10/25/2015 ME Senior Design Spring Bi-Directional Rotary Actuator Group 9 Sung Bae Robert Hooge Chris Imparato Jose Jaramillo

10/25/2015 ME Senior Design Spring What is a Rotary Actuator? N S S N N S S N N S S N 360 deg Non-energized N N S S N N S S N N S S N N N S S S N S S N N S S N N S S N S S S N N N Energized - polarity 30 deg CW rotation Energized + polarity 30 deg CCW rotation Upper stator Rotor Lower stator N S S N N S S N N S S N - or + Sandia coil design: Coil is constrained to one side of actuator. Magnetic field conducts thru can to opposite stator.

10/25/2015 ME Senior Design Spring Needs Assessment  Replace two uni-directional solenoids with single bi-directional solenoid.  Used in weapon components systems  Should be adaptable to Micro-Electro- Mechanical System (MEMS) for miniaturization.

10/25/2015 ME Senior Design Spring Scope  Design a bi-directional rotary actuator Compact and easy to assembleCompact and easy to assemble Rotates either clockwise or counterclockwise with a return to a neutral positionRotates either clockwise or counterclockwise with a return to a neutral position Electro-magnetic with a permanent magnet rotorElectro-magnetic with a permanent magnet rotor Takes full advantage of maximum moment arm availability (pancake style)Takes full advantage of maximum moment arm availability (pancake style) Single coil designSingle coil design Directionality is controlled by coil polarityDirectionality is controlled by coil polarity

10/25/2015 ME Senior Design Spring Constraints/Goals  Rotor must be 2” in diameter  No springs to return to neutral position  Torque must be 0.31Nm or greater  Step size of 20° - 30°

10/25/2015 ME Senior Design Spring Original Designs

10/25/2015 ME Senior Design Spring Major changes  Cylindrical housing Uniformly distributed magnetic fieldUniformly distributed magnetic field  Inner magnets used. Helped to increase torque.Helped to increase torque.  Changed from 4 poles to 3  Taller coil Lowered current densityLowered current density Distributed temperature over larger area.Distributed temperature over larger area.

10/25/2015 ME Senior Design Spring Final Design Magnets left out for clarity NS

10/25/2015 ME Senior Design Spring Exploded View 1-64 Flat Head Screws Outer Housing Snap Ring Shaft Upper StatorBase Plate Lower Stator Shoulder BearingCoil CoreCoil RotorBushing

10/25/2015 ME Senior Design Spring D Simulation Using Maxwell 2-D SV Off Position (No Current)

10/25/2015 ME Senior Design Spring D Simulation On Position (1500A) Shading in above figure represents magnetic field, lines represent magnetic flux

10/25/2015 ME Senior Design Spring D Simulation De-EnergizedEnergized Using Maxwell 3-D

10/25/2015 ME Senior Design Spring Thermal Modeling  Surface Temperature Surrounding objectsSurrounding objects SafetySafety Determined materials used for coilDetermined materials used for coilE-Physics Calculated - 72°C Max

10/25/2015 ME Senior Design Spring Calculations Calculations from Assumed ValuesCalculations from Measured Values

10/25/2015 ME Senior Design Spring Fabricated Parts Base Plate Coil Core Lower Stator Housing Upper Stator Coil & Spool Rotor & Shaft Winding Device Screws

10/25/2015 ME Senior Design Spring Assembly Coil and Lower Stator AssemblyRotor Assembly AssemblyFull Assembly

10/25/2015 ME Senior Design Spring Assembly Problems  Tolerances on shaft and rotor Remade rotor and shaftRemade rotor and shaft Made shoulder on shaftMade shoulder on shaft  Used bushing in upper stator Press fitting 2 bearings posed disassembly problemsPress fitting 2 bearings posed disassembly problems

10/25/2015 ME Senior Design Spring Operational Setup

10/25/2015 ME Senior Design Spring Operation

10/25/2015 ME Senior Design Spring Torque Test Using Torque Gauge Generated N-m

10/25/2015 ME Senior Design Spring Thermal Tests Temperature after 2 minutesTemperature after 5 minutes 47.4° C53.2° C

10/25/2015 ME Senior Design Spring Conclusions  Proof of concept Single bi-directional solenoidSingle bi-directional solenoid  Torque.068 N-m 1/5 Predicted value.068 N-m 1/5 Predicted value 2 nd Test TBD2 nd Test TBD  Measure stall torque  Step Size 10°-15°10°-15°

10/25/2015 ME Senior Design Spring Recommendations  Housing with 3 walls aligned with stators.  Magnet spacing.  Stators: wider with larger radius than magnets. Diagrams to be inserted

10/25/2015 ME Senior Design Spring Acknowledgments  Sponsor - Gilbert Benavides (SNL)  Advisors Dr. MassonDr. Masson Dr. EnglanderDr. Englander  NHMFL Lee MarksLee Marks  Graduate Machine Shop Staff  Dr. Luongo

10/25/2015 ME Senior Design Spring Questions?