Actuator Sizing – Part II

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Actuator Sizing

Actuator Sizing
Algorithm

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Actuator Sizing

1. Define the geometric relationship between the actuator and load. In other words,
select the type of motion transmission mechanism between the motor and the
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load (N).
Actuator Sizing

2. Define the inertia and torque/force characteristics of the load and the
transmission mechanism, that is define the inertia of the tool as well as the
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inertia of the gear reducer mechanisms (Jl, Tl).
Actuator Sizing

3. Define the desired cyclic motion profile in the form of load speed versus
time ( ̇𝜃 l(t)).
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Actuator Sizing

4. Using the reflection equations developed above, calculate the reflected load
inertia and torque/forces (Jl,eff , Tl,eff ) that will effectively act on the actuator shaft as
well as the desired motion at the actuator shaft ( ̇𝜃m(t) = ̇𝜃in(t)). 6
Actuator Sizing

5. Guess an actuator/motor inertia from an available list (or make the first calculation
with zero motor inertia assumption), and calculate the torque history, Tm(t), for the
desired motion cycle. Then calculate the peak torque and RMS torque from Tm(t). 7
Actuator Sizing

Datasheets of motors

6. Check if the actuator meets the required performance in terms of peak and RMS
torque, and maximum speed capacity (Tp, Trms, ̇𝜃max). If the above selected actuator/
motor from the available list does not meet the requirements (i.e., too small or too large),
repeat the previous step by selecting a different motor. 8
Actuator Sizing

7. The continuous torque rating of most electric servo motors is given for 25 ◦C
ambient temperature and an aluminum face mount for heat dissipation
considerations. If the nominal ambient temperature is different form 25 ◦C, the
continuous (RMS) torque capacity of the electric motor should be derated using
the following equation for a temperature,

If the Trms rating is exceeded, the temperature of the motor winding will increase proportionally. If
the temperature rise is above the rated temperature for the winding insulation of the motor, the
motor will be damaged permanently.

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Actuator Sizing
Actuator Sizing

Inertia Match
Between Motor and
Load

The ratio of the motor’s rotor inertia and the reflected load inertia is always a concern in
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high performance motion control applications. 10
Actuator Sizing

It is a rule of thumb that the ratio of motor inertia to

load inertia should be between one-to-one and up to
one-to-ten,

The one-to-one match is considered the optimal match. Below, we show that the one-
to-one inertial match is optimal only in the ideal case where the motor drives a purely
inertial load and that this inertia ratio results in minimum heating of the motor.

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Actuator Sizing

Let us consider the case that the motor is coupled to a

purely inertial load through an effective gear ratio. The
torque and motion relationship is

Minimal heating occurs when the required torque is minimized, since torque is
proportional to current and heat generation is related to current (Pelec = R ⋅ i2,
where Pelec is the electric power dissipated at the motor windings due to its
electrical resistance R and current i).
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Actuator Sizing

The minimum torque occurs at the gear ratio where

the derivative of Tm with respect to N is equal to zero,

Therefore, the optimal gear ratio between the motor and a purely inertial load which
minimizes the torque requirements (hence, the heating), is

It is important to note that this ideal inertia match (1:1) between the motor’s rotor inertia and reflected load inertia is
optimal only for purely inertial loads. In applications where the load may be dominated by friction or other
application related load torque or forces, the ideal inertia match may not be a good design.
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Actuator Sizing

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Actuator Sizing

The load inertia

The acceleration, top speed, and deceleration rates are calculated from the
kinematic relationships,

The required torque to move the load through the desired

cyclic motion

The peak torque

Hence, the RMS torque

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Revision Exercises

1. A planetary gearbox has 200 teeth on its ring, and 40 teeth on its sun gear. The input to the
sun gear is 100 rev min−1 clockwise. Determine the output speed if the ring is fixed, or rotating at
5 rev min−1 either clockwise or counterclockwise.

2. Determine the speed and torque requirements for the following lead screw application:
• The length (Ls) of a lead screw is 1 m, its radius (Rs) is 20 mm and is manufactured from
steel (  = 7850 kg m−3). The lead (L) is 6 mm rev−1. The efficiency () of the lead screw is
0.85.
• The total linear mass (ML) to be moved is 150 kg. The coefficient of friction (μ)between
the mass and its slipway is 0.5. A 50 N linear force (FL) is being applied to the mass.
• The maximum speed of the load (VL) has to be 6 m min−1 and the time (t) the system is
required to reach this speed in 1 s.

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Revision Exercises

3. Determine the speed and torque requirements for the following belt drive:
• A belt drive is required to position a 100 g load. The drive consists of two aluminium
pullies ( = 2770 kgm−3), 50 mm in diameter and 12 mm thick driving a belt weighting 20
g. The efficiency () of the drive is 0.95.
• The maximum speed of the load (VL) is 2 m min−1 and the acceleration time (t) is 0.1 s.

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