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Overview
DC Motors (Brushed and Brushless) Brief Introduction to AC Motors Stepper Motors Linear Motors
Sean DeHart
Sean DeHart
Sean DeHart
Sean DeHart
DC Motor considerations
Back EMF - every motor is also a generator More current = more torque; more voltage = more speed Load, torque, speed characteristics
Sean DeHart
Brushless DC Motors
Essential difference - commutation is performed electronically with controller rather than mechanically with brushes
Sean DeHart
Commutation is performed electronically using a controller (e.g. HCS12 or logic circuit) Similarity with stepper motor, but with less # poles Needs rotor positional closed loop feedback: hall effect sensors, back EMF, photo transistors
Sean DeHart
Delta
Wye
Sean DeHart
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Brushless DC Motors
Applications CPU cooling fans CD/DVD Players Electric automobiles Pros (compared to brushed DC) Higher efficiency Longer lifespan, low maintenance Clean, fast, no sparking/issues with brushed contacts Cons Higher cost More complex circuitry and requires a controller
Sean DeHart
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AC Motors
Two main types of AC motor, Synchronous and
Induction. Synchronous motors supply power to both the rotor and the stator, where induction motors only supply power to the stator coils, and rely on induction to generate torque.
Sean DeHart
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Sean DeHart
13
AC induction Motors
Induction motors only supply current to the stator,
and rely on a second induced current in the rotor coils. This requires a relative speed between the rotating magnetic field and the rotor. If the rotor somehow matches or exceeds the magnetic field speed, there is condition called slip. Slip is required to produce torque, if there is no slip, there is no difference between the induced pole and the powered pole, and therefore no torque on the shaft.
Sean DeHart
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Synchronous AC Motors
Current is applied to both the Rotor and the Stator.
This allows for precise control (stepper motors), but
requires mechanical brushes or slip rings to supply DC current to the rotor. There is no slip since the rotor does not rely on induction to produce torque.
Sean DeHart
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Stepper Motor
A stepper motor is an electromechanical device which converts electrical pulses into discrete mechanical movements. The shaft or spindle of a stepper motor rotates in discrete step increments when electrical command pulses are applied to it in the proper sequence.
Smriti Chopra
Main features
The sequence of the applied pulses is directly related to the direction of motor shafts rotation.
The speed of the motor shafts rotation is directly related to the frequency of the input pulses.
The length of rotation is directly related to the number of input pulses applied.
Smriti Chopra
Brushless
Very reliable since there are no contact brushes in the motor. Therefore the life of the motor is simply dependant on the life of the bearing.
Incremental steps/changes
The rotation angle of the motor is proportional to the input pulse.
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Working principle
Stepper motors consist of a permanent magnet rotating shaft, called the rotor, and electromagnets on the stationary portion that surrounds the motor, called the stator.
When a phase winding of a stepper motor is energized with current, a magnetic flux is developed in the stator. The direction of this flux is determined by the Right Hand Rule.
Smriti Chopra
At position 1, the rotor is beginning at the upper electromagnet, which is currently active (has voltage applied to it). To move the rotor clockwise (CW), the upper electromagnet is deactivated and the right electromagnet is activated, causing the rotor to move 90 degrees CW, aligning itself with the active magnet. This process is repeated in the same manner at the south and west electromagnets until we once again reach the starting position.
Smriti Chopra
Understanding resolution
Resolution is the number of degrees rotated per step.
Step angle = 360/(NPh * Ph) = 360/N
NPh = Number of equivalent poles per phase = number of rotor poles. Ph = Number of phases. N = Total number of poles for all phases together. Example: for a three winding motor with a rotor having 4 teeth, the resolution is 30 degrees.
Smriti Chopra
unipolar
Smriti Chopra
bipolar
Main difference
A unipolar stepper motor has two windings per phase, one for each direction of magnetic field. In this arrangement a magnetic pole can be reversed without switching the direction of current.
Bipolar motors have a single winding per phase. The current in a winding needs to be reversed in order to reverse a magnetic pole. Bipolar motors have higher torque but need more complex driver circuits.
Smriti Chopra
Stepping modes
Wave Drive (1 phase on) A1 B2 A2 B1
(25% of unipolar windings , 50% of bipolar)
Full Step Drive (2 phases on) A1B2 B2A2 A2B1 B1A1 (50% of unipolar windings , full bipolar windings utilization) Half Step Drive (1 & 2 phases on) A1B2 B2 B2A2 A2 ---(increases resolution)
Smriti Chopra
Smriti Chopra
Smriti Chopra
Applications
Stepper motors can be a good choice whenever controlled movement is required. They can be used to advantage in applications where you need to control rotation angle, speed, position and synchronism.
These include printers plotters medical equipment fax machines automotive and scientific equipment etc.
Smriti Chopra
Linear Motors
Hannes Daepp
Force (F) is generated when the current (I) (along vector L) and the flux density (B) interact F = LI x B
Hannes Daepp
http://www.parkermotion.com/video/Braas_Trilogy_T3E_Video.MPG
Hannes Daepp
Hannes Daepp
High Precision
Accuracy, resolution, repeatability limited by feedback device, budget Zero backlash: No mechanical transmission components.
Fast Response
Response rate can be over 100 times that of a mechanical
Stiffness
No mechanical linkage, stiffness depends mostly on gain & current
Durable
Modern linear motors have few/no contacting parts no wear
Hannes Daepp
load
No (minimal) Friction
No automatic brake
Hannes Daepp
material Mounting Plate on top Usually contains sensors (hall effect and thermal)
Magnet Rail
Iron Plate / Base Plate Rare Earth Magnets of alternating
F=
lI x B
Ironless Core
Dual back iron
Slotless
Coil and back iron
Hannes Daepp
Copper windings around forcer laminations over a single magnet rail Highest force available per unit volume Efficient Cooling Lower cost High attractive force between forcer & magnet track Cogging: iron forcer affects thrust Laminated forcer force as it passes over each assembly and mounting magnet (aka velocity ripple)
plate Coil wound Around Forcer lamination Hall effect and thermal sensors
Advantages:
Disadvantages:
Hannes Daepp
Iron Plate
Distinguishing Feature
Forcer constructed of wound coils held together with epoxy and running between two rails (North and South) Also known as Aircore or U-channel motors
Advantages:
No attractive forces in forcer No Cogging Low weight forcer - No iron means higher accel/decel rates
Disadvantages:
Low force per package size Lower Stiffness; limited max load without improved structure Poor heat dissipation
Higher cost (2x Magnets!)
Front View Forcer Mounting Plate Winding, held Rare by epoxy Earth Magnets Hall Effect and Horseshoe Thermal Shaped Sensors in coil backiron
Hannes Daepp
Mix of ironless and iron core: coils with back iron contained within aluminum housing over a single magnet rail
Front View Thermal sensor Coil Back assembly iron Mounting plate
Lower cost (1x magnets) Better heat dissipation Structurally stronger forcer More force per package size
Lighter weight and lower inertia forcer Lower attractive forces Less cogging
Hannes Daepp
Iron plate
Some attractive force and cogging Less efficient than iron core and ironless - more heat to do the same job
Thermal sensor
Iron plate
Force Cogging
Power Density Forcer Weight
Highest
Highest Heaviest
None
Medium Lightest
Medium
Medium Moderate
Hannes Daepp
4. Cable management
Hannes Daepp
Sample Pricing
$3529
Trilogy T1S Ironless linear
motor 110V, 1 pole motor Single bearing rail ~12 travel magnetic encoder Peak Velocity = 7 m/s Resolution = 5m
Hannes Daepp
Applications [3],[5],[6]
Small Linear Motors Packaging and Material Handling Automated Assembly Reciprocating compressors and alternators Large Linear Induction Machines (3 phase) Transportation Materials handling Extrusion presses
Hannes Daepp
References
[1] S. Cetinkunt, Mechatronics, John Wiley & Sons, Inc., Hoboken 2007. [2] J. Barrett, T. Harned, J. Monnich, Linear Motor Basics, Parker Hannifin Corporation, http://www.parkermotion.com/whitepages/linearmotorarticle.pdf [3] Trilogy Linear Motor & Linear Motor Positioners, Parker Hannifin Corporation, 2008, http://www.parkermotion.com/pdfs/Trilogy_Catalog.pdf [4] Rockwell Automation, http://www.rockwellautomation.com/anorad/ products/linearmotors/questions.html [5] J. Marsh, Motor Parameters Application Note, Parker-Trilogy Linear Motors, 2003. http://www.parkermotion.com/whitepages/ Linear_Motor_Parameter_Application_Note.pdf [6] Greg Paula, Linear motors take center stage, The American Society of Mechanical Engineers, 1998.
References (continued)
http://www.physclips.unsw.edu.au/jw/electricmotors.ht ml http://www.speedace.info/solar_car_motor_and_drivet rain.htm http://www.allaboutcircuits.com/vol_2/chpt_13/1.html http://www.tpub.com/neets/book5/18d.htm single phase induction motor http://www.stefanv.com/rcstuff/qf200212.html Brushless DC motors https://www.geckodrive.com/upload/Step_motor_basic s.pdf http://www.solarbotics.net/library/pdflib/pdf/motorbas .pdf
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