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December 10, 2011 David Giandomenico - FIRST #846 DC Permanent Magnet Motors A tutorial winch design David Giandomenico Lynbrook High School Robotics FIRST.

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Presentation on theme: "December 10, 2011 David Giandomenico - FIRST #846 DC Permanent Magnet Motors A tutorial winch design David Giandomenico Lynbrook High School Robotics FIRST."— Presentation transcript:

1 December 10, 2011 David Giandomenico - FIRST #846 DC Permanent Magnet Motors A tutorial winch design David Giandomenico Lynbrook High School Robotics FIRST Team #846 DGiandomenico@lynbrookrobotics.com (408)343-1183

2 2010 Breakaway December 10, 2011 David Giandomenico - FIRST #846

3 December 10, 2011 David Giandomenico - FIRST #846 2004 FIRST Frenzy: Raising the Bar

4 December 10, 2011 David Giandomenico - FIRST #846 What We Want. Weight: Distance: Time (speed): 130 lbs 1.5 feet 5 seconds

5 December 10, 2011 David Giandomenico - FIRST #846 What We’ve Got: Some of the Motors supplied in FIRST Robotics Kit

6 December 10, 2011 David Giandomenico - FIRST #846 “CIM” Motor Specification

7 December 10, 2011 David Giandomenico - FIRST #846 “CIM” Motor Performance

8 December 10, 2011 David Giandomenico - FIRST #846 “CIM” Motor Performance Stall Torque Stall Torque No Load Current No Load Current No Load Speed Stall Current Stall Current

9 December 10, 2011 David Giandomenico - FIRST #846 FUSE Limits on Motor Power Stall Current Stall Current 40 A Fuse Limit ~100 Oz-In

10 December 10, 2011 David Giandomenico - FIRST #846 Kit Motors – Which One? Make / Model Max Power (Watts) Stall Torque (oz-in) Free Speed (RPM) Free Current (A) Stall Current (A) BaneBots RS395 48.116.7 15,5000.515 BaneBots RS540 123.539.5 16,800142 BaneBots RS550 253.570.6 19,3001.485 BaneBots RS775 83.161.1 7,3001.130 CIM FR801-001 340.1344.0 5,3102.7133 Denso 262100-3030-(Right) 23.51501.1 841.818.6 Denso 262100-3040-(Left) 23.51501.1 841.821 Fisher-Price 00801-0673-(2011) 291.675.4 20,7700.82108.7 Fisher-Price 00968-9015-(2010) 185.063.7 15,6001.2570 All Data at 12VDC

11 December 10, 2011 David Giandomenico - FIRST #846 Motors - Sorted by Power Make / Model Max Power (Watts) Stall Torque (oz-in) Free Speed (RPM) Free Current (A) Stall Current (A) CIM FR801-001 340.1344.0 5,3102.7133 Fisher-Price 00801-0673-(2011) 291.675.4 20,7700.82108.7 BaneBots RS550 253.570.6 19,3001.485 Fisher-Price 00968-9015-(2010) 185.063.7 15,6001.2570 BaneBots RS540 123.539.5 16,800142 BaneBots RS775 83.161.1 7,3001.130 BaneBots RS395 48.116.7 15,5000.515 Denso 262100-3030-(Right) 23.51501.1 841.818.6 Denso 262100-3040-(Left) 23.51501.1 841.821

12 December 10, 2011 David Giandomenico - FIRST #846 Choosing a motor based on Maximum Output Power 1.Calculate Energy required to lift load. 2.Given the Time & Energy, calculate the mechanical Power required. 3.Boost Power requirement to adjust for Friction in the gearbox and elsewhere. 4.Choose a motor whose Maximum Output Power is at least 4/3 * (safety margin)

13 December 10, 2011 David Giandomenico - FIRST #846

14 December 10, 2011 David Giandomenico - FIRST #846 Motor Selection Make / Model Max Power (Watts) Stall Torque (oz-in) Free Speed (RPM) Free Current (A) Stall Current (A) CIM FR801-001 340.1344.0 5,3102.7133 Fisher-Price 00801-0673-(2011) 291.675.4 20,7700.82108.7 BaneBots RS550 253.570.6 19,3001.485 Fisher-Price 00968-9015-(2010) 185.063.7 15,6001.2570 BaneBots RS540 123.539.5 16,800142 BaneBots RS775 83.161.1 7,3001.130 BaneBots RS395 48.116.7 15,5000.515 Denso 262100-3030-(Right) 23.51501.1 841.818.6 Denso 262100-3040-(Left) 23.51501.1 841.821 Make / Model Max Power (Watts) Stall Torque (oz-in) Free Speed (RPM) Free Current (A) Stall Current (A) CIM FR801-001 340.1344.0 5,3102.7133 Fisher-Price 00801-0673-(2011) 291.675.4 20,7700.82108.7 BaneBots RS550 253.570.6 19,3001.485 Fisher-Price 00968-9015-(2010) 185.063.7 15,6001.2570 BaneBots RS540 123.539.5 16,800142 BaneBots RS775 83.161.1 7,3001.130 BaneBots RS395 48.116.7 15,5000.515 Denso 262100-3030-(Right) 23.51501.1 841.818.6 Denso 262100-3040-(Left) 23.51501.1 841.821 Make / Model Max Power (Watts) Stall Torque (oz-in) Free Speed (RPM) Free Current (A) Stall Current (A) CIM FR801-001 340.1344.0 5,3102.7133 Fisher-Price 00801-0673-(2011) 291.675.4 20,7700.82108.7 BaneBots RS550 253.570.6 19,3001.485 Fisher-Price 00968-9015-(2010) 185.063.7 15,6001.2570 BaneBots RS540 123.539.5 16,800142 BaneBots RS775 83.161.1 7,3001.130 BaneBots RS395 48.116.7 15,5000.515 Denso 262100-3030-(Right) 23.51501.1 841.818.6 Denso 262100-3040-(Left) 23.51501.1 841.821

15 December 10, 2011 David Giandomenico - FIRST #846 www.johnsonmotor.com

16 December 10, 2011 David Giandomenico - FIRST #846 2011 Fisher Price Motor Make / Model Max Power (Watts) Stall Torque (oz-in) Free Speed (RPM) Free Current (A) Stall Current (A) Fisher-Price 00801-0673-(2011) 291.675.4 20,7700.82108.7 All Data at 12VDC Make / Model Max Power (Watts) Stall Torque (N-m) Free Speed (RPM) Free Current (A) Stall Current (A) Fisher-Price 00801-0673-(2011) 291.60.532 20,7700.82108.7 Convert oz-in to N-m: 1 oz-in = 0.007061552 N-m

17 December 10, 2011 David Giandomenico - FIRST #846 Fisher Price Motor 2010 From FIRST_MOTOR_CALC.xls V=12VDC

18 December 10, 2011 David Giandomenico - FIRST #846 What is Torque? But isn’t that “Work”

19 December 10, 2011 David Giandomenico - FIRST #846 Units of Work vs. Torque Work (Energy) Torque pound feet(lbf-ft), ft-lbf, oz-in, N-m … ft-lbf, Joules (=N-m), KWh, …

20 December 10, 2011 David Giandomenico - FIRST #846 Work in a Rotating System Force r T

21 December 10, 2011 David Giandomenico - FIRST #846 Power, Torque & Speed

22 December 10, 2011 David Giandomenico - FIRST #846 From FIRST_MOTOR_CALC.xls V=12VDC (speed,torque) Fisher Price Motor 2011

23 December 10, 2011 David Giandomenico - FIRST #846 From FIRST_MOTOR_CALC.xls V=12VDC Fisher Price Motor 2011

24 December 10, 2011 David Giandomenico - FIRST #846 From FIRST_MOTOR_CALC.xls V=Rated Voltage

25 December 10, 2011 David Giandomenico - FIRST #846 Speed & Torque in a DC PM Motor Let  ={0,100%} such that

26 December 10, 2011 David Giandomenico - FIRST #846 From FIRST_MOTOR_CALC.xls V=Rated Voltage

27 December 10, 2011 David Giandomenico - FIRST #846 Speed & Torque in a DC PM Motor Or, w/o calculus, Max occurs between two roots of quadratic, at  =0,  =1 that is,  =½ or equivalently, when  =50% Using calculus, Max Power occurs when:

28 December 10, 2011 David Giandomenico - FIRST #846 From FIRST_MOTOR_CALC.xls V=Rated Voltage 75%

29 December 10, 2011 David Giandomenico - FIRST #846 Max Power in a DC PM Motor

30 December 10, 2011 David Giandomenico - FIRST #846 2011 Fisher Price Motor All Data at 12VDC Make / Model Max Power (Watts) Stall Torque (N-m) Free Speed (RPM) Free Current (A) Stall Current (A) Fisher-Price 00801-0673-(2011) 291.60.532 20,7700.82108.7

31 December 10, 2011 David Giandomenico - FIRST #846 Fisher Price Motor 2011 From FIRST_MOTOR_CALC.xls V=12VDC

32 December 10, 2011 David Giandomenico - FIRST #846 Fisher Price Motor 2011 From FIRST_MOTOR_CALC.xls V=12VDC Current rises linearly with Torque

33 December 10, 2011 David Giandomenico - FIRST #846 Motor Current Where α is the % No Load speed

34 December 10, 2011 David Giandomenico - FIRST #846 Electrical Power

35 December 10, 2011 David Giandomenico - FIRST #846 Fisher Price Motor 2011 From FIRST_MOTOR_CALC.xls V=12VDC Input power is Current X Voltage

36 December 10, 2011 David Giandomenico - FIRST #846 Fisher Price Motor 2010 From FIRST_MOTOR_CALC.xls V=12VDC

37 December 10, 2011 David Giandomenico - FIRST #846 Fisher Price Motor 2010 From FIRST_MOTOR_CALC.xls V=12VDC

38 December 10, 2011 David Giandomenico - FIRST #846 Fisher Price Motor 2011 From FIRST_MOTOR_CALC.xls V=12VDC

39 December 10, 2011 David Giandomenico - FIRST #846 Fisher Price Motor 2011 From FIRST_MOTOR_CALC.xls V=12VDC

40 December 10, 2011 David Giandomenico - FIRST #846 DC PM Motor Summary Max Power occurs at 50% No-Load Speed Best efficiency typically occurs at about 80%-93% No-Load Speed Most DC PM Motors will overheat if operated continuously at speeds less than 50% when full voltage is applied.

41 December 10, 2011 David Giandomenico - FIRST #846 Gear Loss Estimate Suppose we have n=3 inline sets of gears, each with a 4:1reduction. What is the total efficiency if each gear set loses 4%?  T =  i n or  T = (100%-4%) 3 = 88.5%

42 December 10, 2011 David Giandomenico - FIRST #846 When x is small,

43 December 10, 2011 David Giandomenico - FIRST #846 Estimate of how many gear sets. Suppose we want a gear reduction of 1200. How many gear sets with a reduction of 3 do we need? Solve 3 N = 1200 N = ln(1200)/ln(3) = 6.45

44 December 10, 2011 David Giandomenico - FIRST #846 Gear loss estimate We need 6.45 3:1 gear sets. Assuming a loss of 4% for each gear set,  T =  i n or  T = (1-4%) 6.45 = 76.8%

45 December 10, 2011 David Giandomenico - FIRST #846 Putting it all together 1.Choose a winch drum size 2.Calculate the drum rpm 3.Choose the % motor operating speed 4.Calculate the required gear reduction to operate at that speed 5.Verify the output winch line force meets or exceeds the original specification, including gear box losses

46 December 10, 2011 David Giandomenico - FIRST #846 Winch Design Specification

47 December 10, 2011 David Giandomenico - FIRST #846 Winch Drum Speed

48 December 10, 2011 David Giandomenico - FIRST #846 Determine the Gear Reduction Drum speed Revolutions / second0.191 Revolutions / minute (rpm)11.46 Motor spec at 12VDC No load speed20770RPM Stall Torque75.4oz0in Stall Torque (1 Oz-In= 0.007061552 N-m)0.532N-m Max Power Output289.5W Free Current0.82A Stall Current108.7A Operating Point at FUSE current at 20A17.8% at 30A27.0% at 40A36.3% Select Motor Speed and Torque % motor speed90% Motor current11.6A Motor Speed18693rpm Torque0.0532N-m Power out104.2W Required Gear Reduction1631.3

49 Required Gear Reduction1631.3 Loss estimate assuming 'n' small gear sets Individual gear set reduction ratio4times % Loss per gear set5% Number of gear reductions5.336sets Total estimated gear efficiency76.06% December 10, 2011 David Giandomenico - FIRST #846 Gear Loss Estimate

50 Winch line output at speed Motor torque at speed (above)0.0532N-m Torque after gearbox (no loss)86.86N-m After gear box losses66.06N-m Force on Line866.92N Force on Line (lbs)194.61lbs December 10, 2011 David Giandomenico - FIRST #846 Verify We Meet or Exceed Pull Strength Specification

51 December 10, 2011 David Giandomenico - FIRST #846 Feat Accomplished! 194 lb exceeds required spec of 130lbs

52 December 10, 2011 David Giandomenico - FIRST #846 More than you wanted to know about Robot Winch Design David Giandomenico Lynbrook High School Robotics FIRST Team #846 DGiandomenico@lynbrookrobotics.com (408)343-1183

53 December 10, 2011 David Giandomenico - FIRST #846 Addendum: Interest or Time permitting

54 December 10, 2011 David Giandomenico - FIRST #846

55 December 10, 2011 David Giandomenico - FIRST #846

56 December 10, 2011 David Giandomenico - FIRST #846 Pascal’s Triangle 1 1 2 1 1 3 3 1 1 4 6 4 1 1 1 2 1 1 3 3 1 1 4 6 4 1

57 December 10, 2011 David Giandomenico - FIRST #846 Binomial Theorem

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