

Both gas engine and electric motor connected to drivetrain Improved fuel economy and reduced emissions Regenerative braking supplements battery charging Energy density of fuels higher than current battery technologies
Stefan B. Williams 1540 Introduction To Mechatronics: Slide 58

Hybrid Electric Drives - Series

Charge batteries with combustion engine and generator Combustion engine efficiency increased by operating at a single optimised speed Energy density of fuels higher than current battery technologies

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 59

FUTURE ACTUATORS...

Actuators using functional materials Piezoelectric element actuator Ultrasonic Motors Actuators of shape memory alloys Plasma motors Bio-actuators ..and many more !

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 60

Piezo Micro Actuators

http://www.piezo.com/bendedu.html
Stefan B. Williams 1540 Introduction To Mechatronics: Slide 61

Piezo Nano Motors

Thin film lead zirconate titanate (PZT) on silicon

PZT Micro motor

Stefan B. Williams 1540 Introduction To Mechatronics: Slide 62

Shape Memory Alloys (SMA)

SMA=TiNi alloy Height 160mm Weight 0.06kg Changes shape on (electric) heating

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 63

And finally.MEMs

Stefan B. Williams

1540 Introduction To Mechatronics: Slide 64