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On design methods for mechatronics: servo motor and gearhead
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Mechatronics.
2005 (English)Licentiate thesis, comprehensive summary (Other scientific)
Abstract [en]

The number of electric powered sub-systems in road-vehicles is increasing fast. This development is primarily driven by the new and improved functionality that can be implemented with electro-mechanical sub-systems, but it is also necessary for the transition to electric and hybrid-electric drive trains.

An electromechanical sub-system can be implemented as a physically integrated mechatronic module: controller, power electronics, electric motor, transmission and sensors, all integrated into one component. A mechatronic module, spans, as all mechatronic systems, over several closely coupled engineering disciplines: mechanics, electronics, electro-mechanics, control theory and computer science. In order to design and optimize a mechatronic system it is therefore desirable to design the system within all domains concurrently. Optimizing each domain or component separately will not result in the optimal system design. Furthermore, the very large production volumes of automotive sub-systems increase the freedom in the mechatronics design process. Instead of being limited to the selection from off-the shelf components, application specific components may be designed.

The research presented in this thesis aims at development of an integrated design and optimization methodology for mechatronic modules. The target of the methodology is the conceptual design phase, where the number of design parameters is relatively small. So far, the focus has been on design methods for the electric motor and gearhead, two of the most important components in an actuation module. The thesis presents two methods for design and optimization of motor and gearhead in mechatronic applications. One discrete method, intended for the selection of off-the-shelf components, and one method mainly intended for high volume applications where new application specific components may be designed. Both methods can handle any type of load combination, which is important in mechatronic systems, where the load seldom can be classified as pure inertial or constant speed.

Furthermore, design models relating spur gear weight, size and inertia to output torque and gear ratio are presented. It is shown that a gearhead has significantly lower inertia and weight than a motor. The results indicate that it almost always is favorable from a weight and size perspective to use a gearhead. A direct drive configuration may only be lighter for very high speed applications. The main contribution of this thesis is however the motor/gear ratio sizing methods that can be applied to any electromechanical actuation system that requires rotational motion.

Place, publisher, year, edition, pages
Stockholm: KTH , 2005. , ix, 13 p.
Series
Trita-MMK, ISSN 1400-1179 ; 2005:02
Keyword [en]
Applied mechanics, mechatronics design methodology, servo systems, electric motors, gears, auxiliary systems
Keyword [sv]
Teknisk mekanik
National Category
Mechanical Engineering
Identifiers
URN: urn:nbn:se:kth:diva-167OAI: oai:DiVA.org:kth-167DiVA: diva2:7612
Presentation
2005-02-01, B442, KTH, Brinellvägen 83, Stockholm, 10:00
Supervisors
Note
QC 20101220Available from: 2005-04-15 Created: 2005-04-15 Last updated: 2010-12-20Bibliographically approved
List of papers
1. Towards a design and optimization methodology for automotive mechatronics
Open this publication in new window or tab >>Towards a design and optimization methodology for automotive mechatronics
2004 (English)Conference paper, Published paper (Refereed)
Abstract [en]

The number of mechatronic sub-systems in road vehicles is growing fast. Auxiliary systems that traditionally have been driven by the combustion engine via, for instance, gears, belts or hydraulics are being replaced with electric systems. This development is primarily driven by new and improved functionality, but it is also necessary for the transition to electric and hybrid-electric drive trains.

 

A mechatronic sub-system can be very complex to design and especially to optimize, mainly due to the multi domain characteristics of mechatronics. Usually, in traditional methodologies for mechatronic design, the mechanical structure is determined separate from the controller and also from the electric motor design. To improve the results from the mechatronic development process, a more holistic approach is necessary. The foreseen very large production volumes of mechatronic actuation modules for the automotive industry enable such a holistic approach, where all constituent components can be designed and optimized in one common process.

 

The problem that is being approached in this research is delimited to a methodology for conceptual design and optimization of mechatronic actuation modules. Such modules will be the low level corner stones to achieve advanced functionality such as vehicle stability control and collision avoidance. The goal with the methodology is to capture all relevant system design parameters and properties, from all involved engineering domains, in one single evaluation and optimization process.

 

Some previous work has been done in this area, and many different research groups are working on new methods for mechatronics design. Most of the work is however concentrated on design of system dynamics from a control perspective, i.e. optimization of a system’s dynamic performance. The goal with this research project is to find methods that combine the structure design (statics & dynamics) with the controller design (dynamics). Further, the goal is to derive optimization methods that can find the most optimal system configuration and parameter set with respect to both static and dynamic criteria.

Keyword
Mechatronics, Design Methodology, Optimization, Modeling and Simulation
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:kth:diva-5023 (URN)
Conference
30th FISITA World Automotive Congress, Barcelona, May 2004
Note
QC 20101220Available from: 2005-04-15 Created: 2005-04-15 Last updated: 2010-12-20Bibliographically approved
2. Optimal Design of Motor and Gear ratio in Mechatronic Systems
Open this publication in new window or tab >>Optimal Design of Motor and Gear ratio in Mechatronic Systems
2004 (English)Conference paper, Published paper (Refereed)
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:kth:diva-5024 (URN)
Conference
3’rd IFAC Symposium on Mechatronic Systems, Sydney, September 2004
Note
QC 20101220Available from: 2005-04-15 Created: 2005-04-15 Last updated: 2010-12-20Bibliographically approved
3. 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
4. Optimal Selection of motor and gearhead in mechatronic applications
Open this publication in new window or tab >>Optimal Selection of motor and gearhead in mechatronic applications
2006 (English)In: Mechatronics (Oxford), ISSN 0957-4158, E-ISSN 1873-4006, Vol. 16, no 1, 63-72 p.Article in journal (Refereed) Published
Abstract [en]

A method for the selection of motor and gearhead in mechatronic applications is proposed. The method is applicable to any kind of load and helps to find the optimal motor gearhead combination with respect to output torque, peak power, mass/size and/or cost. The input to the method is the load cycle and component data on candidate motors and gearheads. Output is a set of graphs of all motor/gear ratio combinations that can drive the given load. From these graphs it is easy to read out the peak power, motor torque and energy efficiency for all feasible motor/gear ratio combinations.

Keyword
Design methodology, Gears, Motor drives, Servomotors, Servosystems
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:kth:diva-5026 (URN)10.1016/j.mechatronics.2005.08.001 (DOI)000234035300007 ()2-s2.0-28044450848 (Scopus ID)
Note
QC 20100927. Uppdaterad från Submitted till Published (20100927).Available from: 2005-04-15 Created: 2005-04-15 Last updated: 2017-12-05Bibliographically approved

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