Masters Thesis

Design and Development of a Novel Direct Drive

Radial Gap Permanent Magnet Worm Drive
Actuator for Mechatronics Applications
[ ]

Principal supervisor: Prof. Yasutaka Fujimoto

Division of Electrical and computer Engineering

Graduate School of engineering

Yokohama National University, Japan

Student number: 14GD196

EFOBI Okechukwu Chimezie

September 2016
 Abstract

Electromechanical (EM) actuators are the most widely used actuators in robots, au-
tomation equipment, industrial machines, and power tools. EM actuators combine electric
motors and mechanical gears. This combination is often characterized by high force/torque
density. However, the use of gears in EM actuators introduce unfavorable outcomes,
thereby limiting their applications.
Significant limitations of EM actuators are seen in the field of humanoid and care
robots that have to operate in close proximity to humans. Expectedly, the most important
consideration for these robots is the issue of safety on contact with humans. EM actuators
tend to be sti on collision. Therefore, they fail the safety test for humanoid and care
robots. Nevertheless, series elastic actuator (SEA) has been introduced to combat this
drawback. SEAs are EM actuators with a spring element to absorb energy on collision.
However, SEAs pose significant control problems in high frequency region as they have
narrow bandwidth. Furthermore, presence of gears in SEAs, and likewise for EM actuators,
lead to friction losses, backlash, acoustic noise, and vibration.
Therefore, recent and ongoing researches aim to develop direct drive actuators that
would meet the requirements for use in humanoid and care robots. Direct drive means no
mechanical gears are required for output force/torque transmission. With the introduction
of very strong rare-earth permanent magnets (PMs), electromagnetic actuators (combina-
tion of electric motor and magnetic screw/gear) are now capable of supporting high force
density performance that are comparable to those of EM actuators. Consequently, various
electromagnetic actuators are being developed. An example is a linear actuator termed
Spiral Motor [1] and [2]. Another example is the Trans-rotary Magnetic Gear [7].
In line with these developments, the authors of this thesis set out to develop a novel
direct drive electromagnetic actuator termed Worm drive actuator (WDA). WDA is a
combination of special permanent magnet synchronous motor (PMSM) and a modified
magnetic screw configuration. Its major parts include multiple stator-worms and a cen-
trally positioned wheel. As the name suggests, in both mechanism and structure, it mimics
the mechanical worm drive gear. However, while the worm gear has threads wound on its
worm and wheel, those of WDA contain appropriately shaped, radially magnetized PMs.
The authors hope for adoption of this technology in mechatronics applications, namely
robots and industrial machines, where direct-drivable actuators that can support complex
joints, in addition to providing multiple degrees of freedom (DOF) are desirable. However,
for starters, a single stator-worm WDA is developed. This is enough to demonstrate the
principles, performance, and merits of WDA. Therefore, the scope of this work includes
mathematical modeling and analysis of WDA, development of a workable design, and
finite element analysis (FEA) simulation using the design. Furthermore, results from FEA
and analytical calculations are compared, and adjustments are made in the design. On
completion of the groundwork, the first prototype of WDA is manufactured and tested.

ii
 Acknowledgements

I express my gratitude to the following organization, individuals, and group. Please

note that order does not necessarily signify importance.

Government and people of Japan for the award of MEXT scholarship that made it
possible for me to come to Japan for graduate study.

Prof. Yasutaka Fujimoto, who, despite my zero experience in research, not to talk
of his area of research, granted me the opportunity to join his research group. His
practical supervision and patient support has opened up a promising career path for
me.

Mr. Hasegawa Yuudai, my tutor and the first person I met in Japan. He introduced
me to life in Japan and provided tremendous help and support.

Messrs. Koyama Masato, Hagino Yutaro, Nagano Kenta, Arai Ryoji, Sasaki Shun-
suke, Bui Van Dinh, and Nguyen Huy Nhien. These individuals provided immense
help in the course of my work through simple translations/interpretations, discussions
on aspects about my research, and demonstrations on how to use software packages
and equipment in the laboratory.

The list of names above is not exhaustive. I am very appreciative of all the help and
support I received from members of Y. Fujimoto Laboratory during the course of my
graduate study in Japan.

iii
Table of Contents

List of Tables vi

List of Figures vii

1 Introduction 1
1.1 Thesis outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 Features and principles of WDA 4

2.1 Features of WDA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 The magnetic screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Relationship between rotational displacement of the nut and linear displace-
ment of the screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Magnetic screw configuration of WDA . . . . . . . . . . . . . . . . . . . . 6

3 Preliminary finite element analysis (FEA) 8

3.1 Linear electromagnetic actuator based on the magnetic screw concept . . . 8
3.1.1 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.2 FEA of thrust force . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Preliminary FEA of WDA . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.1 Eect of number of magnet poles around the worm on magnitude of
thrust force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.2 Eect of stack length (axial length of the worm) on magnitude of
thrust force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.3 Maximum torque capacity of a single stator-worm WDA . . . . . . 15

4 Modeling and analysis of WDA 16

4.1 Voltage and torque equations of the stator-worm . . . . . . . . . . . . . . . 16
4.2 Equation for tangential force acting on the wheel . . . . . . . . . . . . . . 21

iv
5 WDA prototype design considerations and parameters estimation 23
5.1 Design considerations and parameters estimation . . . . . . . . . . . . . . 23
5.2 Typical WDA operating performance . . . . . . . . . . . . . . . . . . . . . 26

6 Techniques for the manufacture of WDA prototype 31

6.0.1 Stator core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.0.2 Stator insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.0.3 Stator windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.0.4 Worm and wheel magnets . . . . . . . . . . . . . . . . . . . . . . . 34
6.0.5 Worm yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.0.6 Wheel yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.0.7 WDA frame/cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.0.8 Measured back emf . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7 Summary and future work 42

7.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.2 Future work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

v
List of Tables

3.1 Parameters of the linear model of WDA. . . . . . . . . . . . . . . . . . . . 9

3.2 Simulation conditions for FEA of thrust force . . . . . . . . . . . . . . . . 10
3.3 Parameters for preliminary FEA of WDA. . . . . . . . . . . . . . . . . . . 12

4.1 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.1 WDA specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.2 Estimated WDA parameters. . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.1 List of WDA parts and components . . . . . . . . . . . . . . . . . . . . . . 33

6.2 WDA stator measured parameters . . . . . . . . . . . . . . . . . . . . . . . 35

vi
List of Figures

1.1 3-D CAD model of a multiple stator-worm WDA. . . . . . . . . . . . . . . 2

2.1 Single stator-worm WDA. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Magnetic screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Longitudinal cross section of magnetic screw. . . . . . . . . . . . . . . . . . 6

3.1 Linear model of WDA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2 Table 3.2, Step 1 FEA results. . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Table 3.2, Step 2 FEA results. . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 Table 3.2, Step 3 FEA results. . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Single stator-worm WDA. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Eect of number of worm magnet poles on magnitude of thrust force. . . . 14
3.7 Eect of stack length on magnitude of thrust force. . . . . . . . . . . . . . 15
3.8 Thrust force of WDA in operation. . . . . . . . . . . . . . . . . . . . . . . 15

4.1 WDA stator-worm. The part enclosed within the blue lines are represented
as the magnetic circuit in Fig. 4.2. . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Magnetic circuit of the stator-worm. . . . . . . . . . . . . . . . . . . . . . 18
4.3 Graphs for estimated PM flux and its derived sinusoidal equivalent. . . . . 19
4.4 B-H magnetization curve of WDA PM.. . . . . . . . . . . . . . . . . . . . . 19
4.5 Worm-wheel of WDA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6 Block diagram of WDA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.1 Force-displacement relationship of WDA. . . . . . . . . . . . . . . . . . . . 24

5.2 Comparing force-displacement relationship results from FEA and calculations. 24
5.3 Torque-current relationship obtained using FEA. . . . . . . . . . . . . . . . 25
5.4 Torque values from dynamic equations and FEA. . . . . . . . . . . . . . . 25

vii
5.5 fi for i = 0.6 deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.6 fi for i = 1.0 deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.7 fi for i = 1.5 deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.8 r for i = 0.6 deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.9 r for i = 1.0 deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.10 r for i = 1.5 deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.11 Wheel torque vs. worm potential torque. . . . . . . . . . . . . . . . . . . . 30

6.1 CAD models of full stator, main stator (without shoes), and stator shoe. . 32
6.2 Manufactured stator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.3 3-D printed form for winding coils. . . . . . . . . . . . . . . . . . . . . . . 33
6.4 Stator core containing phase coils. . . . . . . . . . . . . . . . . . . . . . . . 34
6.5 Stator windings layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.6 Worm magnet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.7 Wheel magnet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.8 CAD models of worm yoke and the manufactured yoke. . . . . . . . . . . . 36
6.9 Worm and shaft assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.10 The two halves of worm yoke with magnets fixed and bonded to the grooves. 37
6.11 Wheel and shaft assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.12 Wheel yoke with magnets fixed and bonded to its curved surface. . . . . . 38
6.13 CAD models of WDA full assembly and left half frame.. . . . . . . . . . . 38
6.14 Manufactured WDA left half frame. . . . . . . . . . . . . . . . . . . . . . . 39
6.15 Assembly of the manufactured WDA left half and right half frames. . . . . 40
6.16 Assembled WDA (left) and inverter/controller unit. . . . . . . . . . . . . . 41
6.17 Back emf recorded by manually turning the worm. . . . . . . . . . . . . . . 41
6.18 Estimated back emf from FEA. . . . . . . . . . . . . . . . . . . . . . . . . 41

viii
Chapter 1

Introduction

Actuation is an integral aspect of many applications. Humanoid robots, industrial ma-

chines and/or robots, and automation equipment are able to operate because of actuators.
Motion and delivery of torque and/or force to locations both within and outside of these
machines are eected by them. Majorly, actuators are classified according to their source
of driving power. Hydraulic, pneumatic, and electromechanical actuators are some ex-
amples. However, owing to poor controllability and maintenance requirements, hydraulic
and pneumatic actuators are rarely used in mid-size to small robots and machines. Elec-
tromechanical (EM) actuators are actuators of choice for these applications. Obviously,
advantages associated with electric power provide reasons for this. Electromechanical ac-
tuators combine rotary motors and reduction gears or lead screws to achieve high force
density performance.
Nevertheless, electromechanical actuators are not devoid of problems. Significant lim-
itations of EM actuators are seen in the field of humanoid and care robots that have to
operate in close proximity to humans. Expectedly, the most important consideration for
these robots is the issue of safety on contact with humans. EM actuators tend to be sti on
collision. Therefore, they fail the safety test for humanoid and care robots. Notwithstand-
ing, series elastic actuator (SEA) has been introduced to combat this drawback. SEAs
are EM actuators with a spring element to absorb energy on collision. However, SEAs
pose significant control problems in high frequency region as they have narrow bandwidth.
Furthermore, presence of gears in SEAs, and likewise for EM actuators, lead to friction
losses, backlash, acoustic noise, and vibration.
Therefore, recent and ongoing researches aim to develop direct drive actuators that
would meet the requirements for use in humanoid and care robots. Direct drive means no
mechanical gears are required for output force/torque transmission. With the introduction
of very strong rare-earth permanent magnets (PMs), electromagnetic actuators (combina-
tion of electric motor and magnetic screw/gear) are now capable of supporting high force
density performance that are comparable to those of EM actuators. Consequently, various
electromagnetic actuators are being developed. An example is a linear actuator termed
Spiral Motor [1] and [2]. Another example is the Trans-rotary Magnetic Gear [7].
In line with these developments, the authors of this thesis set out to develop a novel

1
direct drive electromagnetic actuator termed Worm drive actuator (WDA). WDA is a
combination of special permanent magnet synchronous motor (PMSM) and a modified
magnetic screw configuration. Its major parts include multiple stator-worms and a cen-
trally positioned wheel. As the name suggests, in both mechanism and structure, it mimics
the mechanical worm drive gear. However, while the worm gear has threads wound on its
worm and wheel, those of WDA contain appropriately shaped, radially magnetized PMs.
Figure 1.1 shows a CAD model of WDA.

Figure 1.1: 3-D CAD model of a multiple stator-worm WDA.

WDA is based on the concept of magnetic screw. This concept is not new. A patent
on magnetic screw was registered as early as 1925 [3]. However, in recent times it has
inspired quite a number of research works. Development of very strong rare-earth PMs
could be cited as a contributing factor to this trend. The reader should see the references
for details of past work on magnetic screw and an earlier work somewhat similar to WDA
[6]. Potential application of WDA would be use as direct drive actuator in robots for
complex joints, where multiple degrees of freedom motion is essential. WDA could also
serve as better alternatives to the traditional worm drive gears.

1.1 Thesis outline

Chapter 1 contains introduction and background of the research work presented in this
thesis. Chapter 2 presents features and operating principles of WDA. Chapter 3 presents
preliminary FEA study done using a linear actuator from which the WDA evolved, and

2
ideal WDA models. Chapter 4 presents mathematical modeling and analysis of WDA.
Chapter 5 presents practical design considerations relevant to the design of the first WDA
prototype. Using both FEA and analytical results, parameters of the WDA are determined.
Chapter 6 discusses techniques employed in the manufacture of custom parts for the first
WDA prototype. The last chapter is a summary of the research work. Future work to be
carried out are also mentioned here.

3
Chapter 2

Features and principles of WDA

2.1 Features of WDA

Fig. 1.1 shows a 3-D CAD model of the proposed WDA. Its primary parts are as labeled.
Fig. 2.1 is a single stator-worm configuration of the device. Supply of current to the
stator armature windings sets up a rotating magnetic field in the air gap between the
stator and the worm. In response, the magnet poles of the worm try to line up with this
rotating field. Consequently, torque is developed and forces continuous rotation of the
worm about its axis. Furthermore, interaction between the magnet poles of the worm and
the wheel, which together constitute a magnetic screw, leads to rotation of the wheel. A
comprehensive account of the operation of a magnetic screw comes up in the section that
follows.

2.2 The magnetic screw

Fundamental to the operation of WDA is the concept of magnetic screw, an analogue of
mechanical lead screw. Fig. 2.2 shows a 3-D CAD model of magnetic screw. Like screw
threads, radially magnetized and helically shaped PMs are placed on both the screw and
the nut yokes. However, unlike the mechanical lead screw, there is no contact between
the magnetic screw and the magnetic nut, as an air gap separates them. Axially, as Fig.
2.3 depicts, alternate magnet poles are placed side by side. Any displacement (shift from
alignment) between the nut and the screw magnets initiates attraction and repulsion forces
between magnet poles. Due to the helical shape of the magnets, 360 degrees rotation of
the magnetic nut would result in linear displacement of the magnetic screw by one lead
length ll and vice versa. Therefore, torque and force occur on the magnetic nut and the
magnetic screw, respectively. Assuming ideal conditions, this relationship is represented
by (2.1), where i represents the rotational torque of the nut while fi denotes the thrust
force of the screw.
ll
i = fi (2.1)
2

4
Figure 2.1: Single stator-worm WDA.

Figure 2.2: Magnetic screw.

5
 Figure 2.3: Longitudinal cross section of magnetic screw.

2.3 Relationship between rotational displacement of

the nut and linear displacement of the screw
Defining gear ratio as the ratio of the angular displacement of the magnetic nut to the
linear displacement of the magnetic screw, a mathematical expression is obtained for this
ratio. For each 360 degrees rotation of the nut, 2 rad angular displacement is recorded
while the screw translates a total of one lead length ll . Therefore, the relationship between
the rotational displacement of the nut and the linear displacement of the screw, termed
the gear ratio is obtained as

2 fi
gr = = (2.2)
ll i

2.4 Magnetic screw configuration of WDA

The two preceding sections describe the operation of a linear magnetic screw. Albeit some
modifications, what applies to the linear magnetic screw is fundamentally how the magnetic
screw of the WDA operates. The screw of the linear magnetic screw has evolved into the
wheel of WDA. However, the nut of the linear device is basically the same as the worm of
WDA. Furthermore, WDA is equipped with a stator containing armature windings needed
for the supply of driving power to the device. During operation, a steady tangential force
acts on the wheel at the point between the worm and the wheel, x-axis direction. However,
it is important to note that some displacement (shift from alignment) between the magnet
poles of the worm (magnetic nut) and the wheel (magnetic screw) must be present before
a substantial tangential force can act on the wheel.
Full alignment of the poles of the worm and the wheel prior to excitation of armature
windings would lead to motion of the two moving parts but virtually no force, acting

6
tangentially on the wheel, would be recorded. As a result, negligible torque would be
delivered to the wheel. The magnitude of this tangential force is proportional to the
displacement between magnet poles of the magnetic nut and screw. Mathematically,

fi = Ks z d (2.3)

where fi is the tangential force, Ks represents the magnetic spring constant, and zd is the
displacement between the magnetic nut and screw. Peak force is recorded for a displace-
ment equal to one-quarter of the lead length of the magnetic screw.
(2.1)-(2.3) are not readily appreciated for the magnetic screw configuration of WDA.
This is because unlike in the linear magnetic screw where linear displacement is readily
measured, what is actually recorded for the WDA is the angular displacement of the wheel.
Because the lead length is small compared to the circumference of the wheel, in eect it
approximates to an arc around the wheel. Therefore, for WDA (2.3) is the same as (2.4)

fi = Ks d rw (2.4)
where d is the angular displacement of the wheel, measured in radians. rw is the radius
of the wheel. Furthermore, (2.2) becomes
2
gr = (2.5)
l

where l is the angular displacement of the wheel that would result in an arc length equal
to the lead length of the magnetic screw. (2.6) gives the final angular displacement of the
wheel, given an initial displacement of i , for rotation of the worm through an angle .

rm rm
d = i + l = i + (2.6)
2 gr

7
Chapter 3

Preliminary finite element analysis

(FEA)

Figure 3.1: Linear model of WDA.

3.1 Linear electromagnetic actuator based on the mag-

netic screw concept
Drawing inspiration from the magnetic screw, we proceed to incorporate it into a stator
containing 3-phase windings. Fig. 3.1 shows the three-level PM linear actuator, which is the
linear model of WDA. Its parameters are contained in Table 3.1. Following the labels of Fig.
3.1, the mover is the magnetic screw while the mid-layer rotor corresponds to the magnetic
nut. However, the mid-layer rotor magnets are modified into a checkerboard pattern around
the mover. The stator windings, when excited, supply the rotating electromagnetic field
needed to rotate the mid-layer rotor. The directions of the mover displacement and that
of the angular rotor displacement are as indicated in Fig. 3.1.

8
 Table 3.1: Parameters of the linear model of WDA.
Lead length ll 5 mm
Outer diameter of stator 70 mm
Outer diameter of mid-layer rotor 51.6 mm
Outer diameter of mover 42 mm
Air gap length 0.8 mm
Radial thickness of magnets 4 mm
Pole pitch/axial thickness of magnets 2.5 mm
PM material NMX-41SH

3.1.1 Operating principle

Recall the explanations oered in Chapter 2. Notwithstanding the checkerboard pattern of
the mid-layer rotor, its axial cross-section is similar to that shown in Fig. 2.3. Therefore,
when the poles of both the mover and the mid-layer rotor are aligned (no axial displace-
ment), zero force would be recorded. However, when there is an axial displacement zd
between the magnet poles, equal and opposite tangential forces would be set up between
the two sets of magnets. As the axial displacement increases, the forces increase propor-
tionally to it up to a maximum. For an ideal magnetic screw, the peak force is recorded at
1
l , i.e, one-half a pole pitch. This relationship between force and displacement reminds us
4 l
of Hookes law, and considering the mover-rotor arrangement as being a magnetic spring,
the following mathematical expression applies.

ft = Kzd (3.1)
where, ft represents the magnetic force applied (similar to compression/extension force on
springs) and K stands for the magnetic spring constant of the system.
So far the reader must have acquired some idea of what happens in the magnetic screw
part of the PM linear motor. Displacement zd between the mover magnets and the rotor
magnets is a requirement for development of thrust force, whose magnitude is dependent
on zd . On excitation of the stator windings, this thrust force is maintained and becomes
the output thrust force of the linear electromagnetic actuator. Flux interaction between
the stator and the mid-layer rotor causes the rotor to rotate. Consequently, the mover
translates in the direction indicated in Fig. 4. The gearing ratio of (2.2) is maintained as
this happens. Assuming an initial displacement of zi before armature excitation, the final
displacement of the mover for a total rotor angular displacement of is given by (3.2).

zd = zi + ll = zi + (3.2)
2 gr

9
 Table 3.2: Simulation conditions for FEA of thrust force
FEA Study Parameter Value
Step 1 Current 0A
Mover speed 0.1 m/s
Rotor speed 0 rpm
Initial displacement zi 0 mm
Step 2 Current 2A
Mover speed 0.075 m/s
Rotor speed 900 rpm
Initial displacement zi 0 mm
Step 3 Current 2A
Mover speed 0.075 m/s
Rotor speed 900 rpm
Initial displacement zi 0.2 mm

3.1.2 FEA of thrust force

For confirmation of the developed theory, computation was done in JMAG Designer using
the finite element method (FEM). Table 3.2 contains the simulation parameters of the
three steps taken to estimate thrust force of the PM linear actuator. The highest force
density of this actuator, with the dimensions given in Table 3.2, works out to about 6
MN/m3 .

Step 1 is to determine the force/torque characteristics of the magnetic screw of the

actuator. The rotor is kept stationary while the mover translates along the z-axis.
Force and torque results obtained are plotted in the graphs of Fig. 3.2. Force recorded
is along the positive z-axis while torque is about the same axis and this remains so for
all three steps. The force graph shows that thrust force is displacement-dependent,
just as (3.1) states. Furthermore, the equal and opposite forces on the mover and the
rotor is an indication that Newtons third law is obeyed, which again is well captured
in (3.1) by the negative sign.

Step 2 goes further to confirm that displacement between the magnet poles of the
rotor and the mover is a requirement for thrust force to be generated by the PM linear
actuator. With zero displacement between the magnet poles, current excitation of
the stator windings would cause the rotor to rotate, which in turn would result in
the translation of the mover in accordance with the gear ratio. In spite of the motion
occurring in the two moving parts, virtually no thrust force is generated.Graph of
Fig. 3.3 shows this.

Step 3 demonstrates that a steady thrust force is generated as long as there is an

initial displacement between the magnet poles before current is supplied to the stator

10
 500 0.5
Mover
400 0.4 Rotor
300 0.3 Stator

200 0.2

Torque [Nm]
100 0.1
Force [N]

0 0
-100 -0.1
-200 -0.2
-300 Mover -0.3
-400 Rotor -0.4
Stator
-500 -0.5
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Displacement [mm] Displacement [mm]

Figure 3.2: Table 3.2, Step 1 FEA results.

400

200
Force [N]

-200

Mover
-400 Rotor
Stator
0 5 10 15 20 25 30 35 40 45 50
Angle [deg.]

Figure 3.3: Table 3.2, Step 2 FEA results.

windings. The generated force is proportional to this initial displacement zi . The

graph of Fig. 7 shows that the generated force for zi = 0.2 mm is about 175 N. A
quick glance at the force graph of Fig. 3.2 would confirm this. The final displacement
of the mover is given by (3.2).

3.2 Preliminary FEA of WDA

The preceding section has prepared the ground for the introduction of WDA. Fig. 3.5 shows
a single stator-worm WDA being investigated, while Table 3.3 contains its specifications.
The mover of the linear actuator has evolved into the wheel of WDA. Albeit some structural
dierences, the stator and the worm (mid-layer rotor) of WDA are very much like those of
the linear actuator. Therefore, the theory of the linear actuator to a large extent applies to
WDA. The stator windings, when energized, supply the rotating magnetic field, the worm
rotates about the positive x-axis, with its center acting as the origin, while the wheel

11
 200

150

100

Force [N] 50

-50

-100
Mover
-150 Rotor
Stator
-200
0 5 10 15 20 25 30 35 40 45 50
Angle [deg.]

Figure 3.4: Table 3.2, Step 3 FEA results.

Table 3.3: Parameters for preliminary FEA of WDA.

Outer diameter of stator yoke 80 mm
Mid-section outer diameter of worm yoke 40 mm
Outer diameter of wheel yoke 100 mm
Air gap length 1 mm
Radial thickness of magnets 4 mm
Axial thickness of magnets 2.61 mm
PM material NEOREC45SH
Remanence of PM 1.3 T

12
 Figure 3.5: Single stator-worm WDA.

translates, its direction being the negative x-axis direction. Overall, the wheel rotates
about the z-axis, whose origin is at the center of the wheel. Notice the curvature of
some surfaces of the three parts of the motor. This maintains a uniform air gap between
magnetically coupled surfaces. The curved surfaces and parts are determined by parametric
equations.
Having established the contents of the preceding paragraph, the task at hand is to
realize a workable design needed to develop an experimental prototype of the proposed
actuator. Preliminary FEA conducted using NMX-41SH PM yielded a peak thrust force
of less than 80 N. This force acts tangentially to the wheel at the midpoint between the
worm and the wheel. Its direction is the negative x-axis. For a single stator-worm, Fig.
3.5, this works out to a torque of about 4 Nm being applied on the wheel. A larger value
is desired. Therefore, solutions are proered to achieve this. A change from NMX-41SH
to the stronger NEOREC45SH realizes over 30 % increase in output force. To arrive at
better informed decisions, the eects of number of magnet poles on the worm, the stack
length (axial length) of the worm, and air gap length are studied using FEA.

3.2.1 Eect of number of magnet poles around the worm on mag-

nitude of thrust force
To understand how the magnitude of thrust force is aected by the number of poles around
the worm, 2-pole, 4-pole, 6-pole, 8-pole, and 12-pole worms are used, and the thrust force
of each configuration is estimated by FEM computations in JMAG Designer. For the
simulations, a model of stack length (axial length of worm) of 31.24 mm is used, while
NMX41-SH is the rare-earth PM used. The speed of the worm is set constant at 3600 rpm,
while current and wheel speed are both set to zero. The results obtained are plotted in the
graph of Fig. 3.6. The graphs are slightly displaced from the origin. This is attributed to
a small negative displacement between the magnets of the worm and the wheel and also

13
 100

80

Thrust Force [N]

60

40
2-pole
4-pole
20 6-pole
8-pole
12-pole
0
0 10 20 30 40 50 60 70 80
Worm angular displacement [deg.]

Figure 3.6: Eect of number of worm magnet poles on magnitude of thrust force.

to dierences in axial thickness (length of arc) of the worm magnets. The wheel PM axial
thickness is constant at 2.61 mm, while that of the worm varies between 2.64 mm and 2.68
mm, depending on the angle of curvature of each PM. The sharper curvature of the worm,
compared to the wheel, is the reason for this variation.
With about 12 N dierence between the highest and the lowest force (Fig. 3.6), one can
conclude that the number of magnet poles around the worm do not have significant impact
on thrust force. Nevertheless, consider an 8-pole worm, the circumferential size of each
magnet would approximate to an arc and not a helical curve, therefore its manufacture
would be relatively easy. On the other hand, taking the reasons just given into account,
the magnet of a 2-pole worm would be difficult and costly to fabricate. Therefore, with an
added incentive of a convenient mechanical angle of 90 degrees, an 8-pole worm would be
appropriate for the design.

3.2.2 Eect of stack length (axial length of the worm) on mag-

nitude of thrust force
Consider the magnetic interaction between the magnetic screw and the magnetic nut of
the basic system. It makes sense for one to conclude that the size of the area between
magnetically coupled surfaces influences the magnitude of thrust force. To confirm this
and to determine a suitable stack length for the prototype, FEA is used to estimate thrust
force for each stack length of 31.24 mm, 42.09 mm, and 52. 55 mm. These lengths
are obtained by adjusting the variables that control the axial length of the worm in the
parametric equations. A stack length beyond 52.55 mm would be structurally impossible
to accurately couple (maintaining uniform air gap) with the wheel (outer diameter of wheel
yoke is 100 mm). For a stack length greater than 52.55 mm, a corresponding increase would
be required for the wheel diameter. This in eect will increase the total size of the WDA,
which is not desirable.
The FEA results are presented in Fig. 3.7. This confirms the opening statement of

14
 200

150

Thrust Force [N]

100

50
31.24 mm
42.09 mm
52.55 mm
0
0 10 20 30 40 50 60 70 80 90
Worm angular displacement [deg.]

Figure 3.7: Eect of stack length on magnitude of thrust force.

200

150

100
Thrust force [N]

50

-50

-100
Stator
-150 Wheel
Worm
-200
0 50 100 150 200 250
Worm angular displacement [deg.]

Figure 3.8: Thrust force of WDA in operation.

the preceding paragraph. Again, (3.1) is observed. Please note that a stronger magnet,
NEOREC45SH (mentioned earlier), is used. Worm speed is set constant at 3600 rpm,
while wheel speed and current are both set to 0. Following the FEA results, a stack length
of 52.55 mm would be appropriate for the prototype.

3.2.3 Maximum torque capacity of a single stator-worm WDA

Finally, Step 3 of the FEA performed for the PM linear actuator in section 3.1 is repeated
here for WDA. The worm speed is set at 3600 rpm, the wheel speed is 60 rpm, while the
current supplied to the stator windings is 2 A. For an initial angular displacement i of 50
degrees, Fig. 3.8 shows the output thrust force. The torque delivered to the wheel by the
single stator-worm works out to about 8.1 Nm.

15
Chapter 4

Modeling and analysis of WDA

Table 4.1 lists symbols used and their meanings. Fig. 4.1 shows the stator-worm (PMSM
part) of WDA.

4.1 Voltage and torque equations of the stator-worm

The stator-worm is a 12-slot, 8-pole PMSM with about one-quarter of the stator truncated.
Therefore, each phase contains three coils connected in series. Windings of the three phases
are wye-connected. Fig. 4.2 shows the magnetic circuit of the portion of the stator-worm
enclosed within the blue lines of Fig. 4.1.

Figure 4.1: WDA stator-worm. The part enclosed within the blue lines are represented as
the magnetic circuit in Fig. 4.2.

In vector matrix form, the phase voltages across the stator windings terminals are
represented by (4.1).
v uvw = r uvw i uvw + uvw (4.1)

16
 Table 4.1: Nomenclature
Br Remanence of PM
fi Tangential force acting on the wheel
lm Radial thickness of PM
l Wheel angular displacement corresponding to lead length
g Nominal length of air gap
0 Permeability of free space
m Permeability of PM
Ns Number of turns of each stator coil
p Number of pole pairs
Ams Eective PM surface area spanned by each coil
Amw Eective PM surface area of the worm-wheel
Ags Air gap area over Ams
Agw Air gap area over Amw
uvw Flux linkages of stator windings, in vector form
m PM flux linking each stator phase windings
vuvw Phase voltages, in vector form
iuvw Phase currents, in vector form
ruvw Phase windings resistances, in vector matrix form
R Resistance of each phase windings
L Self inductance of each phase windings
M Mutual inductance between two phase windings
r Torque acting on the worm
w Torque acting on the wheel
rw Radius of the wheel
g Air gap flux over Ags
r Worm angular displacement, in electrical radians
rm Worm angular displacement, in mechanical radians
Rms PM reluctance for each stator coil
Rmw PM reluctance for the worm-wheel
Rgs Air gap reluctance for each stator coil
Rgw Air gap reluctance for the worm-wheel
if PM magnetizing current
Lf Worm PM inductance
P Magnetic path permeance for each stator coil

17
 Figure 4.2: Magnetic circuit of the stator-worm.

where
(v uvw )T = vu vv vw (4.2)
Likewise (i uvw )T = iu iv iw and ( uvw )
T
= u v w .

r uvw = diag R R R (4.3)

(4.3) assumes that the system is balanced, therefore, all three phases have equal winding
resistances. The flux linkage in (4.1) is a combination of the flux produced by current in
the windings and flux produced by the PMs. The worm is modeled as the rotor of a PMSM
containing a single turn field winding, whose magnetic axis coincides with the direct axis
(d-axis) of the rotor. With this model in mind, flux linkage term in (4.1) is represented by
the following equation.

uvw = Luvw iuvw + m (4.4)

The inductance matrix of the stator windings is given as

0 1
L M M
Luvw = @M L M A (4.5)
M M L

where
L = 3Ns 2 P (4.6)
1
M= L (4.7)
2
1
P = (4.8)
(Rms + Rgs )
lm
Rms = (4.9)
m Ams

18
 g
Rgs = (4.10)
0 Ags

The second term on the right hand side of (4.4) is the vector form of the flux linkages
established by the rotor field winding (flux originating from the worm PMs) referred to
the stator phase windings (or as viewed from the stator windings). This flux linkage is a
periodic function of the angular displacement of the rotor. It is represented by (4.11), the
fundamental harmonic component derived using Fourier analysis. Fig. 4.3 shows estimated
PM flux over one electrical cycle from which a sinusoidal expression was derived; (4.11).
Fig. 4.4 shows the B-H characteristics of the PM to be used for WDA.

1.5
Flux linkage of one coil [Wb]

0.5

-0.5

-1
Flux linking one coil
Fundamental harmonic component
-1.5
0 10 20 30 40 50 60 70 80 90
Mechanical angular displacement [deg.]

Figure 4.3: Graphs for estimated PM flux and its derived sinusoidal equivalent.

1.4

1.2
Flux density [T]

0.8

0.6

0.4

0.2 Demagnetization curve of PM

Load line
0
-1.4 -1.2 -1 -0.8 -0.6 -0.4 -0.2 0
Product of field intensity and permeability of PM [T]

Figure 4.4: B-H magnetization curve of WDA PM..

19
 0 1
cosr
m = A @cos(r 2 3
)A (4.11)
2
cos(r + 3 )
where p
6 3
A = 2 (3Ns g) (4.12)

and
r = prm (4.13)

Recognizing the absence of saliency, the q-axis and the d-axis magnetizing inductances
of the stator windings are defined as
3
Lq = L d = L (4.14)
2
Using (4.15) as the qd0-axis transformation matrix,
0 1
cosr cos(r 2 ) cos( r + 2
)
2 3 3
T = @ sinr sin(r 2 3
) sin(r + 2 3
)A (4.15)
3 1 1 1
2 2 2

where
fqd0 = T fuvw (4.16)
and
(fqd0 )T = fq fd f0 (4.17)
the voltage equations in rotor reference frame are given by (4.18).

vqd0 = ruvw iqd0 + r dq + qd0 (4.18)

where
T
( dq ) = d q 0 (4.19)
and 0 10 1 0 1
Lq 0 0 iq 0
qd0
@
= 0 Ld 0 A @ id A + m
@ 1A (4.20)
0 0 L0 i0 0
In expanded form
vq = Riq + Lq iq + r Ld id + r m (4.21)
vd = Rid + Ld id r Lq iq (4.22)
v0 = Ri0 + L0 i0 (4.23)

The torque acting on the worm is obtained from the coenergy of the magnetic system
as
1 @Luvw @Lf
r = p (iuvw )T iuvw + (iuvw )T if (4.24)
2 @r @r

20
In rotor reference frame

3
r = p[ m iq + (Ld Lq )iq id ] (4.25)
2
It is readily understood that only the PM flux contributes in torque generation in the
stator-worm as Ld = Lq . Therefore, total torque on the wheel is given by (4.26).

drm 3
Jm = p m iq + i (4.26)
dt 2
where Jm is the inertia of the worm.

4.2 Equation for tangential force acting on the wheel

Figure 4.5: Worm-wheel of WDA.

Fig. 4.5 shows the worm-wheel of WDA. Both the worm and the wheel undergo rotary
motion. However, an observer on the worm would see the part of the wheel in its vicinity
as undergoing linear motion. Modeling the worm-wheel as a motor where the worm is a
stationary stator while the wheel is the rotor, its inductance matrix is given by (4.27).

Lm M m
Lww = (4.27)
M m Lm

where
1
Lm = (4.28)
Rmw

21
is the self inductance of the portion of worm PMs in interaction with those on the wheel.
Assuming i = 0, the mutual inductance of the system is given by (4.29).
1
Mm = cosrm (4.29)
(Rmw + Rgw )

From the coenergy of the system, tangential force acting on the wheel can be obtained
using (4.30).
1 @Lww if
fi = if if (4.30)
2 @ if
where
Br
if = lm (4.31)
m
Therefore,
1
fi = gr i2 sinrm (4.32)
(Rmw + Rgw ) f
This tangential force on the wheel sets up a torque about the axis of the wheel given by
(4.33)
w = f i rw (4.33)
Fig. 4.6 is the overall block diagram of WDA.

Vd + +
load 1 1
Jw s s
1 +
1.5Ls+R
w
Id
rw +
1.5L
1.5L Ks r w
1
fi d
+
gr

i 1
gr
Vq + r +
rm
1 1 1
1.5Ls+R 1.5p m Jm s s
Iq + rm

m p

Figure 4.6: Block diagram of WDA.

22
Chapter 5

WDA prototype design

considerations and parameters
estimation

5.1 Design considerations and parameters estimation

After some considerations bordering on cost, safety and practicality, specifications for the
WDA prototype are presented in Table 5.1. The most important decision is the use of
regular arc magnets instead of helical ones. With these specifications, a CAD model of
WDA was designed in SolidWorks and 3-D finite element analysis (FEA) was performed
in JMAG Designer. Fig. 5.1 shows the force-displacement relationship (given by (2.4))
of WDA. The curve is approximated to a straight line by curve fitting. Therefore, the
magnetic spring constant is Ks = 91, 514 N/m. Compare this to the estimated value
obtained via calculations (shown in Fig. 5.2); 89.23kN/m.
For the stator coils, assuming a slot fill factor of 0.25, a theoretical number of turns for
each coil is obtained as 95. Using (4.6) and (4.14), motor inductance is estimated to be
L = 7.4 mH, Lq = Ld = 11.1 mH. Phase windings resistance is estimated to be 1.45 ohm.
Using (4.32), maximum tangential force on the wheel is obtained as fi = 106.97 N. This
is quite close to the FEA value of 100 N. The flux originating from the worm PMs and
linking each stator phase winding is estimated, using (4.11), to be m = 0.0522 Wb.
For the PMSM (stator-worm) torque constant, average torque values for dierent cur-
rent magnitudes obtained from FEA gives an estimated value of torque constant K = 0.3
N.m/A. Fig. 5.3 shows the FEA results. Compare this to the torque values estimated using
(4.25), Fig. 5.4. This gives K = 0.3129 N.m/A. So far results from FEA and analysis
equations conform. WDA parameters are summarized in Table 5.2.

23
 100

Tangential force on wheel [N]

50

-50
Stator
Wheel
Worm
-100 curve fitting
0 0.2 0.4 0.6 0.8 1 1.2 1.4
Wheel anuglar displacement [deg.]

Figure 5.1: Force-displacement relationship of WDA.

100
Tangential force on wheel [N]

80

60

40

20
Calculation
FEA
0 CalculationFit
0 0.2 0.4 0.6 0.8 1 1.2 1.4
Wheel anuglar displacement [deg.]

Figure 5.2: Comparing force-displacement relationship results from FEA and calculations.

24
 1.6

1.4

1.2

Torque [N.m] 1

0.8

0.6

0.4

0.2 Torque points

curve fitting
0
0 1 2 3 4 5
Iq [A peak]

Figure 5.3: Torque-current relationship obtained using FEA.

1.6

1.4

1.2
Torque [N.m]

0.8

0.6

0.4
JMAG torque points
0.2 Equation torque
JMAG torque
0
0 1 2 3 4 5
Iq [A]

Figure 5.4: Torque values from dynamic equations and FEA.

25
 Table 5.1: WDA specifications.
Outer diameter of stator 94.5 mm
Side outer diameter of worm yoke 45.0 mm
Outer diameter of wheel yoke 96.3 mm
Side to side thickness of wheel 20.0 mm
Nominal air gap length 1.0 mm
Radial thickness of magnets 4 mm
PM material NEOREC45SH
Remanence of PM 1.3 T
Magnet wire diameter 0.8 mm
Area of each stator slot 190.5 mm2
Worm-wheel gear ratio gr 60

5.2 Typical WDA operating performance

(2.4) states that a force fi acts tangentially on the wheel when there is a displacement
between the worm and wheel. This relationship is shown in Fig. 5.1. Therefore, FEA was
used to estimate values for fi for initial displacements of i = 0.6, 1.0, and 1.5 degrees.
The following conditions apply: peak current = 3 A, wheel speed = 50 rpm, and worm
speed = 3000 rpm. Fig. 5.5, Fig. 5.6 and Fig. 5.7 show the tangential forces acting on
the wheel. This force is observed to have ripples. However, its average value still conforms
with the expected value from the graph of Fig.5.1. The ripples are attributed to the use
of arc magnets instead of helical-shaped magnets. This decision was simply informed by
cost and the results so far look adequate for the first prototype.
Torque on the worm due to motor action is found to have ripples. However, its average
value remains constant, independent of worm speed and initial wheel angular displacement
or tangential force. Fig. 5.8, Fig. 5.9, and Fig. 5.10 show worm torque for dierent angular
displacement of the wheel. Using (2.1), results of Fig. 5.5, Fig. 5.6, and Fig. 5.7 were used
to calculate active wheel torque and potential worm torque (responsible for the presence
of wheel tangential force). Fig. 5.11 is a graph of wheel torque vs. worm potential torque.
This is eectively a gear ratio curve (specified in Table 5.1).

26
 60

40

20
Force [N]
0

-20

-40
Stator
Wheel
-60 Worm
0 50 100 150 200 250
Angle [deg.]

Figure 5.5: fi for i = 0.6 deg.

100
80
60
40
20
Force [N]

0
-20
-40
-60 Stator
-80 Wheel
Worm
-100
0 50 100 150 200 250
Angle [deg.]

Figure 5.6: fi for i = 1.0 deg.

27
 150

100

50
Force [N]
0

-50

-100 Stator
Wheel
Worm
-150
0 50 100 150 200 250
Angle [deg.]

Figure 5.7: fi for i = 1.5 deg.

1.5

0.5
Torque [N.m]

-0.5

-1 Stator
Wheel
Worm
-1.5
0 50 100 150 200 250
Angle [deg.]

Figure 5.8: r for i = 0.6 deg.

28
 1.5

0.5
Torque [N.m]
0

-0.5

-1 Stator
Wheel
Worm
-1.5
0 50 100 150 200 250
Angle [deg.]

Figure 5.9: r for i = 1.0 deg.

1.5

0.5
Torque [N.m]

-0.5

-1 Stator
Wheel
Worm
-1.5
0 50 100 150 200 250
Angle [deg.]

Figure 5.10: r for i = 1.5 deg.

29
 Table 5.2: Estimated WDA parameters.
Spring constant Ks 91, 514 N/m
Slot fill factor 0.13
Number of turns 50
Phase inductance L 3.507 mH
Lq = Ld 5.261 mH
Phase resistance 1.45
Calculated fi 106.97 N
fi from FEA 100 N
Phase flux linkage m 0.035 Wb
FEA estimated torque constant K 0.3 N.m/A
Calculated torque constant K 0.3129 N.m/A
Maximum current density 6 A/mm2
Estimated maximum current 3A

5
4.5
4
Wheel torque [N.m]

3.5
3
2.5
2
1.5
1
0.5 Wheel-worm torque ratio
data point
0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
Worm potential torque [N.m]

Figure 5.11: Wheel torque vs. worm potential torque.

30
Chapter 6

Techniques for the manufacture of

WDA prototype

This is a novel actuator, therefore, it has custom parts that require special techniques
for manufacture. In order to reduce cost, instead of using helical magnets the authors
designed approximate arc magnets for both the worm and the wheel. Table 6.1 lists parts
and components required for full assembly of WDA. The following are brief notes on each
custom part.

6.0.1 Stator core

Making this part posed quite a challenge, owing to its curved shoes. This curvature is
important in order to maintain uniform air gap between the stator and the worm. It
could not be manufactured as a whole. Therefore, the shoes and the main core were made
separately. Afterwards the shoes were attached to the main core with adhesive. See Fig.
6.1 and Fig. 6.2.

6.0.2 Stator insulation

Stator insulation is needed to prevent scraping of the magnet wire insulating varnish and
consequent shorting of the circuit on contact with other wires or the core. Nomex paper
is used as insulating material for the stator core.

6.0.3 Stator windings

A 0.8 mm diameter magnet wire was used to make the coils. Each coil has 50 turns. This
is just over half the number of turns estimated by calculations. Therefore, the eective
slot fill factor is approximately 0.13 for each coil side.
Each coil was wound on a coil form (Fig. 6.3) and then transferred to the appropriate
slot on the stator core. Attempts to wind the coils directly on the core limited the number

31
Figure 6.1: CAD models of full stator, main stator (without shoes), and stator shoe.

Figure 6.2: Manufactured stator.

32
 Table 6.1: List of WDA parts and components
S/N Item Quantity
1 Stator core 1
2 Stator insulation -
3 Stator windings -
4 Worm magnets 64
5 Worm yoke 2 halves
6 Worm bearings 2
7 Worm shaft rings 6
8 Worm shaft 1
9 Wheel magnets 118
10 Wheel yoke 1
11 Wheel bearings 2
12 Wheel shaft rings 6
13 Wheel shaft 1
14 WDA frame/cover 2 halves
15 Wheel encoder flange 1
16 Wheel rotary encoder 1
17 Worm rotary encoder 1
18 WDA mounting base 1

Figure 6.3: 3-D printed form for winding coils.

of turns for each turn. Fig. 6.4 shows the stator core containing the windings. Fig. 6.5
shows the windings layout. Table 6.2 shows measured resistance and inductance values of
the stator windings. The inductance (measured with LCR meter at 1 kHz setting) was
measured after the worm has been mounted. Compare these values to the one obtained
from calculation; 3.507 mH. It would have been helpful to also compare them with phase
inductance value estimated from FEA. However, the FEA model has a much larger overall
air gap length and area. Therefore FEA inductance is about 3.3 times larger (11.67 mH)

33
than actual measured inductance.

Figure 6.4: Stator core containing phase coils.

Figure 6.5: Stator windings layout.

6.0.4 Worm and wheel magnets

Fig. 6.6 and Fig. 6.7 show samples of worm and wheel magnets, respectively. As mentioned
earlier, the reader would see these are regular arc magnets. Worm magnets would be placed
in the grooves of worm yoke and held in place with epoxy adhesive. Likewise, wheel magnets

34
 Table 6.2: WDA stator measured parameters
Phase Resistance (ohm) Inductance (mH)
U 1.49 3.503
V 1.39 2.826
W 1.40 3.413

will be bonded to the curved surface of the wheel. Gauss meter was used to measure the
magnetic flux density (open circuit measurement) as 0.45 T. It is expected that actual flux
density (closed circuit measurement) will approach the theoretical 1.3 T mark.

Figure 6.6: Worm magnet.

Figure 6.7: Wheel magnet.

35
6.0.5 Worm yoke
This is made of silicon steel (MES3F). The grooves are made to act as receptacles for
worm magnets. They also guide the placement of each magnet. Unlike a cylinder, the
worm cannot be placed in its appropriate position through one flat side of the stator core.
Therefore, it has been divided into two halves to make placement possible. The grooves on
the worm yoke were cut using the CNC milling machine in the laboratory. Fig. 6.8 shows
CAD model and the manufactured yoke. Fig. 6.9 shows the two halves of worm yoke
mounted on worm shaft. Fig. 6.10 shows the two halves of worm yoke with the magnets
bonded to the grooves.

Figure 6.8: CAD models of worm yoke and the manufactured yoke.

Figure 6.9: Worm and shaft assembly.

36
Figure 6.10: The two halves of worm yoke with magnets fixed and bonded to the grooves.

6.0.6 Wheel yoke

This has the same material as the worm yoke. The round side is appropriately curved to
fit the wheel magnets. Like in the stator core, the curvatures are necessary to maintain
uniform air gap. After it was supplied by the manufacturer, the hole was expanded to fit
its shaft and hole for machine key was cut at the university machine shop. Fig. 6.11 shows
the manufactured and assembled wheel yoke and its shaft. Fig. 6.12 shows the wheel yoke
and the magnets bonded to its curved surface.

Figure 6.11: Wheel and shaft assembly.

6.0.7 WDA frame/cover

The frame/support is made of aluminum. Each half was produced by CNC milling of
aluminum block. Fig. 6.13 shows CAD models of WDA full assembly and left half of

37
 Figure 6.12: Wheel yoke with magnets fixed and bonded to its curved surface.

its frame. Fig. 6.14 shows the manufactured left half WDA frame while Fig. 6.15 shows
assembly of both halves. Fig. 6.16 shows an almost complete assembly of WDA. The setup
on the right consists of the inverter and controller units.

Figure 6.13: CAD models of WDA full assembly and left half frame..

38
Figure 6.14: Manufactured WDA left half frame.

39
 Figure 6.15: Assembly of the manufactured WDA left half and right half frames.

6.0.8 Measured back emf

Fig. 6.17 shows the back emf recorded on an oscilloscope by manually turning the worm of
WDA. The period of the waveform estimates a speed of 430 rpm. Compare the waveforms
to those from FEA; Fig. 6.18. Peak voltage for both cases is about 5 V.

40
Figure 6.16: Assembled WDA (left) and inverter/controller unit.

2
Back emf [V]

-2

-4 U
V
W
-6
-0.16 -0.14 -0.12 -0.1 -0.08 -0.06
Time [s]

Figure 6.17: Back emf recorded by manually turning the worm.

2
Back emf [V]

-2

-4 U
V
W
-6
0 0.01 0.02 0.03 0.04 0.05 0.06
Time [s]

Figure 6.18: Estimated back emf from FEA.

41
Chapter 7

Summary and future work

7.1 Summary
The aim of the research work documented in this thesis is to develop the first prototype
of a novel radial flux direct drive PM worm drive actuator. The basic theory supporting
WDA is the concept of magnetic screw. This has been explained in Chapter 2. Mechanism
of operation of WDA is also explained there. Preliminary FEA of both the linear model
of WDA and ideal model of WDA both test and confirm the merits and feasibility of the
proposed device. These are contained in Chapter 3.
Chapter 4 contains detailed mathematical analysis and modeling of WDA. The equa-
tions obtained are used to estimate relevant parameters of WDA. The results obtained are
compared with those of WDA. However, when the prototype is tested, these results may
dier from measured values from the WDA testing. Reasons for the this include manufac-
turing errors, and the fact that calculations and FEA results were obtained with almost
ideal models of WDA.
Chapter 5 presented important design considerations taken into account in order to
design the first WDA prototype. The most important decision made was using regular
arc magnets instead of ideal helical magnets. The reader must have seen the estimated
results and parameters obtained. Finally, Chapter 6 briefly provides some notes on the cus-
tom parts designed and manufactured in our laboratory and the university machine shop.
However, parts like the stator and magnets were manufactured by third-party contractors.
Presently, all parts needed to put up a full assembly of WDA have been manufactured
and/or procured.

7.2 Future work

The following are the remaining tasks to be completed in the course of this project.

Setup, installation, and connection of WDA prototype to the power inverter unit and
controller unit.

42
 Test running the WDA prototype and measurement of parameters.

Control system design and application of basic position control for the WDA. Other
kinds of control schemes can then be implemented afterwards.

43
Bibliography

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[2] I. A. Smadi, H. Omori, and Y. Fujimoto, Development, analysis and experimental

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[3] B. Andrews, Magnetic screw, U. S. Patent 1 562 730, Nov. 24, 1925.

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[5] J. Wang, K. Atallah, and W. Wang, Analysis of a magnetic screw for high force
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[6] S. Kikuchi and K. Tsurumoto, Design and characteristics of a new magnetic worm
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[9] D. C. Hanselman, Brushless Permanent Magnet Motor Design. Lebanon, Ohio: Magna
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44
 Related publications

O. Efobi and Y. Fujimoto, Design considerations for a radially magnetized perma-

nent magnet worm drive actuator, in Proceedings of the IEEE/ASME International
Conference on Advanced Intelligent Mechatronics, Busan, Korea, 2015, pp. 1303-
1308.

O. Efobi and Y. Fujimoto, Design, analysis, and performance estimation of a novel

worm drive actuator, in Proceedings of the 2nd IEEJ International Workshop on
Sensing, Actuation, Motion Control, and Optimization, Tokyo, Japan, 2016.

45