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Magnitude
1
0.1
0.01
1 10 100 1000 10000
Frequency, Hz
Figure 4. The four solution transfer functions relating the drive volt-
Figure 3. Data Physics model S-100 shaker. age (top curve) and motions of coil (middle curve with pronounced
antiresonance), table and body (bottom curve) to applied current as
by a spring and damper. Secondly, shakers are frequently iso- functions of frequency.
lated from the building floor by use of compliant mounts that
allow the entire machine to translate vertically. This is mod- 10
(g/A)
eled by attaching the shaker body mass to ground using a spring
(g/v)
and damper.
The shakers electrical model must account for the resistance
and inductance of the armature coil. The coil resistance R de- 1
fines the minimum impedance exhibited at the shaker input
terminals. This resistance increases substantially with tempera-
ture (the resistance of copper wire increases by about 40% per
Magnitude
X KC KC 0 k1 XC 0
C
X KC K S + KC KS 0
XT 0
+ =
T
X B
0 KS K B + KS k1 X B 0
0
di / dt R i
e
0
0
1
Peak Acceleration, g
Peak Acceleration, g
tial over the entire range of payloads.
From the system specifications, determine:
fmin = minimum operating frequency (Hz)
fmax = maximum operating frequency (Hz) G H
F rate = sinusoidal force rating (N pk) 1
S rate = stroke rating of shaker (mm pk-pk)
Mmov = moving mass (kg)
M total = total mass of shaker and trunnion (kg)
Mrate = rated maximum test object mass (kg) A With DUT
Ks = stiffness of shaker suspension (N/m) F Bare Table
Vrate = maximum bare table velocity (m/s pk) 0.01
1 10 100 1000 10000
Compute the derated stroke used in the blue With Device
Frequency, Hz
Under Test trace.
static = static deflection of suspension (mm) Figure A. Identification of envelope plotting points.
= 9800 Mrate /K s for a passive suspension
= 0 with load leveling acceleration at point D (g pk) = 2(F D)2S rate/9800
gD =
IDF = isolation derating factor (ratio) fE =
frequency at point E (Hz) = F rate /(2Mmov Vrate )
= 1 for hard-mounted shaker gE =
acceleration at point E (g pk) = F rate /(9.8Mmov )
= (Mtotal Mmov )/(Mtotal + Mrate) when the shaker is iso- fF =
frequency at point F (Hz) = fmin
lated. Note: when hard-mounted to an isolated slab, acceleration at point F (g pk) = 2(F min)2 Sderate /9800
gF =
add slab mass to M total frequency of point G (Hz) = K S /(M mov + M rate ) / 2
fG =
S derate = derated stroke for full payload (mm) gG =
acceleration at point G (g pk) = F rate /[9.8(M mov +
= IDF(S rate 2 static) Mrate )]
Calculate VB, the peak velocity at point B: VB = K s S rate / f H = frequency at point H (Hz) = fmax
2000Mmov (m/s pk). If VB exceeds Vrate , plot the (black) bare- g H = acceleration at point H (g pk) = F rate /[9.8(M mov +
table envelope by connecting points A, B and C. Otherwise, plot Mrate )]
A to D to E to C. Constructing this back of an envelope overview of a shaker
fA = frequency at point A (Hz) = f min systems performance provides a surprisingly comprehensive
gA = acceleration at point A (g pk) = 2(F min) 2S rate/9800 understanding of the equipments capability. Comparing this
fB = frequency of point B (Hz) = K S / M mov / 2 simple envelope with the corresponding detailed model (for
g B = acceleration at point B (g pk)=F rate /(9.8Mmov) our 650 N shaker in trunnion-isolated configuration) shows that
f C = frequency at point C (Hz) = fmax the simple calculations are conservative as shown in Figure B.
gC = acceleration at point C (g pk) = F rate/(9.8Mmov) That is, your shaker will be able to provide the g-versus-fre-
fD = frequency of point D (Hz) = 1000Vrate/(S rate ) quency drive capability of your simple plot (and can actually
with the table as the elastic table/armature structure is de- transfer functions reflects the very significant electromagnetic
formed. Excessive excitation of this mode can damage the vi- damping applied by the cross-coupling terms between the elec-
brator. trical and mechanical components of the system. This is clearly
For purposes of example, the characteristics of the medium- shown by Figure 5 which compares table motion per Amp and
size electromagnetic shaker shown in Figure 3 will be used. per Volt. When connected to an audio voltage amplifier, these
This machine is capable of delivering 650 N (145 lb) peak sine higher damping factors are present.
force to a test object weighing as much as 25 kg (55 lb) over a
frequency range of 2 to 7000 Hz. It has a 25.4 mm (1 in) peak- Determining Maximum Drive Performance
to-peak stroke capability, a 1.5 m/s (59 in/s) peak velocity rat- The solution transfer functions and known system operat-
ing, a suspension stiffness of 22 kN/m (126 lb/in), a moving ing limits allow the maximum available sinusoidal output of
mass of 1.3 kg (2.86 lb), and an 8 ohm coil with an 11.2 (RMS) the shaker at any frequency to be determined. This is accom-
Ampere rating. The shaker and trunnion weigh 80 kg (176 lb). plished by determining the largest current (at each frequency)
This shaker is equipped with base isolators and an automatic that does not exceed:
pneumatic load-leveling system. a the (thermally determined) maximum RMS coil current
The companion power amplifier delivers up to 11.2 A (RMS) a the maximum RMS current capacity of the amplifier
current with a drive voltage of up to 90 V (RMS). The follow- a the maximum RMS voltage capability of the amplifier
ing figures assume a (dynamically inert) test item weighing 10 a the stroke capability (XT XB ) of the shaker
kg (22 lb) attached to the 80 mm (3.15 in) diameter drive table. a the maximum armature force capability
When the system is described by current-driven transfer This composite current, shown in Figure 7, is played-
functions, as shown in Figure 4, the effect of electromagnetic through the transfer functions of Figure 4 to derive the mass
damping is not evidenced. These plots reflect only the struc- motions and drive voltage of the system when it provides maxi-
tural damping terms, those that could be measured with exter- mum excitation to the specified test object. Under these same
nal excitation applied to the shaker with its drive coil conditions, other variables including the floor reaction force
unterminated. These same low damping factors are at play may be deduced from the simulation. Since the mathematical
when the shaker is driven by a transconductance or current model is driven by a small number of measurable parameters,
amplifier. examining variations in the operating configuration is straight-
In contrast, expressing the system motions as voltage-driven forward.
0.01
1 0.001
25 kg Estimate
Bare-Table Estimate
0.0001 Coincident with Force
25 kg Actual Total
Bare-Table Actual Isolated Co
Isolated Total
0.01 0.0001
1 10 100 1000 10000 1 10 100 1000 10000
Frequency, Hz Frequency, Hz
Figure B. Comparison of simple envelope with detailed simulation Figure C. Comparison of total coil velocity and force-coincident com-
shows basic agreement. Shaker can actually exceed the back of an en- ponent of velocity during bare-table test. Data for both hard-mounted
velope expectations around the suspension resonance and at high and trunnion-isolated shaker shown.
frequency with a light payload.
vation of this relationship ignores phase (never a good idea!)
do a little better). and the simple envelope plot assumes the result is valid over
The detailed model discloses a higher performance level near the frequency range f D to fE. In fact, the approximation is only
the suspension resonance than does the simple envelope. In reasonable at a single frequency (approximately equal to fD) as
particular, the constant velocity slope is exceeded. This de- illustrated by the velocity plot of Figure C.
serves a little explanation. At that single frequency where the force-coincident compo-
The bare-table velocity limit, V rate , is not a structural limita- nent of velocity (red) is essentially equal to the total velocity
tion; it is an electrical one. This specification reflects the power (black), the V rate equation is a reasonable model. This unique
amplifiers maximum voltage output and the back-emf gen- frequency is that at which maximum system efficiency is real-
eration capability of the shaker. Vrate is conventionally evalu- ized (see Figure 16). The approximation does not hold over a
ated at an F = Ma level of sophistication in accordance with: broader frequency span and thus the simple estimate is very
Vrate = 2 (er ir ) ir2R / Frate conservative in this region.
The envelope comparison also shows that more aggressive
. . . where er is the maximum RMS voltage that the power am- excitation is possible at high frequency with light load as the
plifier can provide, ir is the maximum RMS current that the back of an envelope estimate does not consider secondary
shaker coil can tolerate (with specified cooling) and Frate is the effects of the coil resonance. Within the top decade of fre-
peak force value the machine can deliver. quency, bare-table operation is actually limited first by current,
However, this equation is only an approximation. The deri- then by force and finally by voltage.
Figure 7. The voltage (upper curve) and current (lower curve) inputs
required to achieve maximum table acceleration. Note that the accel- 1000
eration-limiting factor changes from stroke to current to force to volt-
age with increasing frequency.
100
1000
10
100
Reaction Force, N
Peak Building Reaction Force, N
10 1
1 0.1
Rigid
0.1
2%
0.01 5%
Isolated Trunnion
0.01 10%
Hard Mounted
20%
Isolated Slab
0.001
0.001 1 10 100 1000 10000
Frequency, Hz
0.0001
1 10 100 1000 10000
Figure 11. Effect of trunnion-base isolation damping factor on floor re-
action load.
Frequency, Hz
and high damping levels minimize the low frequency vibration
Figure 8. Floor reaction forces from three different shaker mounting transmitted. This benefit comes at the cost of greater floor trans-
configurations. The floor reaction forces are largest with rigid mount- mission across most of the operating frequency range.
ing (upper curve) and smallest with an isolated slab (lower curve). The
commonly used isolation mounts (middle curve) reduce the reaction
forces at most, but not all, frequencies. Dont Be Passive About The Suspension!
Many older shakers and most small (permanent magnet)
shakers are built with a passive suspension system. Newer
10
designs intended for qualification tests of heavy objects incor-
porate an active or load leveling suspension. This is gener-
ally accomplished by using pneumatic pressure to bear the
Isolated Trunnion static weight of the test object, leaving the suspension flexures
Hard Mounted to bear only the dynamic variation. This approach provides the
Maximum Table Acceleration, g
Isolated Slab full stroke capability of the shaker, regardless of the payload
weight.
1
In Figure 12 our shaker is hard-mounted and its load level-
ing system is disabled, rendering the suspension passive. Maxi-
mum possible table acceleration with various payloads is pre-
sented. Figure 13 presents the same test set with load leveling
enabled. The maximum acceleration levels differ in exactly the
same (F = Ma!) manner in both plots. However, the load-lev-
eled system maintains full stroke capability while the passive
system surrenders it to payload as a static deflection numeri-
cally equal to MDg/KS. With load leveling, the static position
0.1
1 10 100 of the table is always at the shakers mid-stroke position.
Frequency, Hz It is possible to accomplish the same objective by other
means, but none are as convenient as an automatic pneumatic
Figure 9. Maximum table acceleration in three mounting configurations sub-system. External suspensions can be created and tuned for
shows effective stroke loss due to trunnion isolation. a specific test, but such effort is not always straightforward or
10
Maximum Acceleration, g
Bare Table
0.1 5kg Figure 14. Anatomy of a modern shaker discloses space-age materials
10kg and system-level design.
20kg
1000
0.01
1 10 100 1000 10000
Frequency, Hz
100
100
1
0.1
10
Electrical Input
Maximum Acceleration, g
Coil Power
0.01
Input - Coil
1 Mechanical Output
0.001
1 10 100 1000 10000
Frequency, Hz
Coil Power
Non-Dimensional Fraction
10
Input - Coil 0.01
Mechanical Output
1
0.001
0.1
0.0001
0.01
0.00001
0.001
1 10 100 1000 10000
Frequency, Hz
0.000001
1 10 100 1000 10000
Figure 17. Distribution of power with 25 kg test object on shaker. Note
general reduction in mechanical output power (lower curve) with es- Frequency (Hz)
sentially the same input requirement (upper curve), compared to Fig-
ure 15. Figure 20. Efficiency and Power Factors exhibited during 25 kg shake
on isolated shaker. In particular, note the improved efficiency (lowest
curve) around the isolation-mode natural frequency caused by im-
1 proved output power factor.
100
0.01
Power Dissapation, Watts
10
0.001
0.0001
0.1
Electrical Input
0.00001 Coil Power
0.01
Input - Coil
Mechanical Output
0.000001
0.001
1 10 100 1000 10000 1 10 100 1000 10000
Frequency, Hz Frequency, Hz
Figure 18. Fully laden shaker exhibits improved Input Power Factor and Figure 21. Power dissipations during a bare table test on the trunnion-
reduced Efficiency when compared to bare-table test of Figure 16. At isolated shaker. Note the unaccounted added power near the isola-
most frequencies, much less than 0.1% of the electrical input is con- tion frequency.
verted into mechanical power.
10
between force and velocity (the power factor) is the active
mechanical power. This is the component that can do work.
1
The quadrature reactive component merely shuttles retained
system energy between potential and kinetic states.
Our shaker mathematical model contains all of the informa-
0.1 tion necessary to evaluate the power dissipations within the
Electrical Input system. In Figure 15 four different active power spectra are
Coil Power presented. The top line shows the total electrical power dissi-
0.01
Input - Coil pated by the shaker operating with a bare table at maximum
Mechanical Output drive capability. The center trace shows the (i2R) power dissi-
0.001 pated as heat by the drive coil. The (completely obscured) line
1 10 100 1000 10000 presents the difference between these two dissipations, the
Frequency, Hz remaining electrical power available to drive the mechanical
system. The black line presents the active mechanical power
Figure 19. Repeat of 25 kg test on a shaker with trunnion base isola-
tion (2.5 Hz, 20%). Note the mechanical output power no longer ac- dissipated by the motion of the forced coil. This trace exactly
counts for the full difference between input and coil dissipation. matches the electrical power available to drive the mechanics.
10
15
1 10 100 1000 10000
Frequency (Hz)
Figure 22. Active or real power participation of the moving shaker body
during isolated tests. Note the linear vertical axis necessary to show
negative (powering) dissipation below the isolation resonance.