10/25/2015 me senior design spring 2008 1 bi-directional rotary actuator group 9 sung bae robert...
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04/20/23 ME Senior Design Spring 2008 1
Bi-Directional Rotary Bi-Directional Rotary ActuatorActuator
Group 9Group 9
Sung BaeSung Bae
Robert Hooge Robert Hooge
Chris ImparatoChris Imparato
Jose JaramilloJose Jaramillo
04/20/23 ME Senior Design Spring 2008 2
What is a Rotary Actuator?What is a Rotary Actuator?
N S S N
N S S N
N S S N
360 deg
Non-energized
N
N S S N
N S S N
N S S N
N N
S S S
N S S N
N S S N
N S S N
S S S
N N N
Energized - polarity30 deg CW rotation
Energized + polarity30 deg CCW rotation
Upper stator
Rotor
Lower stator
N S S N
N S S N
N S S N
- or +
Sandia coil design: Coil is constrained to one side of actuator. Magnetic field conducts thru can to opposite stator.
04/20/23 ME Senior Design Spring 2008 3
Needs AssessmentNeeds Assessment
Replace two uni-directional solenoids with Replace two uni-directional solenoids with single bi-directional solenoid. single bi-directional solenoid.
Used in weapon components systemsUsed in weapon components systems Should be adaptable to Micro-Electro-Should be adaptable to Micro-Electro-
Mechanical System (MEMS) for Mechanical System (MEMS) for miniaturization.miniaturization.
04/20/23 ME Senior Design Spring 2008 4
ScopeScope
Design a bi-directional rotary actuatorDesign a bi-directional rotary actuator• Compact and easy to assembleCompact and easy to assemble
• Rotates either clockwise or counterclockwise with a return Rotates either clockwise or counterclockwise with a return to a neutral positionto a neutral position
• Electro-magnetic with a permanent magnet rotorElectro-magnetic with a permanent magnet rotor
• Takes full advantage of maximum moment arm availability Takes full advantage of maximum moment arm availability (pancake style)(pancake style)
• Single coil designSingle coil design
• Directionality is controlled by coil polarityDirectionality is controlled by coil polarity
04/20/23 ME Senior Design Spring 2008 5
Constraints/GoalsConstraints/Goals
Rotor must be 2” in diameterRotor must be 2” in diameter No springs to return to neutral positionNo springs to return to neutral position Torque must be 0.31Nm or greaterTorque must be 0.31Nm or greater Step size of 20° - 30°Step size of 20° - 30°
04/20/23 ME Senior Design Spring 2008 6
Original DesignsOriginal Designs
04/20/23 ME Senior Design Spring 2008 7
Major changesMajor changes Cylindrical housingCylindrical housing
• Uniformly distributed magnetic fieldUniformly distributed magnetic field Inner magnets used.Inner magnets used.
• Helped to increase torque. Helped to increase torque. Changed from 4 poles to 3Changed from 4 poles to 3 Taller coilTaller coil
• Lowered current density Lowered current density • Distributed temperature over larger area.Distributed temperature over larger area.
04/20/23 ME Senior Design Spring 2008 8
Final DesignFinal Design
Magnets left out for clarity
NS
04/20/23 ME Senior Design Spring 2008 9
Exploded ViewExploded View
1-64 Flat Head Screws
Outer Housing
Snap Ring
Shaft
Upper StatorBase Plate
Lower Stator
Shoulder BearingCoil CoreCoil
Rotor Bushing
04/20/23 ME Senior Design Spring 2008 10
2-D Simulation2-D SimulationUsing Maxwell 2-D SV
Off Position (No Current)
04/20/23 ME Senior Design Spring 2008 11
2-D Simulation2-D SimulationOn Position (1500A)
Shading in above figure represents magnetic field, lines represent magnetic flux
04/20/23 ME Senior Design Spring 2008 12
3-D Simulation3-D Simulation
De-Energized EnergizedUsing Maxwell 3-D
04/20/23 ME Senior Design Spring 2008 13
Thermal ModelingThermal Modeling
Surface TemperatureSurface Temperature• Surrounding objectsSurrounding objects• SafetySafety• Determined materials Determined materials
used for coilused for coil
E-PhysicsE-Physics
Calculated - 72°C Max
04/20/23 ME Senior Design Spring 2008 14
CalculationsCalculations
Calculations from Assumed Values Calculations from Measured Values
04/20/23 ME Senior Design Spring 2008 15
Fabricated PartsFabricated PartsBase Plate Coil Core
Lower StatorHousing
Upper Stator
Coil & Spool
Rotor&
Shaft
Winding Device
Screws
04/20/23 ME Senior Design Spring 2008 16
AssemblyAssembly
Coil and Lower Stator Assembly Rotor Assembly
Assembly Full Assembly
04/20/23 ME Senior Design Spring 2008 17
Assembly ProblemsAssembly Problems
Tolerances on shaft and rotorTolerances on shaft and rotor• Remade rotor and shaftRemade rotor and shaft• Made shoulder on shaftMade shoulder on shaft
Used bushing in upper statorUsed bushing in upper stator• Press fitting 2 bearings posed disassembly Press fitting 2 bearings posed disassembly
problemsproblems
04/20/23 ME Senior Design Spring 2008 18
Operational SetupOperational Setup
04/20/23 ME Senior Design Spring 2008 19
OperationOperation
04/20/23 ME Senior Design Spring 2008 20
Torque TestTorque Test
Using Torque Gauge
Generated - .068 N-m
04/20/23 ME Senior Design Spring 2008 21
Thermal TestsThermal Tests
Temperature after 2 minutes Temperature after 5 minutes
47.4° C 53.2° C
04/20/23 ME Senior Design Spring 2008 22
ConclusionsConclusions
Proof of concept Proof of concept • Single bi-directional solenoidSingle bi-directional solenoid
TorqueTorque• .068 N-m 1/5 Predicted value.068 N-m 1/5 Predicted value• 22ndnd Test TBD Test TBD
Measure stall torqueMeasure stall torque
Step SizeStep Size• 10°-15°10°-15°
04/20/23 ME Senior Design Spring 2008 23
RecommendationsRecommendations
Housing with 3 walls aligned with stators.Housing with 3 walls aligned with stators. Magnet spacing.Magnet spacing. Stators: wider with larger radius than Stators: wider with larger radius than
magnets.magnets.
Diagrams to be inserted
04/20/23 ME Senior Design Spring 2008 24
AcknowledgmentsAcknowledgments
Sponsor - Gilbert Benavides (SNL)Sponsor - Gilbert Benavides (SNL) Advisors Advisors
• Dr. MassonDr. Masson• Dr. EnglanderDr. Englander
NHMFLNHMFL• Lee MarksLee Marks
Graduate Machine Shop StaffGraduate Machine Shop Staff Dr. LuongoDr. Luongo
04/20/23 ME Senior Design Spring 2008 25
Questions?Questions?