Edm E Drive Orlando Conf Mar2009 V13
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Transcript of Edm E Drive Orlando Conf Mar2009 V13
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EDM Resources Inc.EDM Resources Inc.Harmonic Drive Motor-Generator TechnologyHarmonic Drive Motor-Generator Technology
E. Davison PhD. PEng.
Orlando March, 2009
A New Approach To: A New Approach To:
High Torque, Variable, Low SpeedHigh Torque, Variable, Low Speed
Motor Generator TechnologyMotor Generator Technology
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2Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
1. Introduction
2. Harmonic Motor Technology Primer
3. EDM Resources Harmonic Drive Motor
4. Applications & Benefits
5. Summary
6. Q&A
Overview / Outline
Overview / Outline
2009©
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3Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
1. Introduction
• EDM Resources Inc. Background Based in Moffat Ontario Canada since June 1998 Sole assignee of related patents Contact: [email protected]
• E. Davison PhD, PEng
President and founder of EDM Resources Sole inventor of related patents Developer of innovative high torque density motor-generator
technology since 1965
2009©
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4Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
2. Harmonic Motor Technology Primer
• Harmonic Drive Motor-Generator Technology Combination of harmonic gear and reluctance motor technologies Major claimed benefits of HDMG technology:
High torque & power density Lower cost - reduced parts count Rugged construction, high reliability (stationary rotor) Independent control of: torque, speed & position Tolerant of repeated impact torque High torque2 / low rotational inertia ratio Four quadrant operation, plus regenerative braking (without relays)
2009©
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5Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
2. Harmonic Motor Technology Primer
• Harmonic Gears Developed by C.W. Musser in 1950’s Harmonic Gears provide unique advantages such as:
Compact & light weight High Reduction Ratio in a Single Stage (30:1 to 300:1) High Torque Capability (up to 50% of teeth in mesh) High resistance to repeated impact torque Low tooth contact pressure & wear Tooth contact is surface as opposed to line contact (no Hertzian stress)
Zero Backlash
2009©
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6Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
2. Harmonic Motor Technology Primer
• Harmonic Gear vs Other Gear Types
Ref “Gear Design and Application by N. Chironis, ISBN 0070107874 ”
Characteristic Harmonic
GearEpi-
cyclicHerring
boneSingle Worm
Helical Worm
1 Speed Ratio 100 97 96 108 1002 Efficiency (%) 82 85 85 40 783 # of Gears 2 13 4 2 44 # of Bearings 2 17 6 6 65 Pitch line velocity (ft/min) 18 1,500 1,500 1,500 1,5006 Tooth sliding velocity (ft/min) 28 2,500 2,500 1,500 2,5007 Tooth contact pressure (psi) 605 50,000 50,000 5,000 50,0008 Teeth in contact (%) 50 7 5 2 39 Safety factor 36 3 2 2 210 Height (in) 6 13 14 23 1611 Length (in) 6 15 20 19 1712 Width (in) 6 13 10 14 1013 Cubic volume (in3) 216 2,500 2,800 6,100 2,70014 Weight (lb) 30 246 280 230 20515 Tooth contact Surface Line Line Line Line16 Quiet operation Yes No Yes Yes Yes17 Balanced forces Yes Yes No No No
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7Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
(# flex spline teeth - # circular spline teeth)# flex spline teeth
2. Harmonic Motor Technology Primer
• Harmonic Gears Principle of Operation 2 closely spaced concentric splined interfacing gears with the
number of teeth on the inner gear being fewer in number than the outer gear
An elliptical cam wave generator causes a fraction of the teeth to mesh at 2 opposite poles with up to half of the teeth being in contact
Reduction ratio =
Image courtesy of Harmonic Drive LLC
Reduction Ratio = (200 – 202) = 100:1 200
(Variable Between 30:1 to 300:1)
Motor Shaft Input
Circular Spline Gear
Flexispline Gear
Elliptical Cam Wave Generator
Image courtesy of wikipedia.org
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8Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
2. Harmonic Motor Technology Primer
•Switched Reluctance Motor Principle of Operation SRM invented by Davidson (Scotland, 1838) Rotation & torque achieved by energizing the stator coils sequentially Rotor position determines which coils are
energized (commutation is critical) Field & rotor rotate in opposite directions # of rotor poles must be different from
# of stator poles to avoid starting problems # of working strokes/rev = 24
(for 8 stator poles & 6 rotor poles)
8/6 4 phase SRMImage courtesy of Switched Reluctance
Motor Drives By Ramu Krishnan
Controller
&
Commutator
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9Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
2. Harmonic Motor Technology Primer
•Switched Reluctance Motor Principle of Operation Benefits
Good stall endurance Fault tolerant & reliable High torque to inertia ratio (acceleration) Lower cost due to robust construction
& ease of manufacture High torque density Ability to withstand higher
temperature environment
Speed
Tor
que
Typical SRM Torque-Speed Curve(Harmonic Drive Motor-Generator Similar)
2009©
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10Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• EDM Resources Harmonic Drive Motor Covered by US (7,453,176) and WPO (WO/2004/025815) patents Sometimes referred to as “High Efficiency High Torque WARP Motor” Fundamental difference between EDM HDMG and other
electrical motors: Only motor technology exploiting the large radial
force which is 20+ times that of the tangential torque force
“For example, an 8/6 SRM with a ratio of radius to air gap equaling 100, the ratio between the radial and tangential forces is found to be 26.19; therefore, the radial force is always multiple times that of the tangential force in the SRM and the same can be said for other electrical machines.”(ref Krishnan: Switched Reluctance Motor Drives: Modeling, Simulation, Analysis, Design, and Applications ISBN 0-8493-0838-0, CRC Press 2001, p356 section 7.2.1.1 )
2009©
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11Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• EDM Resources Harmonic Drive Motor Major differences between EDM HDMG and other electric motors
High torque density Traditional rotor is replaced by a stationary (non rotating) element Stator windings occupy space normally occupied by traditional rotor No rotor = no rotor inertia or windage Unipolar DC pulse excitation – minimal flux reversal and iron losses Independent concurrent control of: torque, speed and position
2009©
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12Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• Motor Construction (experimental prototype)
Flexispline (Rotatively Fixed
with internal teeth)
Stator Windings
Output spline gear/flange
(with external teeth)Bearings (2)
2009©
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13Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• Motor Construction – Single Output (two alternatives)
Flexispline- Teeth on insideOutput gear rotation direction - opposite to field rotation
Output gear (rotates)
Bearings (2)Windings
Flexispline- Teeth on outsideOutput gear rotation direction - same as field rotation
2009©
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14Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• Motor Construction - Continuous Through Shaft Applications: ship propulsion, aircraft wing flap actuators, electric
power assist steering
Continuous through shaft construction or linear screw
Motors coupled in series for minimized packaging with high torque density or distributed high torque
Output gear (rotates)
2009©
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15Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• Motor Forces Force is generated by rotating electromagnetic field Rotational sequence: A B C
Flexispline Gear Fixed (teeth on inside)
Circular Spline Gear Rotates (teeth on outside)
A
B
C
Field Rotation
2009©
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16Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• Principle of Operation – Switched Reluctance Version (4 phase – 2 pole) Two energized coils in series
(but of opposite polarity) 8 stator coils in total Flux flow does not rotate
but is switched to next coilin sequence
Flux return path throughflexispline
# of equivalent rotor poles = # of stator poles,therefore # of working strokes / output rev = 16 x N(N = harmonic gear ratio)
Flexispline
Stator Core
2009©
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17Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• Principle of Operation Simulation of flux flow
distribution No outside back up iron
ring or laminations Thick flexispline cup Magnetic flux is confined
mainly to local flexisplinequadrant (lower iron losses)
Excitation unipolar DC pulses (no flux reversal – reduced ironlosses)
2009©
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18Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
Radial force Fr =
A = Air Gap (4 x ½ = 2in2)
Bg = Air Gap Flux Density
μo = 4 x10-7 (permeability)
Fr = 250 lbs/in2 x A (for Bg 2.1Tesla)
Total Radial Force Ftr = 3/2 Fr x 2 x A
= 3 Fr x A = 3 x 250 x 2
1500 lbs
Torque Translation Model
Ftr = Total Radial Force
To = Output Torque
R = Torque Radius (4”)
α = Gear Tooth Angle
N = Harmonic Gear Ratio 100:1
Ki = Mitigating Factors (K1...Kn)
A Bg2
2 μo
Example Core Lamination Stack
To
Ftr
To = Ki x N x Ftr x R
= Ki x 100 x 1500 x 4
= 600,000 x Ki (lbs-in)
MeshingGear Teeth
8”
4”
½”
Fr
Fr
Fr4
Fr4
Fr4
Fr4
• Harmonic Motor – Potential For Torque Production
2009©
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19Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• S.R. Motor Controls Adaptable To Harmonic Motors
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20Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• S.R. Motor Controls Adaptable To Harmonic Motors
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21Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• Experimental Prototype Motor
Windings stationary Flexispline
(rotatively fixed & electromagnetically distorted to engage
rotor output gear)
Output gear rotates
Internal gear teeth
2009©
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22Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• EDM Resources Harmonic Drive Motor Experimental Motor Stator Windings
2009©
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23Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
3. EDM Resources Harmonic Drive Motor
• EDM Resources Harmonic Drive Motor Experimental Prototype Motor gear teeth
Rotor teeth not engaged – rotor free wheeling
Rotor teeth engaged – rotor locked
(Can be clutched & de-clutched)
(Very high locking torque)
2009©
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24Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
• EDM Resources Harmonic Drive Motor Video
3. EDM Resources Harmonic Drive Motor 2009©
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25Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
4. Applications
• EDM Resources Harmonic Drive Motor Applications Navy electrification – ship propulsion & electrical energy generation
system Multi-screw propulsion
(with continuous through shaft motors) Benefits:
– Load diversification» Some units produce torque, some generate electrical energy,
or all units produce propulsion torque,or all units generate electrical energy
» Avoids peak load design for separate generator and propulsion systems » Redundant system with high reliability
– Ability to use super conducting stator windings for increased efficiency– Reduces transmission gear requirements– Reduced cost, simplified maintenance & reduction in highly trained personnel
Replace hydraulic & pneumatic actuators
2009©
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26Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
4. Applications
•EDM Resources Harmonic Drive Motor Applications Military applications
Actuators (turret, fire control) Traction (wheel motors) Winches Power Steering
Benefits High torque density High controllability Replaces hydraulics High reliability (robust) Lower weight Low maintenance Resistant to impact Facilitates liquid cooling
Traction System Actuation
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27Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
4. Applications
• EDM Resources Harmonic Drive Motor Applications Aerospace applications
Actuators– Wing flaps, landing gear
Aircraft – In nose wheel tow motor (for reducing fuel consumption during taxiing)
Robotics Satellites
Benefits High torque density High distributed torque Lower weight & inertia High precision (30:1 to 300:1) Replace hydraulics Redundant system High reliability Low maintenance Fail safe operation Resistant to impact Facilitates liquid cooling
Conceptual design for applying harmonic drive motors to aircraft leading flap actuator to replace hydraulic actuators
Single output HDMGMultiple through-shaft HDMG motors in series
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28Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
4. Applications
• EDM Resources Harmonic Drive Motor Applications Wind turbines
Low weight integral gear generator
Low speed propulsion drives Air ship propulsion
Benefits High reliability High torque at low speeds Low weight / reduced mounting
column requirements Low maintenance Compact Reduces transmission
gear requirements Rotor can free-wheel
or be locked
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29Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
•EDM Resources Harmonic Drive Motor Applications Automotive Applications - Continuous through shaft HDMG motor
Electric power assist steering (pinion, column, rack mounting) Sliding door & lift gate actuators
Benefits High torque density – enabler for heavy truck EPAS Programmable “feel”, speed sensitive variable assist High reliability & fail safe operation Low cost Minimal package space Replaces hydraulics Low weight Low maintenance
4. Applications
Continuous through shaft HDMG motor
Integrated into steering system
Column
Mount
Rack Mount
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30Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
• Summary EDM Resources harmonic drive motor generator:
U.S. & WPO patents Only known motor technology that exploits the large radial force which is 20+ times
that of the tangential torque force and an integral harmonic gear Working prototype – proof of concept
Benefits: High torque density Lower cost construction (SRM, fewer components count) Multi configuration (single output shaft or continuous through shaft) Integral harmonic gearing with high single stage reduction (30:1 to 300:1) Independent concurrent control of: torque, speed and position High reliability (fewer moving parts, up to 50% of gear teeth in mesh)
Enabler for: Electrification for: military, aerospace, robotics, automotive, machine tools Replacing hydraulic or pneumatic actuators Cost & weight reduction vs hydraulics & other motor-gear systems
5. Summary2009©
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31Harmonic Drive Motor-Generator Harmonic Drive Motor-Generator TechnologyTechnology
EDM Resources Inc.EDM Resources Inc.
WARP, high torque, High Efficiency High Torque Motor, Navy, electrification, aircraft flap actuator, replace hydraulics, wheel motor, nose motor, harmonic drive motor, harmonic motor, davison, patent
6. Questions
Questions?