Sensors and Control Systems

Tutorial Sheet RG3

1. Solenoids are often rated for both continuous operation and for intermittent operation.
1.1 Which rating normally gives rise to higher actuator forces?
1.2 What factor or factors limit the force obtainable when running continuously?
1.3 A solenoid manufacturer gives the following data for a particular model of solenoid:
Coil resistance = 100
Coil temp rise = 40 deg C/Watt
Actuator Force at fully in = 20N/A

Max. continuous coil voltage = 12V

Coil thermal time constant = 30 seconds

Using the data, calculate:

(i) The coil temperature rise above ambient when running at maximum permitted continuous condition, and
how long it takes to reach this final temperature (within 1%).
[57.6 deg C, 150 s]
(ii) The actuator force at maximum permitted continuous rating
[2.4N]
(iii) The maximum voltage which could be applied, without overheating the coil, for a period of 10 seconds.
[23.58V]
(iv) The fully in force which the solenoid will develop during those 10 seconds.
[4.71N]

Actuator Force - N

2. A solenoid data sheet gives the following graph for force versus actuator position, for a particular
solenoid model:
5

100 mA coil current

4
50 mA coil current

3
2
1
0
0

2
3
4
5
Distance of actuator from
fully in position (mm)

2.1 By reading from the graph, estimate the following:

(i) The force developed at a distance of 1mm when coil current = 100mA
(ii) The force developed at a distance of 2 mm when coil current = 50 mA
(iii) The force developed at a distance of 1.5 mm when coil current = 75 mA

[2.4N]
[0.8N]
[1.5N]

2.2 Suppose that a force of 10 N is required at a distance of 1 mm, but that this force is only intended to last
for a few seconds. Using the graph, estimate:
(i) The current that would be required to generate this force
[416mA]
(ii) If the coil power dissipation at 100 mA is 1 Watt, the coil power dissipation when generating this higher
force.
[17.36 W]
3. A solenoid is driven via a power transistor and a diode is used to protect the transistor when the
solenoid is switched OFF. If the solenoid coil resistance is 120 ohms and the supply voltage is 12V, for what
maximum current must the diode be rated?
[0.1A]
4. A torque motor gives a torque of 5Nm per Amp. Design a simple, single power-op-amp circuit which
might be used to convert from a control voltage to an output current suitable for driving the motor. Assume
that the maximum required current is 1.2 Amp and that the input voltage for full current output is intended to
be 2.55 Volts. Assume a current sensing resistor value of 0.1 and calculate other circuit values.
RG Oct 2002

5. A hybrid stepper motor has a step size of 7.2 degrees. It uses two unipolar coils for two stator phases
and these are switched ON in an A1, B1, A2, B2 sequence. A stepper motor drive chip is used to
generate the sequence from an input frequency.
5.1 What input frequency is required to run the motor at 1000 revolutions per minute?
[833.3Hz]
5.2 For what length of time is each phase energised when running at this speed?
[1.2ms]
5.3 If the inductance of each coil is 50 mH and the resistance is 25 , what is the coil time constant?
[2ms]
5.4 What maximum coil current is obtained under these conditions, assuming a supply voltage of 12V?
[0.18A]
6.1 What are the main differences between variable reluctance, permanent magnet and hybrid
stepper motor types?
6.2 Which type(s) can be made with small step sizes?
6.3 Which type(s) give a zero drive detent torque?
6.4 Which type(s) can be made with small step sizes and only two sets of drive coils?
6.5 What is the difference between unipolar coils and bipolar coils in the context of stepper motor drives?
7. A stepper motor with unipolar coils is driven via a transistor switch and a series resistance. The coil
resistance is 50 and the series resistance is 100 . If the coil rated current is 200 mA, what supply voltage
must be used for this circuit?
[30V]

RG Oct 2002

Solutions Tutorial sheet RG3

1.1

Power dissipation = V2 /R = 122 /100 = 144/100 = 1.44 Watts

Since T = 40 deg C/W, T = 1.44 x 40 = 57.6 deg. C
Time to reach within 1% of final value is between 4 and 5 TCs. Taking 5 TCs, we get 150 s

1.2

Max continuous current = 12/100 = 0.12 A. If Force = 20 N/A, actual force is 20 x 0.12 = 2.4 N

1.3

Since 12 V is max continuous current, max T is 57.6 deg (from above).

But T = T(max)(1 exp(t/T)). We know that t = 10 s and T = 30 s, so
T = T(max) (1 exp(-0.3)) = T(max) (1- 0.741) = T(max) (0.259)
We know that the T that is required is 57.6, so T(max) is 57.6/0.259 = 222 deg C.
Since temp rise = 40 deg/watt, this means 222/40 watts = 5.56 Watts.
But power dissipation = V2 /R. so 5.56 = V 2 /R, so V2 = 5.56 x 100 and V = 23.58 V

1.4

Current then = 23.58/100 = 235.8 mA. So force = 235.8 x 20 = 4.71 N

2.1

(i) Read off from graph. Force = 2.4N

(ii) Read off from graph. Force = 0.8N
(iii) Read off from graph. Force = 1.5N

2.2

(i) Max force at 1mm for 100 mA = 2.4N. To get 10N, need 10/2.4 x 100mA = 416mA
(ii) Power = I2 R. Hence coil power when generating higher force = 0.4162 x R = 17.36 Watts

3.

Peak current is the same as the current flowing just before switch-off. Hence max value = Vcc/R
This gives 12V/120 ohms = 0.1A

4.

Rx
Vin = 2.55 Volts
1K

R= 0.1

Since Imax = 1.2 A, feedback voltage = 0.12 Volts.

Hence voltage at ve input of op-amp = 0.12 Volts. So, 1K/1K + Rx = 0.12/2.55
and 2.55 x 1K = 0.12 x 1K + 0.12Rx. Re-arranging, we have (2.55-0.12)1K = 0.12Rx
This gives Rx = 2.43/0.12, so Rx = 20.25K. The nearest value is 20K, but just 1% out.
5.1

7.2 degrees = 1/50th revolution.. So 1rps = 50step/sec.

1000rpm = 1000/60 rps = 100/6.
So no. of steps/sec = 100/6 x 50 = 5000/6 = 833.3 steps/sec or 833 Hz

5.2

Time per phase is just 1/833.3 sec= 1.2 ms

5.3

Coil TC = L/R = 50 x 103 /25 = 2ms

5.4

Imax = 12/25 = 0.4A. Actual current = Imax (1 exp(1.2/2)) = 0.4(1- 0.549) = 0.4 x .451 = 0.18A

7.

V = IR x RT = 0.2A x (100 + 50) = 0.2 x 150 = 30 Volts

RG Oct 2002