Jakub WIERCIAK 1)

Modelling of electric linear actuator for predicting its reliability

Broad employment of modelling techniques is one of major features of designing mechatronic devices and systems. It touches . Modelling and simulation of actuators helps to evaluate various concepts as well as select technical solutions. Majority of such works is oriented on functional models in order to obtain performance characteristics of systems under design. The author proposes to enhance the range of the works to get results useful for predicting other properties of systems, in particular their reliability. In the paper a draft of such approach is presented upon an exemplary object electric linear actuator driven by a hybrid stepping motor.

1. Introduction One of essential features of process of designing mechatronic devices and systems is a broad employment of modelling techniques. This fact is emphasised by the most acknowledged specialists within this field of engineering [1, 2, 3, 4]. Modelling and computer simulation are used at various stages of design and apply to various parts of a system. Typically particular actuators and sensors are modelled as well as selected subsystems; mechanical, electronic and microprocessor control unit. Computational determination of performance characteristics of systems is a dominant part of these works. It comes from the natural needs as well as from the availability of necessary data. A diagram developed by the author showing a simple way to building mathematical and simulation models of actuators with electrical drives used in precise devices is shown in Fig.1. The complex evaluation of technical solutions generated during design requires two remaining categories of characteristics to be known. These are availability and reliability. Such approach is described in works of J. M. Juran, the famous specialist within quality [5]. The so called cost-effectiveness concept is based upon comparison between total life cycle cost of a product and its competing parameters characteristics in three groups (Fig.2). A useful model for effectiveness defines system effectiveness as PSE = PA PR PC , (1) where: PSE probability of overall system effectiveness, PA probability that the system will be available for use (availability), PR probability that the system will be reliable (reliability), PC probability that the system has the design capability to perform the function required. In the analysis carried by manufacturer it is a role of design engineer to provide management with various solutions along with their predicted characteristics in the categories listed above. Modelling techniques are still more and more important method for determination of characteristics of a product under design. If functional modelling is a common way to support design of devices, in case of two remaining categories of characteristics computation is used much rarely. Prediction of such characteristics is based more on similarity to previous projects, results of which were tested experimentally. The author makes an attempt to develop

1)

Ph.D., Warsaw University of Technology, Institute of Micromechanics and Photonics, ul. w. A. Boboli 8, 02-525 Warszawa, Poland tel. +48 (22) 660-83-24, fax 660-86-01, e-mail: j.wierciak@mchtr.pw.edu.pl

practical way for predicting reliability of mechatronic actuators taking electrical linear actuator driven by stepping motor as an exemplary object.
M odel of m echanism
M echanical load

M odel of control unit

Control signals

Electrical load

M odel of transm ission 1

Reduced load

M odel of m otor

M otor torque

M odel of rotational m ovem ent

Angle of rotation of rotor

M odel of transm ission 2

Angle of rotation of output shaft

Feedback signals

Fig.1.

A scheme of functional modelling of actuator powered by electrical drive system

Cost effectiveness of a product

Total cost

Effectiveness

Availability

Reliability

Capability

Pa

Pr

Pp

Fig.2.

Concept of cost effectiveness [5]

2. Concept of modelling The proposed way of modelling does not introduce any new elements within commonly used mathematical relations. It refers to random variable models as the best description of phenomena leading to failures. The only modification is suggested at the stage of determination of reliability merits of the system components. Reliability is defined as the probability of a product performing without failure a specified function under given condition for a specified period of time [5]. The following steps make up a reliability prediction method by modelling [5, 7]: define the product and its functional operation, develop the probability model for predicting reliability, collect information relevant to part reliability, combine the above data to obtain the numerical reliability prediction.

3. Modelling of the actuator The exemplary object for analysis there is an electrical linear actuator (Fig.3) driven with hybrid stepping motor manufactured by Mikroma S.A. company [12]. The actuator pusher is located inside hollow shaft of the motor. It has two parts: threaded and smooth. The threaded part along with the nut constitutes a screw gear mechanism that converts rotational movement of rotor into linear movement of pusher. In the rear part of actuator there is an antirotational system installed, which disables rotation of screw. Two different units protect mechanism against incidental blocking: when pusher is moving left classical pin limiter, when moving right a microswitch generating a signal to control unit. The actuator is protected against moisture and dust by a special casing (right) and a sealing at smooth part of pusher (left). Two ball bearings make a bearing system. A special bearing transmits axial forces acting on pusher. It is also used to eliminate axial backlash. The role of the second bearing is to transmit radial forces only. An additional sleeve secures screw mechanism against blockade.
Motor rotor Motor stator Sleeve Seal Special ball bearing Key Threaded part of pusher Special sleeve

Cylindrical part of pusher Ball bearing Hollow shaft Nut Anti-blocade system

Microswitch Casing

Fig. 3.

Linear actuator LA34C2xN6x1,0 [8]

3.1. Defining function of the actuator The main function of the actuator is moving the driven objects into given positions with the assumed speed and the required accuracy while the loading force of a given value acts on the pusher. Block diagram of actuator illustrating this function is presented in Fig.4.
Frictional force and torque

Antirotational system
Frictional resistance torque

Bracket
Force and torque Control voltages

Electrom agnetic torque

Force and torque

Stator

Rotor
M agnetic field

Hollow shaft
Angular displacement

Nut

Screw (pusher)

Reaction

Bearing system

Frictional forces

Linear displacem ent

Sleeve, seal

Loading force and m ass of m oving elements

Fig.4.

Functional block diagram of actuator

Performance of actuator is described by mechanical characteristics (Fig.5) similar to characteristics of the driving stepping motor as well as positioning characteristics, usually in terms of maximum positioning error. Failures of the actuator referring to mechanical characteristics can be defined as either reduction of motor torque or rise of frictional resistance inside actuator. Positioning errors can increase due to errors of the motor step and what is more probable as a result of wear in movement converting mechanism.

Loading force F [N]

0 2 4 Pusher velocity v [mm/s] 6

1500 1000 500 0Pusher velocity v [m m/s] 0 5 10 15

Loading force F [N]

1200 1000 800 600 400 200 0

Fig. 5.

Mechanical characteristics of LA34C2xN6x1,0 actuator obtained with control current of 3 A: a) pull-in, b) pull-out [8]

3.2. Developing of reliability model Reliability model is a modification of functional diagram of a device. This model reflects effect of failures of particular parts on performing the function by the entire device. Serial model of reliability describes majority of typical devices, in which failure of any element effects lost of the main function. So it is in case of linear actuator, which holds neither parallel function nor redundancy. Such statements lead to a diagram presented in Fig.6. Failure rates i were used there as exemplary merits of reliability of each element.
Stator
s

Bearing system
b

Rotor
r

Hollow shaft
h

Nut
n

Sleeve, seal
t

Antirotational mechanism
a

Screw (pusher)
p

Fig.6

Reliability model of linear actuator: i failure rate of a component

In such model reliability can be calculated either as a sum of failure rates of all components

act = s + b + r + h + n + p + a + l ,

(2)

or as a product of relevant probabilities R of proper operation according to the assumed distributions of failures, typically exponential one [5]
Ract = Rs Rb Rr Rh Rn R p Ra Rl ,
(3)

4. Determination of parts reliability Substituting the values of reliability merits into the diagram requires collecting of relevant data. Usually it is difficult even for catalogue components. The manufacturers of such components as electric motors or gears are mostly not interested in publishing numerical data on reliability of their products [10, 11]. The probable reason is that such information can be obtained after time and cost consuming tests and additionally a mere user is not qualified enough to utilise such data properly. For parts and assemblies made especially for a device durability tests may be necessary. In case of analysed actuator special stands were build to carry such tests for various conditions of operation: values of loading force and pusher velocity.

It seems to be important to remember that failures are classified into two main categories: natural and incidental, depending upon reasons causing them. The first category contains failures, which occur due to time elapsed, distance covered, number of operations etc. Incidental failures are result of stresses exceeding those assumed by designer and therefore higher than strength of particular parts. Due to different origin of those two kinds of failures it is proposed to analyse them separately for each of identified part and then to compute the resultant reliability merits. 4.1. Natural failures When analysing technical structure of the actuator one can conclude that natural failures of the device can be caused by: ageing of insulating materials in electrical circuit of motor, wear of movement converting mechanism, bearings, pusher, sleeve and other mechanical parts [6], accumulation of wear products in frictional pairs. Reliability of insulating materials is a function of time and temperature while wear of mechanical parts depends mainly upon distance and load. When relations for computing reliability of such elements are known the task of engineer is to find values of influencing quantities. It is possible to use for this purpose results of computer simulation of a device performance (Fig.7).
Analysis of requirements

Concept of repairability

Functional model of drive system

Model of operation conditions

Simulation experiments

Performance characteristics

Stress characteristics

Development of construction

Technical documentation

Reliability model

Availability

Capability

Reliability

Pa

Pp

Pr

Fig.7.

The enhanced role of modelling in design process the proposed diagram

W in d in g

R o to r

S ta to r

A m b ie n t

Fig.8.

Three body model of thermal structure of a hybrid stepping motor [10]: Ci - thermal capacities of identified thermal bodies, Ti temperatures of relevant bodies, Rij thermal resistances between the bodies; ot ambient, s stator, u winding, w rotor

If functional model of actuator is enhanced with description of thermal phenomena then it is possible to obtain values not only of electrical and mechanical quantities but also temperature rises of selected components. Mathematical models of thermal phenomena used in such works are usually simple circuit models consisting of few bodies. Thermal model of a hybrid stepping motor, which can be helpful in the case of linear actuator is presented in Fig.8. 4.2. Incidental failures Such failures usually occur when conditions of operation of a device such as mechanical, electrical, climate stresses exceed permissible values. One of techniques for determination reliability of parts in this category of failures is conducting the so called strength and stress analysis [6]. It is a statistical approach, so it leads to probability of the event that predicted stress will exceed strength of a part (Fig.9). Such analysis performed during design are helpful for assuming relevant safety margins (Fig.10). v Probability density

Highest stress expected

Average strength

Analysed characteristic

Rys. 9.

Variation and safety factor [6]

Fig.10.

Separation of stresses and strengths by a reliability boundary [6]

5. Computational determination of the actuator reliability If all reliability data is gathered then it is possible to compute reliability of the entire device using formulas such as (2) or (3). It takes place only in case of very important objects, for instance in military appliances [5]. In other situations it seems to be sensible to employ simplified rules for example the weakest chain rule which states that in case of sufficiently little scatter of strength of particular components of a system, its reliability is determined by its weakest part. Simple analysis of the discussed actuator leads to a conclusion that the list reliable part of it movement converting mechanism is. As it is designed just for this purpose the best way for determination of its reliability is to perform durability tests in order to obtain relations between conditions of operation and performance characteristics of the actuator: mechanical as well as positioning. A special stand for such tests is already prepared. 6. Summary A proposal of enhanced view upon role of modelling in evaluation of product effectiveness related to electrical drive systems of mechatronic devices there is presented in the paper. The experience gathered by the author leads to the following conclusions. 1. Prediction of reliability upon modelling technique is a good way for encouraging engineers to include such computations into their everyday practice in order to obtain more valuable information about technical solutions being a subject of discussion and decisions. 2. The systematic approach for reliability prediction introduces into design process some numerical data instead of intuitive information, which can be utilised for more credible evaluation of concepts and solutions. 3. Simulation experiments can be a source of additional responses of those quantities, which effect performance of the device under design. Due to this it is possible to increase accuracy of a device reliability prediction. Bibliography 1. Clarence W. de Silva (editor): Mechatronic Systems: Devices, Design, Control, Operation and Monitoring. CRC Press, 2007

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9.

10. 11. 12.

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