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Fasteners, and Couplers Applied Robotics: Mechanisms ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Reminder: respect the resources General Questions? Issues? ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Mechanisms Primary Movers Drive Mechanisms Cams and Linkages Materials, fasteners, and couplers Design Process Mechanism-related problems/tips ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Primary Movers (convert energy to mechanical form): Motors: AC Brush/Brushless DC Stepper Servo Piezoelectric: ultrasonic motors Electrostatic Hydraulic and pneumatic Solenoids Pneumatics, Hydraulics Bimetal Shape memory alloy ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Motors Torque-speed curves AC vs. DC AC historically used for continuous-speed machines lower torque than DC at low speeds DC historically used in applications where speed and torque must be varied independently high starting and low-speed torque motors more expensive, drives cheaper than AC Variable speed (e.g., permanent magnet or series-wound DC) Constant speed (e.g., synchronous AC or shunt-wound DC) ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Brush Motors Vs. Brushless Motors Rotating winding vs. rotating magnets Brush motor: commutation done with brushes on pads Brushless: sensor and transistors ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Motors Servomotors AC and DC Precise closed-loop control of position, velocity, acceleration Robotics, mechatronics RC servos (self-contained) ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Motors Stepper motors Open-loop control of position (down to ~1 degree resolution) Sends pulses corresponding to the number of steps the motor should move (micro-stepping possible) Advantages: easy control, no feedback sensing, low expense Disadvantages: weak trajectory control, can lose position if over-torqued, accuracy dependent on motor geometry http://en.wikipedia.org/wiki/Stepper_motor ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Motors Which type of motor should you use? Low torque, low speed – stepper High torque, low speed – servo or possibly stepper High torque, high speed – Brush or brushless, maybe servo Short, rapid, repetitive moves – servo if high dynamic requirements, otherwise stepper is economical Low speed, high smoothness – servo or microstep stepper Shop Metal Grinder – AC synchronous motor ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Motors Hydraulic and pneumatic Require hydraulic source or compressed air Pneumatic convenient when air source available for other purposes (e.g., automobile shop) Valve is the hard part High speeds, long stall under load High power, low efficiency, low accuracy, high cost when ancillary equipment is included Hydraulic motors Pneumatic motor ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Primary movers Solenoids Electromechanical (AC or DC) linear and rotary actuators Short strokes (6 mm – 3 cm), varying force over stroke, energy-inefficient Inexpensive, reliable, rapid response Note: sensitive to variations in voltage supply! Applications: auto door locks, flow valves (normally open or normally closed), camera shutter latch Linear Rotary ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Primary movers Bimetal Two metals with different thermal expansion welded together, bend when heated Applications: thermostat, latching, switching Shape memory alloy (SMA) Metal alloy (most used is Ni-Ti) with low elasticity at high temperature, high elasticity (20x normal) at low temperature Two effects: (thermal) shape memory and superelasticity Applications: flight control surfaces, steerable catheters, etc. ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Mechanisms Primary Movers Drive Mechanisms Cams and Linkages Materials, fasteners, and couplers Design Process Mechanism-related problems/tips ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Drive Mechanisms (transfer/save energy, change speed, and linear<->rotary) Rotary-to-rotary motion Friction/traction drives Belt and chain drives, cable drives Gears: spur, helical, bevel, worm Gear trains (including planetary) Harmonic drives Rotary-to-linear motion (and vice versa) Rack and pinion Lead screw and ball screw Energy absorbers and savers Flywheels Accumulators Bearings ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Drive Mechanisms Friction/traction drives Friction drive: high friction, high wear (example: rollers) Traction drive: friction drive with traction oil to decrease friction and wear -- requires sealing Possible slippage Belt and chain drives Extension of roller idea without direct contact V-belt, timing belt, chain ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Drive Mechanisms: Gears Spur Teeth parallel to shaft, most commonly used and available Strengths Simplest, least expensive, high efficiency (96-98%) Limitations Unable to accommodate shaft direction change Helical Teeth at helical angle to axis Strengths Stronger and quieter than spur gears Can handle non-parallel, non-intersecting (skew) gear shafts Limitations Expensive, less common, less efficient (50-90%) Reaction force along gear axis requires thrust bearings ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Drive Mechanisms: Gears Bevel Based on rolling cones Strengths Transfer power between intersecting shafts Arbitrary angle > 0º between shafts Limitations Can’t handle parallel or non-intersecting shafts Limited availability Worm Helical gear (“worm”) with one tooth, like a screw Strengths High gear ratio in small package Non-back-drivable Limitations Low efficiency (40-85%) due to sliding/thrust ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Drive Mechanisms Gear trains Collection of two or more meshing gears Simple: one gear per shaft, gear ratio <= approx. 10:1 Compound: two gears on at least one shaft, higher ratios N2 N1 N4 N3 Simple: Compound: ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Drive Mechanisms Planetary (or epicyclic) gear train Components: sun, planet, and ring gears; arm(s) connecting sun and planet(s) Low-to-high train ratios in small package, default reversion, simultaneous bidirectional outputs from single input Ring gear ==> ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 ATRIAS 1.0 uses a planetary cable drive ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Drive Mechanisms Harmonic drives Components: wave generator, flexspline, circular spline Wave generator drives flexspline around circular spline at high reduction ratio (gear ratio >= 50:1) Strengths: high torque in small space, concentric geometry, high efficiency, back-drivable Limitations: flexure, ripple, no low gear ratios ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Drive Mechanisms Rotary-to-linear motion Rack and pinion Bathroom scale dial Lead screw and ball screw ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Drive Mechanisms ACME lead screw Most prevalent standard in industry Self-locking capability, quiet Lower efficiency than ball screw Reasonable cost http://www.rockfordballscrew.com/acme-screw.htm http://www.roton.com/acme-lead-screws-nuts.aspx?line=Acme ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Drive Mechanisms Bearings Principle: rolling involves less friction than sliding Load types: radial and thrust Bearing types: ball (small radial & thrust loads), roller (large radial loads), ball thrust (small thrust loads), roller thrust (large thrust loads), tapered roller (large radial & thrust loads) ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Mechanisms Primary Movers Drive Mechanisms Cams and Linkages Materials, fasteners, and couplers Design Process Mechanism-related problems/tips ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Complex Motion Converters Cams Function generator: translate simple rotation into complex follower motion Useful for complex timing (e.g. fuel injection) Eccentrics Circle rotates on eccentric axis Simple mechanism for up-and-down motion ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Complex Motion Converters: Geneva Mechanism Produces intermittent rotary motion Alternate periods of motion and rest with no reversal in direction Used for indexing (e.g. for film projectors) ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Linkages: Joint Types Revolute (R) Linear (P: Prismatic) Helical (RP, 1 DOF) Threaded (lead) screw Ball screw Cylindric (RP, 2 DOF) Spherical (RRR, 3 DOF) Ball and socket (shoulder) Universal Planar (RPP, 3 DOF) ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Overconstrained systems What if these two bars aren’t precisely parallel? I mean, exactly? ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Joint type examples One DOF (Simple revolute joint) Two DOF (Double revolute joint) ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Linkages: Four-bar Mechanisms Coupler Tracing point Input Output Base Produce rotating, oscillating, or reciprocating motion from the rotation of a crank or vice versa. Convert rotary to straight-line or complex motion without the need for guides ENGR421/521 Applied Robotics Hurst/Shuman, Spring 2013 Four-bar Mechanisms examples Evans’s (half-beam) linkage: with an
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