Figure 12: Instant Max Voltage vs. controlled voltage ramp
When the motor is at zero speed and the rated voltage (UN in the motor’s data sheet) is instantly applied, the torque achieves a high value but in addition, the electrical current through the motor is at its highest level. This peak current level is called the starting current (IA). This is an important value that needs to be documented for the electrical designers and will be discussed more in detail. See the Calculating Mechanical Efficiency section for further information on the starting current.10
Before this section, the operating point was calculated to be 865 mNm torque and 189.86 rpm speed while the motor torque curve examples are operating at much lower torques (<100 mNm) and much higher speeds (>5000 rpm). This is an obvious disconnect, but one that can be solved by selecting a motor with higher torque or by using a gearing system.
Before determining that a gearing system is required, it is beneficial to look for motors that are closer to meeting your operating point without a gearing system. The addition of a gearing system will add weight and cost, and reduce efficiency. However, the ModBot operating point is at a low enough speed and high enough torque that the available motors would either be too large in diameter or have significantly higher power capacity than necessary, which in turn would probably cost more than adding a gearing system.
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