Formulas Linear Motion Applications
Formulas Linear Motion Applications
MOTORIZED
LINEAR MOTION
SYSTEMS
[Link]
2 Symbols andSYMBOLS
Units AND UNITS
Symbol Description Units Symbol Description Units
θ load orientation (horizontal = 0°, vertical = 90°) degrees vi initial linear velocity m/s
1 [Link]
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
MOTION SYSTEM
3 Motion System Formulas
FORMULAS
/ / /
1 3 1 3 1 3 Trapazoidal Motion Profile
vpk
-a
v
a
t1 t2 t3 t dwell Time
t move
Total Cycle Time
[Link] 2
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
4 Motion System Formulas
MOTION SYSTEM
FORMULAS
-a
v
a
Optimized for minimum
acceleration slope
S is the total move distance Move Profile Peak Velocity (VPK) Acceleration (a )
t is the total move time
/ / /
13 13 13
Area under profile curve
represents distance moved Triangular
v
a2
v
1
-a 3
a1
t1 t2 t3 t4 t5 t Time
dwell
t move
Total Cycle Time
s = vi t + –12 a t 2
(3)
ω = 2 πLv = rad/s
(4) 2 a s = vf 2 - vi 2
v
a = f i = Δv
(v -v ) 60
(5) n= L
= RPM
( tf - ti ) Δt
3 [Link]
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
MOTION SYSTEM
5 Motion System Formulas
FORMULAS
a
in =
2 πa
L
rad/sec 2
2 πv rad/sec
Jin mout ω in =
L
a in a out Τin= Τa+Τf +Τg+ΤD N-m
ωin v out Τa= Jin in a N-m
Tin Fout Τf = cosØm μL
g N-m
2 πη
Τg = sinØm L
g N-m
2 πη
ΤD = drag/preload N-m
refer to
manufacturer’s data
Jin Jout
ωin = (ωout)(N) rad/sec
[Link] 4
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
6 Motion System Formulas
MOTION SYSTEM
FORMULAS
Jin
ωin = (ωout)(N) rad/sec
Jout
a in a out Τin = Τout X
1
η+
ΤD N-m
ωin ωout N
Drag torque can be significant (T D) depending on the
Tin Tout viscosity of the lubricant. For a first approximation analysis,
this can be left out.
Gearbox inertia may be found in manufacturer’s data sheets,
or calculated using gear dimensions and materials / mass.
FS
Linear Power = = watts
t
Rotary Power = T ω = watts
2 2 2 2
ΤRMS = Τ1 t 1 + Τ2 t2 + Τ3 t 3 ...+ Τn tn
t 1 + t 2 + t 3 ... + t n + tdwell
5 [Link]
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
7 Motion System Formulas
MOTION SYSTEM
FORMULAS
DC Motor Formulas
Τ Viscous Damping
Torque (Dv)
–––
Breakaway
Torque – ––––––––––––
Coulomb Friction
–––
ο ω
Motor Locked Rotor Current / Locked Rotor Torque
VT
ILR =
Rmt
TLR = ILR x KT
VT
= x KT
Rmt
Motor Regulation
– Theoretical using motor constants
Rmt
Rm = 9.5493 x
KE x KT
– Regulation calculated using test data
nO
Rm =
TLR
[Link] 6
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
8 Motion System Formulas
MOTION SYSTEM
FORMULAS
Pout = ω x T
– Motor maximum output power
Pmax = 0.25 x ωo x TLR
– Motor maximum output power (Theoretical)
2
V
Pmax = 0.25 x T
Rmt
Temperature Effects on Motor Constants
– Change in terminal resistance
Rmt(f) = Rmt(i) x [ 1 + αconductor (Θf – Θi) ]
αconductor = 0.0040/°C (copper)
In the case of a mechanically commutated motor with graphite brushes, this
analysis will result in a slight error because of the negative temperature coefficient
of carbon. For estimation purposes, this can be ignored, but for a more rigorous
analysis, the behavior of the brush material must be taken into account. This is not
an issue when evaluating a brushless dc motor.
– Change in torque constant and voltage constant ( KT = KE )
K(f) = K(i) x [ 1 + αmagnet (Θf – Θi) ]
7 [Link]
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
9 Motion System Formulas
MOTION SYSTEM
FORMULAS
For PMDC motors (brush type) brush drop can be approximated as a constant
resistance connected in series with the armature winding. This series
resistance is included in the Rmt factor found on manufacturer’s data sheet.
– Thermal resistance
Temperature Rise °C
Rt h =
Machine Losses W
– Final motor temperature
Θm = Θr + Θa
– Motor temperature rise*
Θr = Rth x I2 x Rmt
– OR – 2
Rth x I x Rmt
Θr =
1 – (Rth x I x Rmt x α)
2
– OR –
2
Θr = Rth x ( ) TC
Km
*Use caution when applying these formulas. Depending on the conditions used
to determine motor specifications, only one formula should be used. Contact
Appications Engineering for questions.
[Link] 8
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
9 Motion System Formulas
MOTION SYSTEM
FORMULAS
For PMDC motors (brush type) brush drop can be approximated as a constant
resistance connected in series with the armature winding. This series
resistance is included in the Rmt factor found on manufacturer’s data sheet.
– Thermal resistance
Temperature Rise °C
Rt h =
Machine Losses W
– Final motor temperature
Θm = Θr + Θa
– Motor temperature rise*
Θr = Rth x I2 x Rmt
– OR – 2
Rth x I x Rmt
Θr =
1 – (Rth x I x Rmt x α)
2
– OR –
2
Θr = Rth x ( )
TC
Km
*Use caution when applying these formulas. Depending on the conditions used
to determine motor specifications, only one formula should be used. Contact
Appications Engineering for questions.
9 [Link]
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
10 Motion System Formulas
MOTION SYSTEM
FORMULAS
– Overdriving capability
[Link] 10
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
11 Motion System Reference Tables
MOTION SYSTEM
REFERENCE TABLES
SI Unit Systems
Quantity Name of Unit Symbol
Base Units
Length meter m
Mass kilogram Kg
Time second s
Electric current ampere A
Thermodynamic temperature kelvin K
Luminous intensity candela cd
Amount of substance mole mol
Derived Units
area square meter m2
volume cubic meter m3
frequency hertz Hz s–1
mass density (density) kilogram per cubic meter Kg/m3
speed, velocity meter per second m/s
angular velocity radian per second rad/s
acceleration meter per second squared m/s2
angular acceleration radian per second squared rad/s2
force newton N Kg-m/s2
pressure (mechanical stress) pascal Pa N/m2
kinematic viscosity square meter per second m2/s
dynamic viscosity newton-second per square meter N-s/m2
work, energy, quantity of heat joule J N-m
power watt W J/s or N-m/s
entropy joule per kelvin J/K
specific heat capacity joule per kilogram kelvin J/Kg-K)
thermal conductivity watt per meter kelvin W/(m-K)
11 [Link]
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
12 Motion System Application Example
MOTION SYSTEM
APPLICATION EXAMPLE
vpk
-a
v
a
t1 t2 t3 t dwell Time
0.333 s 0.333 s 0.333 s 0.5 s
Linear Velocity
Linear Acceleration
vf - vi 0.3m/s - 0 m/s
a= =
0.333 s
= 0.901m/s2
t
1st step is to thoroughly understand system constraints and motion profile
requirements.
[Link] 12
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
13 Motion System Application Example
MOTION SYSTEM
FORMULAS
60vPK (60)(0.3m/s)
Lmin = = = 0.018m/rev = 18mm/rev
n 1000 rev/min
Refer to Kerk screw chart – closest lead in an 8mm screw diameter is
v PK ω PK m J
a a F T
Linear to Rotary Conversion: Velocity
2 π vPK (2π)(0.3m/s)
ω PK =
L
=
0.02032 m/rev
= 92.76 rad/s
13 [Link]
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
MOTION SYSTEM
14 Motion System Application Example
FORMULAS
2
L 2 1 0.02032 m 1
Jin= m
2π
X η + JS= 9Kg 2π
X
0.86 + 38.8x10 –7
Kg-m2
= 10.95 X 10
–5
Kg-m2 + 38.8x10– 7 Kg-m2
–5 2
= 11.34 x 10 Kg-m
= 0.0316 Nm
[Link] 14
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
15 Motion System Application Example
MOTION SYSTEM
APPLICATION EXAMPLE
ω Τ Τ2
1 Τ3
t1 t2 t3 t dwell Time
0.333 s 0.333 s 0.333 s 0.5 s
= 0.3632 Nm
15 [Link]
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
16 Motion System Application Example
MOTION
APPLICATION
SYSTEM
EXAMPLE
ΤRMS = 0.2879 Nm
[Link] 16
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
17 Motion System Application Example
MOTION
APPLICATION
SYSTEM
EXAMPLE
Τ1 = 0.3632 Nm M
Τ2 = 0.3316 Nm
Τ3 = – 0.3632 Nm ΤRMS = 0.2879 Nm
ΤRMS = 0.2879 Nm PPK = 33.69 W
PPK = 33.69 W ωPK = 92.76 rad/s
PCV = 30.76 W Other Motor Considerations
– Type: stepper, brush, BLDC
– Input speed (high input speed will result in high noise levels)
– Total motor footprint
– Ambient temperature
– Environmental conditions
– Load-to-rotor inertia
– Encoder ready needed
Motor Selection
A direct-drive motor can be used, however, it would be large and expensive. For
example, a DC057B-3 brush motor...
...would easily meet continuous torque and continuous speed, as well as a 1.8:1
load-to-rotor inertia. This motor, however, has significantly more output power than
needed at 128 watts.
A smaller motor with a transmission would optimize the system. Look for a motor starting
at a rated power around 40 watts... Pittman DC040B-6
DC040B-6
Reference Voltage 24.0 V
Continuous Torque 0.0812 Nm
Rated Current 2.36 A
Rated Power 37 W
Torque Constant 0.042 Nm/A
Voltage Constant 0.042 V/rad/s
Terminal Resistance 1.85 Ω
Max. Winding Temperature 155°C
Rotor Inertia 8.47 x 10–6 Kg-m2
17 [Link]
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
18 Motion System Application Example
MOTION SYSTEM
APPLICATION EXAMPLE
A 5:1 gearbox would allow about a 27% safety margin between what the system
requires and the continuous torque output of the motor.
Τ1 = 0.0807 Nm Τ1 = 0.3632 Nm
Τ2 = 0.0737 Nm Τ2 = 0.3316 Nm
Τ3 = – 0.0807 Nm Τ3 = – 0.3632 Nm
ΤRMS= 0.0640 Nm ΤRMS= 0.2879 Nm
ω PK = 463.8 rad/s ω PK = 92.76 rad/s
J = 5.04 x 10 6 Kg-m2 J = 11.34 x 10 5 Kg-m2
– –
[Link] 18
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
MOTION SYSTEM
APPLICATION EXAMPLE
Motion Profile at the Motor
ω Τ2
Τ1 Τ3 ω PK = 463.8 rad/s
nPK = 4429 RPM
Τ1 = ΤPK = 0.0807 Nm
t1 t2 t3 t dwell Time
0.333 s 0.333 s 0.333 s 0.5 s
TPK 0.0807 Nm
IPK = + IO = + 0.180 A = 2.10 A
KT 0.042 Nm/A
RMS Current Required
TRMS 0.0640 Nm
IRMS = + IO = + 0.180 A = 1.70 A
KT 0.042 Nm/A
Minimum bus Voltage Required
A 30 VDC bus will meet the application requirements as wells supply a margin of safety.
19 [Link]
Haydon Kerk Motion Solutions: 203 756 7441/Pittman Motors: 267 933 2105
RPM 4000
3000
2000
1000
Will the motor meet the temperature rise caused by the application?
Ambient temperature ......... Θa = 30°C
Rated motor temperature ... Θrated = 155°C
Temperature rise ............... Θr = 76.38°C
Motor temperature ............. Θm = 106.38°C
58.81 58.81
= = = 76.38°C
1 – (0.23) 0.77
Θm = Θr + Θa = 76.38°C + 30°C = 106.38°C
ASK THE
NOW... ASK us the EXPERTS
tough motion www. .com
control questions HaydonKerkPittman
ONLINE!
[Link]
© All rights reserved. AMETEK Advanced Motion Solutions. No part of this doc-
ument or technical information can be used, reproduced or altered in any form
without approval or proper authorization from AMETEK, Inc and global affiliates.