Engineering Reference: Sizing and Selection of Exlar Linear and Rotary Actuators
Engineering Reference: Sizing and Selection of Exlar Linear and Rotary Actuators
Engineering Reference: Sizing and Selection of Exlar Linear and Rotary Actuators
This move profile is based on the distance to be traveled and the amount of time available in which to make that move. The calculations below can help you determine your move profile. Each motion device will have a maximum speed that it can achieve for each specific load capacity. This maximum speed will determine which type of motion profile can be used to complete the move. Two common types of move profiles are trapezoidal and triangular.
If the average velocity of the profile, is less than half the max. velocity of the actuator, then triangular profiles can be used. Triangular Profiles result in the lowest possible acceleration and deceleration. Otherwise a trapezoidal profile can be used. The trapezoidal profile below with 3 equal divisions will result in 25% lower maximum speed and 12.5% higher acceleration and deceleration. This is commonly called a 1/3 trapezoidal profile.
Linear Move Profile Calculations Vmax = max.velocity-in/sec (m/sec) Vavg = avg. velocity-in/sec (m/sec) tacc = acceleration time (sec) tdec = deceleration time (sec) tcv = constant velocity (sec) ttotal = total move time (sec) acc = accel-in/sec2 (m/sec2) dec = decel-in/sec2 (m/sec2) cv = constant vel.-in/sec (m/sec) D = total move distance-in (m) or revolutions (rotary) Standard Equations Vavg = D / ttotal If t acc = tdec Then: Vmax = ( t total /( t total -t acc ))( V avg ) and D = Area under profile curve D = ( 12( t acc + t dec ) +t cv )( V max )
Velocity (in/sec)
Velocity (in/sec)
Vavg
acc dec time (sec)
tacc
tcv ttotal
tdec
time (sec)
tacc ttotal
tdec
Trapezoidal Equations If t acc = tcv = t dec Then: Vmax = 1.5( V avg ) D = ( 23)( t total )( V max )
acc = dec =
Triangular Equations If t acc = t dec = t total /2 Then: Vmax = 2.0( V avg ) D = ( 12)( t total )( V max )
acc = dec =
V max t acc
V max t acc
The following pages give the required formulas that allow you to select the proper Exlar linear or rotary actuator for your application. The first calculation explanation is for determining the required thrust in a linear application. The second provides the necessary equations
for determining the torque required from a linear or rotary application. For rotary applications this includes the use of reductions through belts or gears, and for linear applications, through screws. Pages are included to allow you to enter your data and easily perform
the required calculations. You can also describe your application graphically and fax it to Exlar for sizing. Reference tables for common unit conversions and motion system constants are included at the end of the section.
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Thrust Calculations
Definition of thrust: The thrust necessary to perform a specific move profile is equal to the sum of four components of force. These are the force due to acceleration of the mass, gravity, friction and applied forces such as cutting and pressing forces and overcoming spring forces.
F gravity = Force due to gravity-lbf (N) F applied = Applied forces-lbf (N) WL = Weight of Load-lbm (kg)
app.
THRUST = WLcos + [(WL /386.4) (v/t acc)] + WLsin + Fapplied Sample Calculations: Calculate the thrust required to accelerate a 200 pound mass to 8 inches per second in an acceleration time of 0.2 seconds. Calculate this thrust at inclination angles() of 0, 90 and 30. Assume that there is a 25 pound spring force that is applied against the acceleration. WL = 200 lbm, v = 8.0 in/sec., t a = 0.2 sec., Fapp. = 25 lbf, = 0.15
Angle of Inclination 90
Note: at = 0 cos = 1; sin = 0 0 at = 90 cos = 0; sin = 1
= 0 THRUST = WLcos + [(WL /386.4) (v/t acc)] + WLsin + Fapplied = (200)(0.15)(1) + [(200/386.4)(8.0/0.2)] + (200)(0) + 25 = 30 lbs + 20.73 lbs + 0 lbs + 25 lbs = 75.73 lbs force
-90
It is necessary to calculate the required thrust for an application during each portion of the move profile, and determine the worst case criteria. The linear actuator should then be selected based on those values. The calculations at the right show calculations during acceleration which is often the most demanding segment of a profile.
= 90 THRUST = WLcos + [(WL /386.4) (v/t acc)] + WLsin + Fapplied = (200)(0.15)(0) + [(200/386.4)(8.0/0.2)] + (200)(1) + 25 = 0 lbs + 20.73 lbs + 200 lbs + 25 lbs = 245.73 lbs force
= 30 THRUST = WLcos + [(WL /386.4) (v/t acc)] + WLsin + Fapplied = (200)(0.15)(0.866) + [(200/386.4)(8.0/0.2)] + (200)(0.5) + 25 = 26 lbs + 20.73 lbs + 100 + 25 = 171.73 lbs force
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Velocity Equations
Screw drive: vL = m*S/2 in/sec (m/sec) Belt or gear drive: m = L*R rad/sec
Torque Equations
Torque Under Load Screw drive (GS, FT or separate screw): =
SF lbf-in ( N-m) 2
Belt and Pulley drive: = TL / R lbf-in ( N-m) Gear or gear reducer drive: = TL / R lbf - in ( N-m)
Torque Under Acceleration a = (Jm + JR+ (Js + JL)/R2) lbf-in = angular acceleration = ((RPM / 60) x 2) / tacc, rad/sec2. Js = L x r4 lb - in - s2 ( N - m - s2 ) 2g
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Force 500 lb. 250 lb. F1 F2 100 lb. 0.5 inches s1 2.9 inches s2 1.0 inches s3 F3 50 lb. 3.5 inches s4
s = Distance traveled during each move segment
F4
Lifetime Calculations
The expected L10 life of a roller screw is expressed as the linear travel distance that 90% of the screws are expected to meet or exceed before experiencing metal fatigue. The mathematical formula that defines this value is below. The life is in millions of inches (mm). This standard L10 life calculation is what is expected of 90% of roller screws manufactured and is not a guarantee. Travel life estimate is based on a properly maintained screw that is free of contaniments and properly lubricated. Higher than 90% requires de-rating according to the following factors: 95% X 0.62 96% X 0.53 97% X 0.44 98% X 0.33 99% X 0.21
( ) (
9/10
where: L10 = Travel life in millions of inches (mm) L10(1) = Expected life in the extend direction, as determined by the single nut lifetime equation L10(2) = Expected life in the retract direction, as determined by the single nut lifetime equation
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F gravity = Force due to gravity-lbf (N) F applied = Applied forces-lbf (N) 386.4 = Acceleration of gravity - in/sec2 (9.8 m/sec2)
= _________________ lbf. Calculate the thrust for each segment of the move profile. Use those values in calculations below. Use the units from the above definitions.
F13 t1= ____________ F23 t2= ____________ F33 t3= ____________ F43 t4= ____________
Move Profiles may have more or less than four components. Adjust your calculations accordingly.
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Torque Calculations
= Torque, lb-in (N-m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = F = Applied Load, non inertial, lbf (N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = S = Screw lead, in (m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = = Screw or ratio efficiency (~85% for roller screws) . . . . . . . . . . . . . . . . . . . . . . . . . = g = Gravitational constant, 386 in/s2 (9.8 m/s2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = = Acceleration of motor, rad/s2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = R = Belt or reducer ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = TL = Torque at driven load, lbf-in (N-m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = vL = Linear velocity of load, in/sec (m/sec) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = L = Angular velocity of load, rad/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = m = Angular velocity of motor, rad/sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = m = Mass of the applied load, lbm (kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = JR = Reflected Inertia due to ratio, lb-in-s2 (N-m-s2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . = JS = Reflected Inertia due to screw, lb-in-s2 (N-m-s2) . . . . . . . . . . . . . . . . . . . . . . . . . . . = JL = Reflected Inertia due to load, lb-in-s2(N-m-s2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . = JM = Motor armature inertia, lb-in-s2 (N-m-s2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = = pi (3.14159) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = K t = Motor Torque constant, lb-in/amp (N-m/amp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . =
* For the GS Series JS and JM are one value from the GS Specifications.
3.14159
Torque Equations
Torque From Calculated Thrust. = SF lb - in ( N - m) = ( 2 Torque Due To Load, Rotary. Belt and pully drive: = TL / R lbf-in (N-m) Gear or gear reducer drive: = TL / R lbf-in (N-m) Torque During Acceleration due to screw, motor, load and reduction, linear or rotary. = (Jm + (JS + JL) / R2 ) lb-in (N-m) = [( )+( + )/( )]( )= )x( )/2(0.85) = ( )x( )/5.34 =
Total Torque = Torque from calculated Thrust + Torque due to motor, screw and load ( ) +( ) +( )= Motor Current = / K t = ( )/( )=
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FAX to:
Exlar Corporation
(952) 368-4359 Attn: Applications Engineering
Date: Company Name: Address: City: Phone: Contact: Sketch / Describe Application State: Fax: Title: Zip Code:
distance
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Maximum Stroke Needed . . . . . . . . . . . . . . . . . __________________ inches (mm), revs Index Stroke Length . . . . . . . . . . . . . . . . . . . . . __________________ inches (mm), revs Index Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . __________________ sec Max Speed Requirements . . . . . . . . . . . . . . . . . __________________ in/sec (mm/sec), revs/sec Min Speed Requirements . . . . . . . . . . . . . . . . . __________________ in/sec (mm/sec), revs/sec Required Positional Accuracy . . . . . . . . . . . . . . __________________ inches (mm), arc min Load & Life Requirements Gravitational Load . . . . . . . . . . . . . . . . . . . . . . . __________________ lb (N) External Applied Load . . . . . . . . . . . . . . . . . . . . __________________ lbf (N) Inertial Load . . . . . . . . . . . . . . . . . . . . . . . . . . . __________________ lbf (N) Friction Load . . . . . . . . . . . . . . . . . . . . . . . . . . __________________ lbf (N) Rotary Inertial Load . . . . . . . . . . . . . . . . . . . . . __________________ lbf-in-sec2 (kg-m2) or rotary mass, radius of gyr. _____________ lb (kg) ___________ in (mm)
Side Load (rot. or lin. actuator) . . . . . . . . . . . . . __________________ lb (N) Force Direction ___ Extend ___ Retract ___ Vertical Down ___ Both ___ Horizontal
Actuator Orientation ___ Vertical Up ___ Fixed Angle ___ Changing Angle
Cycling Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . __________________ Cycles/min/hr/day Operating Hours per Day . . . . . . . . . . . . . . . . . . __________________ Hours Life Requirement . . . . . . . . . . . . . . . . . . . . . . . __________________ Cycles/hr/inches/mm Configuration Mounting: Rod End: ___ Side ___ Male ___ Flange ___ Female ___ Appl Inherent ___ Yes ___ Ext Tie Rod ___ Sph Rod Eye ___ External Reqd ___ No ___ Clevis ___ Rod Eye ___ Trunnion ___ Clevis
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