EGB111

FOUNDATION OF
ENGINEERING DESIGN
Studio Week 8
Machine Elements and Actuators
Semester 1, 2015
[Tutor 1]
[Tutor 2]
enquiries.egb111@qut.edu.au

WEEK 7 REVIEW
Lecture (week 7)
Machine Elements and Actuators

Studio (week 7)
Linear dynamics
Rotational dynamics
Power transfer
Efficiency

Workshop (week 7)
Newtons second law, transient vs. steady state

LAST WEEKS STUDIO WORKSHEET

1. FT = 19.6 N
2. PLIFT = 5.7 W
3. rDRUM = 0.096 m or 9.6 cm
4. t = 1.72 s
5. FT = 20.18 N

TODAYS STUDIO
Electric motors
Gearboxes
Bearings
Pulleys

ELECTRIC MOTORS
Convert electrical power to rotational power

Pin = VI

Pout = T

Motors have a voltage at which they run most efficiently. This is called the

nominal voltage.
To describe motor behaviour at nominal voltage, motor curves are used
As torque required increases:

Speed decreases

Current required increases

Efficiency changes

MOTOR CURVE EXAMPLE

ELECTRIC MOTOR UNITS

Electric motors: High speed, small torque
Usually wont be provided data in SI units
Torque: gcm

Speed: rpm

ELECTRIC MOTOR DATA

Motor curves generally dont come with cheap motors, but can be generated

provided data.
Nominal voltage

The voltage that the motor most efficiently runs at. If the input voltage is too far away from the
nominal voltage, the motor will be very inefficient.

No load speed

The motors speed when spinning freely

Stall torque

The maximum torque the motor can provide

Maximum efficiency

This is where a motor should be operating in a well designed system

MOTOR DATA EXAMPLE

EXAMPLE MOTOR QUESTION

Using the following motor data:
a. Determine the input power, output power and efficiency of the motor at maximum

efficiency. Would this motor be good to use for your project?

Ans: PIN = 48 W, POUT = 26.36 W, MAX = 0.549, too powerful for project.
b. Draw the motor curves for speed and current and find the speed and current for a

torque of 50 gcm.
Ans: Speed = 12458 rpm, current = 1.29 A.
Nominal voltage No Load
Maximum
= 12V
Efficiency
Speed (rpm) 13000
Torque (g.cm) Current (A) 0.6

Stall

10489

246

1200

17.2

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MOTOR SELECTION + DESIGN TIPS

Select a motor that is appropriate considering the power requirements, and

design system to operate at maximum efficiency

Make sure your motor has data!
If operating motor outside of max efficiency conditions, use motor curves to

predict behaviour
Test your motors once you receive them
Avoid high voltages and testing close to stall conditions. This could burn your

motor out.

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MOTOR TROUBLESHOOTING
If a motor needs to move a load faster

Increase the voltage

Increase the drum size (only if far away from stall conditions)

Select a more appropriate motor

If a motor is unable to lift a load

Increase current limit

Decrease the drum size

Select a more appropriate motor

Use a gearbox

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GEARBOXES
Gearboxes use mechanical advantage to increase torque capability at the

expense of decreasing speed

Gear ratio = (N2/N1) + (N4/N3) +

N is no. of teeth

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GEARBOX EXAMPLES

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EXAMPLE GEARBOX QUESTION

The motor from the previous example is used at max efficiency (T = 0.024

Nm, = 1098 rad/s). The output of the gearbox is required to provide a

torque of 5 Nm. Determine the following, assuming the gearbox has an
efficiency of 80%:
a) The gear ratio required by the gearbox
b) The output speed from the gearbox
c)

The gearbox size youd select if gear ratios were only available in multiples of 50 eg. 50, 100,
150, ..

Ans: GR = 260.4, = 4.22 rad/s, select GR = 300 (safer to round up).

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BEARINGS
Bearings are a machine component that restrain motion to a particular

direction and reduce friction in that direction.

Highly recommended for designs that require rotating members. Bearings

must be strong enough to support the moment created by the 0.5 kg mass as
well as the self weight of he crane.

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PULLEYS
Create mechanical advantage by increasing force capability, while decreasing

speed capability
Good for small amounts of mechanical advantage, but not well suited to large

amounts

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MECHANICAL DESIGN TIPS

Design system for load capability, then check speed capability
Make sure speed isnt too fast this will create very large dynamic loads and

make the device too difficult to control

Select the best gearbox for your application there are plenty of different

sizes and types

Use bearings for rotating members
Remember to include efficiencies in your calculations
Test all components before assembling the device

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PROJECT APPLICATION
Designs will require at least one motor.
Mechanical advantage will be required since motors can only

provide very small torques.

Should be able to design appropriate mechanical systems so
that system operates under 10W and moves the object in under
a minute.

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WHERE TO PURCHASE COMPONENTS

Hobby stores
Electronic stores eg. Jaycar
The internet Little Bird Electronics and Pololu (parts may take

1-2 weeks to be delivered)

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TODAYS STUDIO SUMMARY

Electric motors
Gearboxes
Bearings
Pulleys

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COMING UP IN THE NEXT WEEK

Workshop (week 8)

Motor testing

Wear enclosed footwear, have silver sticker

Print and bring worksheet!

Lecture (week 8)

Introduction to electrical energy

Studio (week 9)

Voltage, current, resistance, power, energy

Basic circuit analysis

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WORKSHEET
Complete 5 problems provided
Show all working in solutions
Include your details
Student name
Student number
Group ID

Submit to tutors by end of studio

SEMESTER 2, 2014

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