SERVOMOTOR SIZING AND APPLICATION

by
Gary Kirckof, P.E.
 Contents

About the Author xvii

Introduction xix

1 -

Basic Kinematics 1
Introduction 1

Rectilinear Motion 2

Position and Distance 2

Velocity and Speed 3

Acceleration and Deceleration 4

Jerk 4

Constant of Integration and Initial Values 4

Four Basic Motion Cases 6

Velocity Profile 12

Common Motion Profiles 14

Rotational Motion 49

Angular Position 50

Angular Velocity 51

Angular Acceleration 52

Angular Jerk 52

Vectors 53

Rotational Motion Summary 53

2 -
Advanced Kinematics 55

Introduction 55

Harmonic Profile 56

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 Servomotor Sizing and Application

Scaling Normalized Profiles 57

Cycloid Profile 58

Constructing Profiles 59

Time Scaling 60

Distance Scaling 62

Offsets 63

Profile Construction Rules 63

Profile Construction Process 67

Modified Trapezoid Profile 68
General Modified Trapezoid 76

Modified Sine Profile 80

General Modified Sine Profile 83

.
Poly 5 87

Poly 5 Example 89

Poly 5 as a Segment 91

Electronic Camming 92

Pick and Place Example 92

Changing Profiles 101

Tracking Example 103

Recovery 109

User Profiles 110

Linear Interpolation 111

Cubic Spline Interpolation 113

Summary 114

Duty Cycle 115

Introduction 115

Peak Velocity 115

Peak Torque 116

Continuous Torque 116

Duty Cycle 117

Duty Cycle Example 118

Adding or Subtracting Friction 121

Effective Torque 121

Effective Torque Example 123

Combining Effective Torques 124

Torque versus Velocity Curves 126

Motor Selection 128

Torque Margin 129

 Contents

Non-Duty-Cycle Conditions 131

Dynamic Braking 133

Rectifier and DC Bus 133
Inverter 134
Dynamic Braking Circuit 134

Sizing the Dynamic Braking Resistor 135

Minimum Stopping Time 139
Sharing the DC Bus 140
Motor Sizing Steps 140

4 -
Profile Comparison 143
Introduction 143
Effective Acceleration 143
General Trapezoid 144

Scaling Example 146

S Curve Segment 147
General Bell 148

Harmonic 148

Cycloid 149
Modified Trapezoid 149
General Modified Trapezoid 149
Modified Sine 149

General Modified Sine 149

Poly 5 as a Profile 150

Profile Comparison 151
Recommendations 154
Constant Speed 155
Coordinated Motion 156
Conclusion 156

5-Inertia 157
Introduction 157
What is Inertia? 159

System of Particles 160

Inertia of a Hoop 162
Inertia of a Cylinder 163
Inertia of a Hollow Cylinder 165
Inertia of a Solid Cone 168
Inertia of a Solid Sphere 169

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 Servomotor Sizing and Application

Parallel Axis Theorem 171

Example 173

Units of Inertia 176

Perpendicular Axis Theorem 177

Inertia of a Cylinder about a Perpendicular Axis 178

Inertia through a Gear Ratio 181

Inertia of a Belt and a Load on a Belt 183

Total Reflected Inertia 184

Inertia of a Lead Screw 185

Servomotor Sizing Procedure 187

Conclusion 187

Object Inertia Summary 189

6 -
Gear Ratios 199
Introduction 199

Gear Ratio Physics 199

Position, Speed and Acceleration Changes 200

Torque Changes 202

Inertia Changes 204

Selecting a Gear Ratio 205

Speed Matching 206

Optimal Gear Ratio 208

Stability and Inertia Ratio 212

Selection Process 216

Backlash 224

Common Mechanism Types 226

Inline Planetary Gearboxes 226

227
Right Angle Gearboxes
Worm Gears 229

Timing Belts and Pulleys 230

j

Lead Screws 236

Rack and Pinions 238

Roller Chain 240

7 -
Friction 247
Introduction 247

Coulomb Friction 248

Vibration 251

Normal Force 252

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 Contents

Rolling Friction 254

Viscous Friction 256

Lead Screws 258

Ball Screws 263

Disk Brakes 264

Stopping Time 266

Thrust Bearings 268

Journal Bearings 271

Bushings 274

Seals 276

Loading 278

8 -

Sizing Steps 281

Sizing Procedure 281

9 -
Horizontal Pusher Example 291
Introduction 291

Application Data 293

Product Kinematics 295

Load Conditions 296

Load Kinematics 297

Inertia 297

Frictional Torque and Torque Due to Additional Loading 298

Preliminary Torque 299

Prepare Gearbox Data 300

Prepare Servomotor Data 301

Select a Servomotor 302

Finalize Calculations 304

Special Conditions 305

Dynamic Braking 306

10 -
Vertical Elevator Example 311
Introduction 311

Gravitational Force 312

Power flow 313

Application 316

Application Data 316

Product Kinematics 319

Load Conditions 320

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 Servomotor Sizing and Application

Load Kinematics 321

Load Inertia 321

Friction and Additional Torque 322

Preliminary Torque 322
Prepare Gearbox Data 324
Prepare Servomotor Data 324
Select a Servomotor 325

Finalize Calculations 327

Special Conditions 329

Emergency Stopping 329

Dynamic Braking 331
Motor Brake 333

Efficiency Correction 335

Motor Brake Revisited 335

Motoring versus Regenerating 336

Efficiency Variables 336
Group 1 337

Group 2 339

Group 3 340

Comparison 341

Nip Roller Example 343

Introduction 343

Application Data 344

Product Kinematics 348

Constant Velocity Case 348

Normal Acceleration Case 349

Emergency Stopping Case 350

Jogging Case 350
Load Conditions 351

Load Kinematics 352

Load Inertia 352
Load Friction and Additional Torque 353
Preliminary Torque 353

Prepare Gearbox Data 354

Prepare Motor Data 354
Select a Servomotor 355
Finalized Calculations 356
 Contents

Dynamic Braking 356

Registration Control 357

12 -
Vectors 363
Introduction 363

Position Vectors 363

Vector Addition 365

Vector Subtraction 367

Polar Representation 367

Arc Tangent 368

Velocity Vector 370

Acceleration Vector 373

Loop Closure Method 375

Cross Product 377

Torque Example 380

Solving for Forces and

Torques 382
Link Forces and Torques 382

Joint Forces 383

Solving for Forces and Torques for a System of Linkages Summary 384

13 -
Crank Arm 387
Introduction 387

Position Vectors 387

Quadratic Angle Equation 391

Crank Angle 394

Arm Angle 395

Velocity Vectors 395

Relative Velocity 398

Acceleration Vectors 400

Relative Acceleration 404

Forces and Torques 405

Crank Free-Body Diagram 406

Arm Free-Body Diagram 408

Slider Free-Body Diagram 410

Joint Forces 411

Motor Torque 412

Common Configurations 413

Forward Kinematics 413

Test 417

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 Servomotor Sizing and Application

Angles 418
Angular Velocities 418
Accelerations 420

Peak Torque 421

RMS Torque 422

General Design Considerations 423

Linkage Length 423

Friction 425

14 -
Crank Arm Example 427
Introduction 427

Application Data 427

Load Kinematics 431

Reverse Kinematics and Torque 436

Gear Box Selection 437

Peak and RMS Torque 439

Motor Conditions 440

15 -

Two Axis Parallel Robot 443

Introduction 443

Mechanism 444

Position Vectors 445

Position Limits 450

Preventing Envelope Violations 453

Velocity Vectors 457

Velocities 459
Acceleration Vectors 461

Accelerations 463

Supporting Links 465

Forces and Torques 467

Link 2 Free-Body Diagram 468
Link 3 Free-Body Diagram 470

Link 5 Free-Body Diagram 472

Link 4 Free-Body Diagram 473

Link 10 Free-Body Diagram 475

Link 8 Free-Body Diagram 477

Link 7 Free-Body Diagram 478

Link 6 Free-Body Diagram 480

Off-Center Loads 482

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 Contents

Joint Forces 483

System of Equations 484

486
Torque Solution for Motor A
Torque Solution for Motor E 488

Motor Sizing Process 490

Step 1 -
Gather Application Data 490

Step 2 -
Determine Load Kinematics 491

Step 3 -
Calculate Reverse Kinematics 491

Step 4 -
Calculate Accelerations 491

Step 5 -
Calculate Motor Torques 491

Summary 492

16 -

Two Axis parallel Robot Example 493

Introduction 493

Application Data 494

Robot Mechanics 495

Product 496
Kinematics 496

Tool Points 496

Motion Profiles 499

Reverse Kinematics and Torque 507

Gearbox and Motor Selection 510

Appendix 1 -
Units and Symbols 513
Unit Abbreviations 516

SI Unit Prefixes 517

Greek Alphabet 518

Unit Conversion 519

Angular Position 519

Energy 520

Force 520

Inertia 520

Length 520
Mass and Weight 521

Moment (Torque] 521

Power 521

Temperature 522

Volume 523

Weight and Fo rce 523

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Appendix 2 -

Shapes 525
Triangle 525

Circle 526

Trapezoid 527

Ellipse 528

Parabola 529
Cylinder 530

Cone 531

Sphere 532
Toroid 532

Paraboloid 533

Appendix 3 Common Integrals and Differentials

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535
Terminology 535
Integrals of X 535
Derivatives of X 537

Trigonometric Integrals 539

Trigonometric Derivatives 540
Exponentials 541
Chain Rule 541

Appendix 4 -

Trigonometric Identities 543

Basic Relationships 543

Pythagorean Identities 544

Sum of Angles 544
Sum to Product 545
Product to Sum 545
Power Reduction 545
Half and Double Angle 546
Phase Shift 546

Negation 547
Law of Sines 547

Law of Cosines 548

Law of Tangents 548
Inverse Functions 548
Power Series 548

Complex Plane 549

Quadratic (1) 549
Quadratic (2) 550
 Contents

Appendix 5 -

Timing Diagram Example 551

Appendix 6 -

Cubic Spline 553

Introduction 553

Creating a Cubic Spline 555

Reduce Quantity of Unknowns 556

Coefficient Summary 558

Governing Equation 558

Boundary Conditions 559

Solving System of Equations 566

Natural Cubic Spline Example 572

Glossary 579

Index 589

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