Catalog 8000-3/USA

Introduction

Compumotor Catalog Engineering Reference

Engineering Reference Guide

Over the past twenty years, Compumotor has been developing an Engineering Reference that compiles important information on the technology and practical application of motion control. Compumotors Engineering Reference was the foundation for the Virtual Classroom CD ROM. The Virtual Classroom CD-ROM is an interactive, multi-media tool that makes the Engineering Reference come alive. To request your free copy, go to www.compumotor.com. For your convenience, we are providing an abbreviated version of the Engineering Reference that concentrates on the Sizing and Selection of a motion system. In the future, the complete Engineering Reference will be printed as a separate text to allow greater use and distribution to colleges and universities. Check the website for availability.

Engineering Reference Table of Contents:

Sizing and Selection Process 223 Sizing and Selection Software Application Considerations Technology Comparison Summary Glossary of Terms Technical Data Advanced Application Examples 6000 Position-Based Following Contouring (Circular Interpolation)

232 233 235 237 240 241 241 245

Motor Sizing and Selection Process

Before you can select your motors drives and controls, you must define the mechanical system and determine the performance requirements of each axis of motion. The information in this section will help you: 1. Calculate move profile for each axis of motion. 2. Calculate total inertia for each axis of motion 3. Calculate torque required for acceleration for each axis of motion 4. Calculate max motor speed for each axis of motion 5. Review the application considerations to determine special

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Sizing & Selection Process Sizing Step 1: Move Profile

Before calculating torque requirements of an application, you need to know the velocities and accelerations needed. For those positioning applications where only a distance (X) and a time (S) to move that distance are known, the trapezoidal motion profile and formulas given below are a good starting point for determining your requirements. If velocity and acceleration parameters are already known, you can proceed to one of the specific application examples on the following pages. Move distance X in time S. Assume that: 1. Distance X/4 is moved in time S/3 (Acceleration) 2. Distance X/2 is moved in time S/3 (Run) 3. Distance X/4 is moved in time S/3 (Deceleration) The graph would appear as follows:
V

Compumotor Catalog Engineering Reference

The acceleration (a), velocity (v) and deceleration (d) may be calculated in terms of the knowns, X and S.

(X) 4 a = -d = 2X = t (S) 3
2
2 2

X = 2 2x 9 = 4.5X S S2

v = at = 4.5X x S 3 S2

= 1.5X S

Example You need to move 6" in 2 seconds inches a = -d = 4.5 (6 inches) = 6.75 second2 (2 seconds)2 v = 1.5 (6 inches) = 4.5 inches (2 seconds) second

Velocity

0 S/3

S/3 S/3

2S/3 S/3

time

Common Move Profile Considerations

Distance: ______________ Inches of Travel ________________________ Move Time: ____________________________________________________ Accuracy: ______________________________________________________ Repeatability: ___________________________________________________ Duty Cycle on tme: ____________________________________________________ off time: ___________________________________________________ Cycle Rate: ____________________________________________________ seconds seconds sec. min. hour revolutions of motor seconds arcminutes, degrees or inches arcseconds, degrees or inches

Sizing Step 2 and Step 3: Inertia and Torque Calculations

Leadscrew Drives
Leadscrews convert rotary motion to linear motion and come in a wide variety of configurations. Screws are available with different lengths, diameters, and thread pitches. Nuts range from the simple plastic variety to precision ground versions with recirculating ball bearings that can achieve very high accuracy. The combination of microstepping and a quality leadscrew provides exceptional positioning resolution for many applications. A typical 10-pitch (10 threads per inch) screw attached to a 25,000 step/rev. motor provides a linear resolution of 0.000004" (4 millionths, or approximately 0.1 micron) per step. A flexible coupling should be used between the leadscrew and the motor to provide some damping. The coupling will also prevent excessive motor bearing loading due to any misalignment.

Leadscrew Application Data

Inertia of Leadscrews per Inch Diameter In. 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 Steel 0.0017 0.0275 0.1392 0.4398 1.0738 2.2266 4.1251 7.0372 11.2723 17.1807 Brass 0.0018 0.0295 0.1491 0.4712 1.1505 2.3857 4.4197 7.5399 12.0774 18.4079 Alum. 0.0006 0.0094 0.0478 0.1512 0.3691 0.7654 1.4180 2.4190 3.8748 5.9059 oz-in oz-in2 oz-in2 oz-in2 oz-in2 oz-in2 oz-in2 oz-in2 oz-in2 oz-in2
2

Diameter In. 2.75 3.00 3.25 3.50 3.75 4.00 4.25 4.50 4.75 5.00 Steel 25.1543 35.6259 49.0699 66.0015 86.9774 112.5956 143.4951 180.3564 223.9009 274.8916 Brass 26.9510 38.1707 52.5749 70.7159 93.1901 120.6381 153.7448 193.2390 239.8939 294.5267 Alum. 8.6468 12.2464 16.8678 22.6880 29.8985 38.7047 49.3264 61.9975 76.9659 94.4940 oz-in2 oz-in2 oz-in2 oz-in2 oz-in2 oz-in2 oz-in2 oz-in2 oz-in2 oz-in2

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Sizing & Selection Process Coefficients of Static Friction Materials

(Dry Contact Unless Noted) Steel on Steel Steel on Steel (lubricated) Aluminum on Steel Copper on Steel Brass on Steel PTFE on Steel S 0.58 0.15 0.45 0.22 0.19 0.04

Compumotor Catalog Engineering Reference

Leadscrew Efficiencies Type Ball-nut Acme with metal nut* Acme with plastic nut Efficiency (%) Median 90 40 65

High 95 55 85

Low 85 35 50

*Since metallic nuts usually require a viscous lubricant, the coefficient of friction is both speed and temperature dependent.

Leadscrew Drives
Vertical or Horizontal Application: ST Screw type, ball or acme e Efficiency of screw S Friction coefficient L Length ofscrew D Diameter of screw p Pitch W Weight of load F Breakaway force Directly coupled to the motor? If yes, CT Coupling type If no, belt & pulley or gears Radius of pulley or gear Gear: Number of teeth Gear 1 Number of teeth Gear 2 Weight of pulley or gear Weight of belt ST = e= S = L= D= p= W= F= yes/no

% inches inches threads/inch lbs. ounces

inches

ounces ounces

Leadscrew Formulas
The torque required to drive load W using a leadscrew with pitch (p) and efficiency (e) has the following components: TTotal = TFriction + TAcceleration TFriction = F 2pe

= density, ounces/in3 g = gravity constant, 386 in/sec2 The formula for load inertia converts linear inertia into the rotational equivalent as reflected to the motor shaft by the leadscrew.

Where: F = frictional force in ounces p = pitch in revs/in e = leadscrew efficiency F = s W for horizontal surfaces where s = coefficient of static friction and W is the weight of the load. This friction component is often called breakaway. Dynamic Friction: F = DW is the coefficient to use for friction during a move profile. However, torque calculations for acceleration should use the worst case friction coefficient, s. 1 (JLoad + JLeadscrew + JMotor) TAccel = g t = 2pv 4 JLoad = w 2 ; JLeadscrew = LR (2p) 2 Where: T = torque, oz-in = angular velocity, radians/sec t = time, seconds v = linear velocity, in/sec L = length, inches R = radius, inches

Problem
Find the torque required to accelerate a 200-lb steel load sliding on a steel table to 2 inches per second in 100 milliseconds using a 5 thread/inch steel leadscrew 36 inches long and 1.5 inches in diameter. Assume that the leadscrew has an Acme thread and uses a plastic nut. Motor inertia is given as 6.56 oz-in2. In this example, we assume a horizontally oriented leadscrew where the force of gravity is perpendicular to the direction of motion. In non-horizontal orientations, leadscrews will transmit varying degrees of influence from gravity to the motor, depending on the angle of inclination. Compumotor Sizing Software automatically calculates these torques using vector analysis. 1. Calculate the torque required to overcome friction. The coefficient of static friction for steel-to-steel lubricant contact is 0.15. The median value of efficiency for an Acme thread and plastic nut is 0.65. Therefore: F = sW = 0.15 (200 lb) (16 oz) = 480 oz lb 480 oz = = 23.51 oz-in TFriction = F 2 x 5 rev x 0.65 2pe rev in

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Sizing & Selection Process

2. Compute the rotational inertia of the load and the rotational inertia of the leadscrew: JLoad = W = 200 lb x 16 oz = 3.24 oz-in2 (2p)2 (25)2 lb in2 JLeadscrew = LR = (36 in)(4.48 oz)(0.75 in)4 = 80.16 oz-in 2 2 in3
4 2

Compumotor Catalog Engineering Reference

TAccel = 1( 1J + J + JMotor) Load Leadscrew g e t sec ( )(2 in) = 20 sec

= 2 5 in =

20. 1 2 sec 2 [4.99 + 80.16 + 6.56(oz-in )] 386 in/sec 0.1sec = 149 oz-in TTotal = TFriction + TAccel

3. The torque required to accelerate the load may now be computed since the motor inertia was given:

TTotal = 23.51 oz-in + 149 oz-in = 172.51 oz-in

Directly Driven Loads

There are many applications where the motion being controlled is rotary and the low-speed smoothness and high resolution of a Compumotor system can be used to eliminate gear trains or other mechanical linkages. In direct drive applications, a motor is typically connected to the load through a flexible or compliant coupling. This coupling provides a small amount of damping and helps correct for any mechanical misalignment. Direct drive is attractive when mechanical simplicity is desirable and the load being driven is of moderate inertia.

Direct Drive Formulas

R2
R L

L
5.96

R1

R Radius R(1) Inner radius R(2) Outer radius L Length W Weight of disc Density/Material g Gravity constant

R= R(1) = R(2) = L= W= = g=

inches inches inches inches ounces ounces/inch3 386 in/sec2

Solid Cylinder (oz-in2) 2 Inertia: JLoad = WR 2 Where weight and radius are known 4 Inertia (oz-in2) JLoad =LR 2 Where , the material density is known Weight W = LR2 Inertia may be calculated knowing either the weight and radius of the solid cylinder (W and R) or its density, radius and length (, R and L.) The torque required to accelerate any load is: T (oz-in) = Ja - 1 a= 2 = 2 (accel.) for Accel. in rps2 t

Where: a = angular acceleration, radians/sec2 2 = final velocity, radians/sec 1 = initial velocity, radians/sec t = time for velocity change, seconds J = inertia in units of oz-in2 The angular acceleration equals the time rate of change of the angular velocity. For loads accelerated from zero, 1 = 0 and a= t TTotal = 1 (JLoad + JMotor) g t TTotal represents the torque the motor must deliver. The gravity constant (g) in the denominator represents acceleration due to R gravity (386 in/sec2) and L converts inertia from units of oz-in2 to oz-in-sec2.

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Sizing & Selection Process

Hollow Cylinder w JLoad = 2 (R21 + R22) Where W, the weight, is known or JLoad =

Compumotor Catalog Engineering Reference

Problem Calculate the motor torque required to accelerate a solid cylinder of aluminum 5" in radius and 0.25" thick from rest to 2.1 radians/sec (0.33 revs/sec) in 0.25 seconds. First, calculate JLoad using the density for aluminum of 1.54 oz/in3.
4 4 JLoad = LR = x 0.25 x 1.54 x 5 = 378 oz-in2 2 2 Assume the rotor inertia of the motor you will use is 37.8 ozin 2.

L 2

(R42 R41)

Where r, the density, is known W = L (R22 R21) 1 (J + JMotor) t T= Load g

R2

TTotal = 1 g
L
5.96

(JLoad + JMotor) x t

R1

1 x (378 + 37.8) x 2.1 386 0.25

= 9.05 oz-in

Gear Drives
Traditional gear drives are more commonly used with step motors. The fine resolution of a microstepping motor can make gearing unnecessary in many applications. Gears generally have undesirable efficiency, wear characteristics, backlash, and can be noisy. Gears are useful, however, when very large inertias must be moved because the inertia of the load reflected back to the motor through the gearing is divided by the square of the gear ratio. In this manner, large inertial loads can be moved while maintaining a good load-inertia to rotor-inertia ratio (less than 10:1).

Gear Driven Loads

R Radius R(1) Radius gear #1 R(2) Radius gear #2 N(1) Number of teeth G#1 N(2) Number of teeth G#2 G Gear ratio N(1) N(2) W Weight of load W(1) Weight G#1 W(2) Weight G#2 L Length L= F Friction F= BT Breakaway torque R= R(1) = R(2) = N(1) = N(2) = G=
W= W(1) = W(2) = inches BT =

inches inches inches

ounces ounces ounces

ounce/inches

N1 G1
R

Gears

R1 W R2 G2 N2

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Sizing & Selection Process

Gear Drive Formulas

Compumotor Catalog Engineering Reference

N1

NGear 2 2 WLoad JLoad = R2Load NGear 1 2 or NGear 2 LLoadLoad 4 JLoad = R Load NGear 1 2

G1

Gears

R1 W R2 G2 N2

W JGear1 = Gear1 R2Gear1 2

NGear 2 NGear 1

Where: J T W R N L t g = = = = = = = = = = inertia, oz-in (gm-cm2) as seen by the motor torque, oz-in (gm-cm) weight, oz (gm) radius, in. (cm) number of gear teeth (constant) length, in (cm) density, oz/in3 (gm/cm3) angular velocity, radians/sec @ motor shaft time, seconds gravity constant, 386 in/sec2

JGear2 = TTotal =

WGear2 2 R Gear2 2
1 g

(JLoad + JGear1 + JGear2 + JMotor) t

Tangential Drives
W

R Radius W Weight (include weight of belt or chain) W(P) Weight of pulley or material F Breakaway force V Linear velocity CT Coupling type SL Side load

R= W= W(P) F= V= CT = SL =

inches ounces ounces ounces inches/sec

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Sizing & Selection Process

Tangential Drive Formulas
TTotal = TLoad + TPulley + TBelt + TMotor + TFriction TTotal = 1 (JLoad + JPulley + JBelt + JMotor) +TFriction t g JLoad = WLR2
2 JPulley = WpR 2

Compumotor Catalog Engineering Reference

Problem
What torque is required to accelerate a 5-lb load to a velocity of 20 inches per second in 10 milliseconds using a flat timing belt? The motor drives a 2-inch diameter steel pulley 1/2-inch wide. The timing belt weighs 12 oz. Load static friction is 30 ozs. Motor rotor inertia is 10.24 oz-in.2 JLoad = WLR2 = 5 lb x 16 oz x (1 in)2 = 80 oz-in2 lb
JPulley =
2(LR4) = x 0.5 in x (4.48 oz/in3) (1 in)4 2

JBelt = WBR2 TFriction = FR = V R

Where: T = torque, oz-in (gm-cm) = angular velocity, radians/sec t = time, seconds W L = weight of the load, oz W P = pulley weight, oz W B = belt or rack weight, oz

Remember to multiply by 2 if there are two pulleys.

= 7.04 oz-in2

JBelt = WBR2 = 12 oz (1 in)2 = 12 oz-in2 TFriction = F x R = 30 oz x 1 in = 30 oz-in

1 rad V in rad = R = 20 sec x 1 in = 20 sec
F R V g frictional force, oz (gm) radius, in (cm) linear velocity gravity constant, 386 in/sec2 = density, oz/in3 = = = =

20 1 TTotal = 386 (80 + 7.04 + 12 + 10.24) .01 + 30

TTotal = 596.2 oz-in

Sizing Step 4: Motor/Drive Selection

Based on Continuous Torque Requirements
Having calculated the torque requirements for an application, you can select the motor/drive suited to your needs. Microstepping motor systems (Gemini, ZETA Series OEM750 Series) have speed/torque curves based on continuous duty operation. To choose a motor, simply plot total torque vs. velocity on the speed/torque curve. This point should fall under the curve and allow approximately a 50% margin for safety. A ZETA106-178 and a ZETA83-135 curve are shown here. Note: When selecting a ZETA or Gemini product, a 50% torque margin is not required. Example Assume the following results from load calculations: F = 25 oz-in A = 175 oz-in T = 200 oz-in V = 15 rev/sec Friction torque Acceleration torque Total torque Maximum velocity
20 (9.08) 16 (7.26)

Force lbs (kg)

12 (6.45) 8 (3.83) 4 (1.82) 0

14.0 lbs

53.2 ips

20 (50.8)

40 60 (101.6) (152.4) Speed in (cm)

80 (203.2)

100 (254.0)

The ZETA83-135 has approximately 250 oz-in available at V max (25% more than required). The Zeta106-178 has 375 ozin available, an 88% margin. In this case, we would select the Zeta106-178 motor/drive to assure a sufficient torque margin to allow for changing load conditions.

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