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Towards a methodology for integrated design of mechatronic servo systems
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Design (Div.).
2007 (English)Doctoral thesis, comprehensive summary (Other scientific)
Abstract [en]

Traditional methods for mechatronics design are often based on a sequential approach, where the mechanical structure is designed first, and then fitted with off-the-shelf electric motors, drive electronics, gearheads and sensors. Finally a control system is designed and optimized for the already existing physical system. Such a design method, that doesn’t consider aspects from a control point of view during the design of the physical system, is unlikely to result in a system with optimal control performance. Furthermore, to separately design and optimize each of the physical components will, from a global perspective, generally not result in a system that is optimal from a weight, size or cost perspective.

In order to reach the optimal design of an integrated mechatronic system (mechatronic module) it is necessary to treat the system as a whole, considering aspects from all involved engineering domains concurrently. In this thesis such an approach to integrated design of mechatronic servo systems is presented. A design methodology that considers the simultaneous design of the electric machine, gearhead, machine driver and control system, and therefore enables global optimization, has been developed. The target of the design methodology is conceptual design and evaluation. It is assumed that the load to be driven by the servo system is known and well defined, a load profile describing the wanted load motion and the corresponding torque, is required as input. The methodology can then be used to derive the lightest or smallest possible system that can drive the specified load. Furthermore, the control performance is evaluated and optimized, such that the physical system design and the controller design are integrated.

The methodology is based on modelling and simulation. Two types of component models have been developed, static and dynamic models. The static models describe relations between the parameters of the physical components, for example a component’s torque rating as function of its size. The static models are based on traditional design rules and are used to optimize the physical parts of the system. The dynamic models describe the behaviour of the components and are used for control system design and performance optimization.

The gear ratio is identified to be the most central design variable when designing and optimizing electromechanical servo systems. The gear ratio directly affects the required size of the gearhead, electric machine and the machine driver. But it has also large influences on the system’s control performance. It is concluded that high gear ratios generally are better from a control point of view than low ratios. A consequence of this is that it is possible, without compromising the control performance, to use less expensive (less accurate) sensors and microprocessors in high gear ratio servo systems, while low gear ratio systems require more expensive hardware. It is also concluded that it is essential to include all performance limiting phenomena, linear as well as non-linear, in this type of integrated analysis. Using for example a linearized system description for controller design, means that many of the most important couplings between control system and physical system design are overlooked.

Place, publisher, year, edition, pages
Stockholm: KTH , 2007. , viii, 106 p.
Series
Trita-MMK, ISSN 1400-1179 ; 2007:07
Keyword [en]
Mechatronics, Servo Systems, Design Methodology, Integrated Design
National Category
Reliability and Maintenance
Identifiers
URN: urn:nbn:se:kth:diva-4473OAI: oai:DiVA.org:kth-4473DiVA: diva2:12432
Public defence
2007-09-14, Sydvästra galleriet, KTH main library, Osquars backe 31, Stockholm, 10:00
Opponent
Supervisors
Note
QC 20100816Available from: 2007-08-23 Created: 2007-08-23 Last updated: 2010-08-16Bibliographically approved
List of papers
1. Optimial design of motor and gear ratio in mechatronic systems
Open this publication in new window or tab >>Optimial design of motor and gear ratio in mechatronic systems
2004 (English)In: Proceedings of the 3rd IFAC Symposium on Mechatronic Systems, Manly Beach, Sydney, 2004Conference paper, Published paper (Refereed)
National Category
Reliability and Maintenance
Identifiers
urn:nbn:se:kth:diva-7408 (URN)
Note

QC 20100816

Available from: 2007-08-23 Created: 2007-08-23 Last updated: 2017-04-10Bibliographically approved
2. Relations between size and gear ratio in spur and planetary gear trains
Open this publication in new window or tab >>Relations between size and gear ratio in spur and planetary gear trains
2005 (English)Report (Other academic)
Abstract [en]

In this report equations for the minimum gear sizes necessary to drive a given load are derived. The equations are based on the Swedish standards for spur gear dimensioning:SS 1863 and SS1871. Minimum size equations for both spur gear pairs and three-wheel planetary gears are presented. Furthermore, expressions for the gear weight and inertiaas function of gear ratio, load torque and gear shape are derived.For a given load torque and gear material, it is possible to retrieve the necessary gearsize, weight and inertia as function of gear ratio. This is useful for gear optimization,but also for optimization of a complete drive system, where the gear size, inertia and weight may affect the requirements on the other parts of the drive system.The results indicate that the Hertzian flank pressure limits the gear size in most cases.The teeth root bending stress is only limiting for very hard steels. Furthermore, then ecessary sizes, weights and inertias are shown to be smaller for planetary gears than for the equivalent pinion and gear configuration. Both these results are consistent with state of practice; planetary gears are commonly known to be compact and to have low inertia.

Place, publisher, year, edition, pages
Stockholm: KTH, 2005. 35 p.
Series
Trita-MMK, ISSN 1400-1179 ; 2005:01
National Category
Reliability and Maintenance
Identifiers
urn:nbn:se:kth:diva-7409 (URN)
Note
QC 20100816. Uppdaterad från Artikel till Rapport 20100816.Available from: 2007-08-23 Created: 2007-08-23 Last updated: 2010-12-20Bibliographically approved
3. Integrated design of servomotor and gearhead assemblies
Open this publication in new window or tab >>Integrated design of servomotor and gearhead assemblies
(English)In: Mechatronics (Oxford), ISSN 0957-4158Article in journal (Refereed) Submitted
National Category
Applied Mechanics
Identifiers
urn:nbn:se:kth:diva-7410 (URN)
Note
QC 20100816Available from: 2007-08-23 Created: 2007-08-23 Last updated: 2010-08-16Bibliographically approved
4. The influence of gear ratio on performance of electro-mechanical servo systems
Open this publication in new window or tab >>The influence of gear ratio on performance of electro-mechanical servo systems
2006 (English)In: Proceedings of the 4th IFAC Symposium on Mechatronic Systems, 2006, 884-889 p.Conference paper, Published paper (Refereed)
Abstract [en]

The gear ratio's influence on the performance of electromechanical servo systems is analyzed. Even though a gear primarily is used to reduce the actuator size and weight it is important to understand how the gear ratio affects the dynamics of the system. A good choice of gear ratio may improve the control performance while reducing the physical size of the system. It is concluded that for low gear ratios the plant bandwidth is increased with gear ratio. The torque margin of the motor is also shown to increase with gear ratio. Thus, from a control perspective, high gear ratios appear to be better than low.

Series
IFAC Proceedings, ISSN 1474-6670 ; 4
National Category
Reliability and Maintenance
Identifiers
urn:nbn:se:kth:diva-7411 (URN)2-s2.0-79961145561 (Scopus ID)978-390266117-3 (ISBN)
Conference
The 4th IFAC Symposium on Mechatronic Systems, Heidelberg
Note

QC 20100816

Available from: 2007-08-23 Created: 2007-08-23 Last updated: 2014-10-30Bibliographically approved
5. Integrated control and mechanism design of electromechanical servo systems
Open this publication in new window or tab >>Integrated control and mechanism design of electromechanical servo systems
2007 (English)In: IEEE/ASME transactions on mechatronics, ISSN 1083-4435, E-ISSN 1941-014XArticle in journal (Other academic) Submitted
National Category
Reliability and Maintenance
Identifiers
urn:nbn:se:kth:diva-7412 (URN)
Note
QS 20120319Available from: 2007-08-23 Created: 2007-08-23 Last updated: 2012-03-19Bibliographically approved

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Citation style
  • apa
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