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MEV 403 Introduction to Mechatronics

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MEV 403 Introduction to Mechatronics MEV 403 Introduction to Mechatronics Module 2: Sensors and Actuators 1 Santhakumar Mohan, Assistant Professor, MED, NITC Introduction to Actuators • Actuators are basically the muscle behind a mechatronics system that accepts a control command (mostly in the form of an electrical signal) and produces a change in the physical system by generating force, motion, heat, flow, and so forth . 2 Santhakumar Mohan, Assistant Professor, MED, NITC Classification of Actuators • Based on motion • Based on energy supplied – Linear actuator – Electrical – Rotary actuator – Mechanical • Based on number of stable – Electromechanical state outputs – Electromagnetic – Binary – Hydraulic and Pneumatic – Continuous – Smart actuators 3 Santhakumar Mohan, Assistant Professor, MED, NITC Electrical Actuators • Advantages of Electrical actuators – Electricity is easily routed to the actuators; cables are simpler than pipe work. – Electricity is easily controlled by electronic units – Electricity is clean – Electric faults are often easier to diagnose • Disadvantages of electric actuators – Fire hazard – Poor torque – speed characteristics – Basically Rotary motion and complicated mechanism needed for linear motion – Power to weight ratio is inferior to hydraulic motors 4 Santhakumar Mohan, Assistant Professor, MED, NITC Types of Electrical Actuators • DC Motor – Wound field – Permanent magnet – Electronic commutation (brushless motor) • AC Motor – Induction motor – Synchronous motor – Universal motor • Stepper Motor – Variable reluctance – Permanent magnet – Hybrid 5 Santhakumar Mohan, Assistant Professor, MED, NITC Stepper motor • A stepper motor is an electromechanical device which converts electrical pulses into discrete mechanical movements . • The stepper motor is a discrete (incremental) positioning device that moves one step at a time for each pulse command input. • Since they accept direct digital commands and produce a mechanical motion, the stepper motors are used widely in industrial control applications. • They are mostly used in fractional horsepower applications. With the rapid progress in low cost and high-frequency solid- state drives, they are finding increased applications. 6 Santhakumar Mohan, Assistant Professor, MED, NITC Why Stepper Motor? • Relatively inexpensive • Ideal for open loop positioning control – Can be implemented without feedback – Minimizes sensing devices – Just count the steps! • Torque – Holds its position firmly when not turning – Eliminates mechanical brakes – Produces better torque than DC motors at lower speeds • Positioning applications 7 Santhakumar Mohan, Assistant Professor, MED, NITC Types of Stepper Motor Permanent Magnet (PM) type Variable reluctance (VR) type Magnetic Rotor Non Magnetic, Geared Rotor Hybrid type Combines characteristics from PM and VR Magnetic, geared rotor 8 Santhakumar Mohan, Assistant Professor, MED, NITC Stepper motor: Principle of operation Variable Reluctance Type Permanent Magnet Type 9 Santhakumar Mohan, Assistant Professor, MED, NITC Comparison of different types 10 Santhakumar Mohan, Assistant Professor, MED, NITC Stepper motor characteristics 1. Stepper motors are constant power devices. 2. As motor speed increases, torque decreases. 3. The torque curve may be extended by using current limiting drivers and increasing the driving voltage. 4. Steppers exhibit more vibration than other motor types, as the discrete step tends to snap the rotor from one position to another. 5. This vibration can become very bad at some speeds and can cause the motor to lose torque. 6. The effect can be mitigated by accelerating quickly through the problem speeds range, physically damping the system, or using a micro-stepping driver. 7. Motors with a greater number of phases also exhibit smoother operation than those with fewer phases. 11 Santhakumar Mohan, Assistant Professor, MED, NITC Torque vs. speed characteristics • Holding torque The maximum torque produced by the motor at standstill. • Pull-In Curve The pull-in curve defines a area referred to as the start stop region. • Maximum Start Rate The maximum starting step frequency with no load applied. • Pull-Out Curve The pull-out curve defines an area referred to as the slew region. • Maximum Slew Rate The maximum operating frequency of the motor with no load applied. 12 Santhakumar Mohan, Assistant Professor, MED, NITC Step angle and Stepping mode For Permanent Magnet type × Step angle = 360º / (N r Ns ) For Variable Reluctance type × Step angle = (Nr -Ns ) 360º / (N r Ns ) where, N r number of rotor poles and Ns number of phases The following are the most common drive (stepping) modes. – Wave Drive (1 phase on) – Full Step Drive (2 phases on) – Half Step Drive (1 & 2 phases on) – Micro-stepping (Continuously varying motor currents) 13 Santhakumar Mohan, Assistant Professor, MED, NITC Advantages of stepper motors • Low cost • Can work in an open loop (no feedback required) • Excellent holding torque (eliminated brakes/clutches) • Excellent torque at low speeds • Low maintenance (brushless) • Very rugged - any environment • Excellent for precise positioning control • No tuning required 14 Santhakumar Mohan, Assistant Professor, MED, NITC Disadvantages of Stepper Motors • Rough performance at low speeds (unless you use micro- stepping) • Consume current regardless of load • Limited sizes available • Noisy • Torque decreases with speed (you need an oversized motor for higher torque at higher speeds) • Stepper motors can stall or lose position running without a control loop 15 Santhakumar Mohan, Assistant Professor, MED, NITC Applications of Stepper motor • Cruise control • Auto air vents • Light leveling • Printers • Industrial machines • Automotive gauges • Office equipment • Computer drives • Medical scanners • Scientific Instrumentation 16 Santhakumar Mohan, Assistant Professor, MED, NITC Servo Motors • A servomotor (servo) is an electromechanical device in which an electrical input determines the position of the armature of a motor. 17 Santhakumar Mohan, Assistant Professor, MED, NITC Types of Servo motors • AC servo motors , based on induction motor designs; • DC servo motors , based on dc motor designs; • AC brushless servo motors , based on synchronous motor designs. Servo motors are special category of motors, designed for applications involving position control, velocity control and torque control . These motors are special in the following ways: 1. Lower mechanical time constant. 2. Lower electrical time constant. 3. Permanent magnet of high flux density to generate the field. 4. Fail-safe electro-mechanical brakes. 18 Santhakumar Mohan, Assistant Professor, MED, NITC Difference between Stepper and Servo • The basic difference between a traditional stepper and a servo-based system is the type of motor and how it is controlled. Steppers typically use 50 to 100 pole brushless motors while typical servo motors have only 4 to 12 poles. A pole is an area of a motor where a North or South magnetic pole is generated either by a permanent magnet or by passing current through the coils of a winding. • Steppers don't require encoders since they can accurately move between their many poles whereas servos, with few poles, require an encoder to keep track of their position. • Steppers simply move incrementally using pulses [open loop] while servo's read the difference between the motors encoder and the commanded position [closed loop], and adjust the current required to move. 19 Santhakumar Mohan, Assistant Professor, MED, NITC Difference between Stepper and Servo • Stepper motors have many more poles than servo motors. One rotation of a stepper motor requires many more current exchanges through the windings than a servo motor. The stepper motor's design results in torque degradation at higher speeds when compared to a servo. Using a higher driving bus voltage reduces this effect by mitigating the electrical time constant of the windings. Conversely, a high pole count has a beneficial effect at lower speeds giving the stepper motor a torque advantage over the same size servo motor. • Traditional steppers operate in the open loop constant current mode. This is a cost savings, since no encoder is necessary for most positioning applications. However, stepper systems operating in a constant current mode creates a significant amount of heat in both the motor and drive, which is a consideration for some applications. Servo control solves this by only supplying the motor current required to move or hold the load. It can also provide a peak torque that is several times higher than the maximum continuous motor torque for acceleration. However, a stepper motor can also be controlled in this full servo closed loop mode with the addition of an encoder. 20 Santhakumar Mohan, Assistant Professor, MED, NITC Difference between Stepper and Servo • Steppers are simpler to commission and maintain than servos. They are less expensive, especially in small motor applications. They don't lose steps or require encoders if operated within their design limits. Steppers are stable at rest and hold their position without any fluctuation, especially with dynamic loads. • Servos are excellent in applications requiring speeds greater than 2,000 RPM and for high torque at high speeds or requiring high dynamic response. Steppers are excellent at speeds less than 2,000 RPM and for low to medium acceleration rates and for high holding torque. • Servo control systems are best suited to high speed, high torque applications that involve dynamic load changes. Stepper control
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