powerpoint motor presentation
TRANSCRIPT
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F.I.R.S.T. Motors &F.I.R.S.T. Motors &Drive System FundamentalsDrive System Fundamentals
December 7, 2002Team Ford FIRST
Paul CopioliUtica Community Schools & Ford Motor Company
The ThunderChickens (Team #217)
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AgendaAgenda
1. Introduction (why we are here)
2. Intro to Things Mechanical
3. First Motor Characteristics
4. Robot Drive Systems - Design Objectives
5. Questions & Answers
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IntroductionIntroductionWho am I?
•Paul Copioli
•Bachelors of Science - Aeronautical Engineering•U.S. Air Force Academy
•M.S.E. - Aerospace & Mechanical Engineering•University of Michigan
•FANUC Robotics North America•Senior Product Development Engineer
•4th Season with FIRST
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Intro to Things MechanicalIntro to Things Mechanical
Force - units are Pounds (Lbf) & Newtons (N)Force - units are Pounds (Lbf) & Newtons (N) Velocity - meters/sec, ft/sec, MPHVelocity - meters/sec, ft/sec, MPH Acceleration - m/sAcceleration - m/s22, ft/s, ft/s22, g = 9.81 m/s, g = 9.81 m/s2 2
Angular Velocity - RPM, rad/sec, deg/secAngular Velocity - RPM, rad/sec, deg/sec Torque - N*m, ft*LbfTorque - N*m, ft*Lbf Torque = Force * Lever Arm (Wheel Radius)Torque = Force * Lever Arm (Wheel Radius) Velocity = Ang. Velocity * Wheel RadiusVelocity = Ang. Velocity * Wheel Radius
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Formulas & UnitsFormulas & Units
Unit conversions of interestUnit conversions of interest 1lbs = 4.45 N1lbs = 4.45 N 1 inch = 0.0254 meters1 inch = 0.0254 meters 1 in-lbs = 0.11 N-m 1 in-lbs = 0.11 N-m 1 RPM = 60 Rev / Hour = 0.105 Rad / Sec 1 RPM = 60 Rev / Hour = 0.105 Rad / Sec 1 mile = 5280 X 12 inches = 63,000 inches1 mile = 5280 X 12 inches = 63,000 inches
Power = Force (N) X Velocity (m/s)Power = Force (N) X Velocity (m/s) Power = Torque (N-m) X Angular Velocity (Rad/Sec)Power = Torque (N-m) X Angular Velocity (Rad/Sec) Electrical Power = Voltage X CurrentElectrical Power = Voltage X Current
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FIRST MotorsFIRST Motors
1. Motor Characteristics (Motor Curve)
2. Max Power vs. Power at 30 Amps
3. Motor Comparisons
4. Combining Motors
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Motor CharacteristicsMotor Characteristics
Torque v Speed CurvesTorque v Speed Curves Stall Torque (T0)Stall Torque (T0) Stall Current (A0)Stall Current (A0) Free Speed (Wf)Free Speed (Wf) Free Current (Af)Free Current (Af)
SpeedT
orqu
e, C
urre
nt
T0
Wf
Af
A0
K (slope)
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Slope-Intercept (Y=mX + b)Slope-Intercept (Y=mX + b)
Y=Motor TorqueY=Motor Torque m=K (discuss later)m=K (discuss later) X=Motor SpeedX=Motor Speed b=Stall Torque (T0)b=Stall Torque (T0)
Speed
Tor
que,
Cur
rent
T0
Wf
Af
A0
K (slope)
What is K? … It is the slope of the line.
Slope = change in Y / change in X = (0 - T0)/(Wf-0) = -T0/Wf
K = Slope = -T0/Wf
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(Y=mX + b) Continued ...(Y=mX + b) Continued ...
Y=Motor TorqueY=Motor Torque m=K = -T0/Wfm=K = -T0/Wf X=Motor SpeedX=Motor Speed b=Stall Torque = T0b=Stall Torque = T0
Speed
Tor
que,
Cur
rent
T0 (b)
Wf
Af
A0
K (-T0/Wf)
Equation for a motor:
Torque = (-T0/Wf) * Speed + T0
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Current (Amps) and FIRSTCurrent (Amps) and FIRST
What are cutoff Amps?What are cutoff Amps? Max useable ampsMax useable amps Limited by breakersLimited by breakers Need to make assumptionsNeed to make assumptions
Speed
Tor
que,
Cur
rent
T0
Wf
Af
A0
Cutoff Amps
Can our Motors operate above 30 amps?
- Absolutely, but not continuous.
When designing, you want to be able to perform continuously; so finding motor info at 30 amps could prove to be useful.
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Torque at Amp LimitTorque at Amp Limit
T30 = Torque at 30 AmpsT30 = Torque at 30 Amps W30 = Speed at 30 AmpsW30 = Speed at 30 Amps
Speed
Tor
que,
Cur
rent
T0
Wf
Af
A0
Cutoff AmpsCurrent Equation:
Current = (Af-A0)/Wf * Speed + A0
Motor Equation:
Torque = (-T0/Wf) * Speed + T0
S @ 30A (W30) = (30 - A0) * Wf / (Af-A0)
T @ 30A (T30) = (-T0/Wf) * W30 + T0
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Power - Max vs. 30 AmpsPower - Max vs. 30 Amps
Speed
Tor
que,
Cur
rent
T0
Wf
Af
A0
PowerPower = Torque * Speed
Must give up torque for speed
Max Power occurs when:
T = T0/2 & W=Wf/2
What if max power occurs at a current higher than 30A?
Power is Absolute - It determines the Torque - Speed tradeoff!
Paul’s Tip #1: Design drive motor max power for 30A!
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Motor ComparisonsMotor Comparisons
• Chiaphua Motor
• Drill Motor
• Johnson Electric Fisher-Price Motor
Let’s Look at Some FIRST Motors
We will compare T0, Wf, A0, Af, T30, W30, max power (Pmax), amps @ max power (Apmax), and power at 30 amps (P30).
We will be using Dr. Joe’s motor spreadsheet updated to handle the new motors.
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Motor ComparisonsMotor Comparisons
T0 Wf A0 Af Pmax T30 W30 P30N-m RPM Amps Amps Watts N-m RPM Watts
Chiaphua 2.2 5,500 107 2.3 321 0.58 4045 245.7Johnson F-P 0.51 20,000 109 1.84 273 0.14 15000 219.9Bosch Drill 0.65 20,000 117 2.5 340 0.15 15333 240.9
Motor
Motor Equations:
1. Fisher-Price: T = (-0.51/20,000) * W + 0.51
2. Bosch Drill: T = (-0.65/20,000) * W + 0.65
3. Chiaphua: T = (-2.2/5,500) * W + 2.2
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Combining MotorsCombining MotorsUsing multiple motors is common for drive trains. We will look at matching the big 3 motors.
I try to match at free speed, but you can match at any speed you like!!
FP and drill will match 1:1
Wf FP(drill) / Wf Chiaphua = 20000/5500 = 40/11
Gear ratio to match Chip & FP(drill) is 40/11.
We will use an efficiency of 95% for the match gear.
More to come on Gear Ratio & Efficiency in the Second Half!
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Combined Motor DataCombined Motor DataT0 Wf Pmax T30 W30 P30
N-m RPM Watts N-m RPM WattsF-P & Drill 1.16 20,000 607 0.29 15,000 456F-P & Chip 3.96 5,500 570 1.09 4,045 462Drill & Chip 4.45 5,500 641 1.13 4,045 479F-P, Drill, & Chip 6.21 5,500 894 1.63 4,045 690
Motor
Motor Equations:
1. F-P & Drill: T = (-1.16/20,000) * W + 1.16
2. F-P & Chip: T = (-3.96/5,500) * W + 3.96
3. Drill & Chip: T = (-4.45/5,500) * W + 4.45
4. F-P, Drill, & Chip: T = (-6.21/5,500) * W + 6.21
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Motor Q & AMotor Q & A
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Robot Drive SystemsRobot Drive Systems
1. Drive System Terms
2. Types of Mechanisms
3. Traction Basics
4. Gearing Basics
5. Design Condition
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Drive System TermsDrive System Terms1. Gear Ratio: Can be described many ways
- Motor Speed / Output Speed- When GR > 1 Torque Increaser
2. Efficiency - Work lost due to drive losses- Friction, heat, misalignment
3. Friction Force - Tractive (pushing) force generated between floor and wheel.
4. W is rotational speed & V is linear Speed (velocity)
5. N1 is # of teeth on input gear/sprocket
6. N2 is # of teeth on output gear/sprocket
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Types of Drive MechanismsTypes of Drive Mechanisms
2. Spur GearsEfficiency ~ 95% - 98%GR = N2/N1
N1 N2
1. Chain & BeltEfficiency ~ 95% - 98%GR = N2/N1
N2N1
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Types of Drive MechanismsTypes of Drive Mechanisms
4. Other Types- Worm Gears Efficiency ~ 40% - 70%
- Planetary Gears Efficiency ~ 80% - 90%
3. Bevel GearsEfficiency ~ 90% - 95%GR = N2/N1
N2
N1
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Traction BasicsTraction BasicsTerminologyTerminology
The friction coefficient for any given contact with the floor, multiplied by the normal force, equals the maximum tractive force can be applied at the contact area.
Tractive force is important! It’s what moves the robot.
normalforce
tractiveforce
torqueturning the
wheel
maximumtractiveforce
normalforce
frictioncoefficient= x
weight
Friction coefficient = Mu
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Traction FundamentalsTraction Fundamentals“Normal Force”“Normal Force”
weightfront
The normal force is the force that the wheels exert on the floor, and is equal and opposite to the force the floor exerts on the wheels. In the simplest case, this is dependent on the weight of the robot. The normal force is divided among the robot features in contact with the ground.
normalforce(rear)
normalforce(front)
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Traction FundamentalsTraction Fundamentals“Weight Distribution”“Weight Distribution”
more weight in backdue to battery andmotors
front
The weight of the robot is not equally distributed among all the contacts with the floor. Weight distribution is dependent on where the parts are in the robot. This affects the normal force at each wheel.
morenormalforce
lessnormalforce
less weight in frontdue to fewer partsin this areaEXAMPLE
EXAMPLEONLYONLY
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Traction FundamentalsTraction FundamentalsWeight Distribution is Not ConstantWeight Distribution is Not Constant
arm position inrear makes the weightshift to the rear
front
arm position in frontmakes the weightshift to the front
EXAMPLEEXAMPLEONLYONLY
normalforce(rear)
normalforce(front)
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Traction FundamentalsTraction FundamentalsWeight Distribution is Not ConstantWeight Distribution is Not Constant
Where the weight is in the robot is only part of the story!
When the robot accelerates (changes speed), inertial forces tend to change the weight distribution.
(Example of inertial force: the force exerted by the seat on your back in a Z06 Corvette as it accelerates.)
So, it is important to consider how the weight distribution changes when the robot changes speed.
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Traction FundamentalsTraction Fundamentals“Weight Transfer”“Weight Transfer”
robot acceleratingfrom 0 mph to6 mph
inertial forcesexerted bycomponentson the robot
EXAMPLEEXAMPLEONLYONLY
more normal force is exertedon the rear wheels becauseinertial forces tend to rotatethe robot toward the rear
less normal force is exertedon the front wheels becauseinertial forces tend to rotatethe robot away from the front
In an extreme case (with rear wheel drive), you pull a wheelieIn a really extreme case (with rear wheel drive), you tip over!
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Gearing BasicsGearing Basics• Consecutive gear stages multiply:
N1
N2
N3
N4
• Gear Ratio is (N2/N1) * (N4/N3)• Efficiency is .95 *.95 = .90
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Gearing Basics - Wheel AttachmentGearing Basics - Wheel Attachment
N1
N2
N3
N4
• Gear 4 is attached to the wheel• Remember that T = F * Rw• Also, V = W * Rw• T4 = T1 * N2/N1 * N4/N3 * .95 * .95• W4 = W1 * N1/N2 * N3/N4• F = T4 / Rw• V = W4 * Rw
Motor Shaft
Wheel Diameter - Dw
Dw = Rw * 2
Fpush
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Design ConditionDesign Condition• Assumptions
•Each of the 4 wheels have their own motor.• Weight is evenly distributed.• Using all spur gears.
• Terms• W = Weight of robot• Wt = Weight transferred to robot from goals• n = # of wheels on the ground (4)• p = # driving wheels per transmission (1)• q = # of transmissions (4)• Tout = wheel output Torque
• Find the gear ratio & wheel diameter to maximize push force.
The maximum force at each wheel we can attain is ???
Fmax = Ffriction = Mu*(W + Wt)/n {on a flat surface}
Now T = F * Rw ----> F = Tout / Rw
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Design Condition ContinuedDesign Condition Continued• Tout = T30 * GR * eff {@ each wheel}
The above gives you the best combination of gear ratio and wheel diameter for maximum pushing force!
Ffriction = Tout / Rw: Mu*(W + Wt)/n = T30 * GR * eff / Rw
Mu*(W + Wt) GR/Rw = ---------------------------
n*T30*eff
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Design Condition ContinuedDesign Condition Continued
O.K. So what is my top speed?
0.85 * Wfree * π * 2 * Rw Vmax [m/sec] = ------------------------------
60 * GR
Where Wfree is in RPM, Dw is in meters.
The 0.85 accounts for drive friction slowing the robot down.
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Design Condition ContinuedDesign Condition Continued
0.85 * Wfree * π * 2 * Rw 0.85 * Wfree * π * 2 * n * T30 * eff Vmax = --------------------------------- = --------------------------------------------
60 * GR 60 * Mu * (W + Wt)
T30 * GR * eff Fmax = -------------------- = Mu * (W + Wt)
Rw
Max force and max velocity are fighting each other
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Drive System FundamentalsDrive System Fundamentals
QUESTIONS?