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Motors: Past and Future
I was looking through some Chief Delphi threads for history on how the FRC technology has developed over the years and I noticed that the motors have not changed much in recent time.
How long has the CIM ben around? I noticed that there was a Bosch drill motor from years ago, why did they discontinue it in FRC? Do you think there is room for a new company to develop motors and improve upon what has already ben proven over the years? |
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The CIM has been around since 2002, and four were first legal in 2005, making it practical for robots to use CIMs exclusively for drive motors.
I wasn't around then, but from what I hear drill motors stopped being used because they tended to blow up in situations where CIMs do not. There's certainty not much that can be done to surpass the CIM for outright durability. Perhaps lighter or more efficient motors could be developed, but reliability under non-optimal conditions is what makes for a great FRC motor, and the CIMs are phenomenal at this. |
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There's definitely room for more motors. I could see stepper motors coming in at some point.
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There has certainly been plenty of new motors introduced over the years. The MiniCIM and BAG motor were introduced in 2013. The AndyMark motors were not much before that. The throttle motors have only been around since like 2010, iirc (but nobody uses those anyway). The 775 banebots motors have only been around since 2011 or 2012 (don't remember when they first introduced the 550, but it was around the same time I think). Not to mention several useful motors have been discontinued in the past decade, namely the globe and fisher price motors (not to mention the significant variations between different FP model numbers).
Very few motors are developed for FRC specifically (I think the two VexPro CIM variants being the only ones). More often, FRC-suppliers develop gearboxes to integrate with them (namely the CIM-size or 500 series motors). In some cases, namely with AndyMark, they are reatiled as gearmotors with these gearboxes affixed as a standard COTS item. Honestly, if anything, I kinda yearn for the days of fewer high powered motors. The drivetrain arms race is getting ridiculous, and now you don't even have to sacrifice motors from elsewhere on your robot to compete. Scarcity isn't really a factor in designing with motors anymore. I'm not sure if that's a good thing or not, but my personal nostalgia biases me. |
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Personally I wish the motor rules were:
6 - Cims 4 - MiniCims Unlimited Bags! No need for any new motors. |
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They're more power dense, which can be utilized if teams understand the failure mode from heat. They're good for high bursts of power (like a 2013 shooter spinning up) with intermittent low load between. |
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The 550s were useful in 2013 when we needed a lot of speed. |
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Using 8 BAGs vs. 8 550s (4 competition bot + 4 practice bot) is a difference of $148. |
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I'd like to see a motor that was a little more powerful than the 775 but packaged the same way, so that it could be used instead of the CIMs for drive. The reliability of the CIMs is great, but they're really heavy compared to a 775, and not that much more powerful.
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Since drivetrains often experience stall or near-stall conditions, it's important to have a motor that can survive stall or near-stall heating. Fan cooled motors are a poor choice for this (thus why so many Bosch drill motors failed back in the day). As a result, you need the additional mass to help these motors survive in a drivetrain. Of course, if you were to install some other cooling system this could be worked around, but I'd venture that the additional mass and space of the cooling system would outweigh the benefits. I don't think you're going to get your wish. |
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The only improvement I could scrounge up about the CIM that would be quite beneficial was improving the heat release (body conducted heat away from the brushes faster/possibly incorporated a better heat sink, to make the motor more than just a 10% On 90% Off, perhaps up to a 50/50 or continuous duty without aftermarket passive or active cooling
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My "dream" lineup for motors, current and past:
--CIMs (and variants--big, mini, bag), any combination but no more than 6 (Awright, quit complainin', 7). --775s, 550s and the old FP motors (which were very similar), no more than 2 (maybe 4). --Up to two Globe motors (need to specify allowed configurations, but those were very nice motors for light duty that was tough). --Window and van door motors, no more than 4 total. For the right applications... --Unlimited servos and VEX motors/servos (increase power on servos, though!) --Additions: 2x brushless motors with speed controllers (restricted power/size, though, at least at first). The big thing here is that brushless motors are also known for not liking stalling, which would probably need to be pointed out to the teams. |
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Just one point to add: power available from a motor falls off rapidly as the internal parts (i.e., brushes, armature windings, and magnets) get hot. This happens faster if the motor is smaller -- so even if a fan-cooled (e.g., 775) motor is nominally rated for more peak power than a totally enclosed non-ventilated (TENV) motor like a CIM, the TENV motor will deliver more power in all but the most intermittent of applications. Bottom line: stick to CIMs for your FRC drivetrain (duh). |
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With the available current monitoring feature on next year's PDB, stalled motors can easily be detected. It is true that a 775 will burn up quickly when stalled at 12V, but it can last a significant amount of time at 6V. A minicim weighs 1.5 lbs more than a 775, and is less powerful. Given 1.5 lbs, I could add a decent heatsink and fan to a 775 for roughly the same total cost, and have more power. Also, a more powerful 775 would be really useful in climbers/hangars, where you (ideally) never stall. |
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I like the way things are now. The only improvement I could see would be to use SSS-5940 10kw brushless motors in place of cims (they are the same size). :P
Oh, and raise the main breaker limit to like 600 amps. |
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I'd love to see brushless motors.
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Jason |
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I'd love to see some brushless motors as well.
I'm not allowed to give any details at all at this point, but I know of a pretty big company looking at donating some pretty good motors to the KOP and FIRST Choice for next season. Only time will tell how substantial the introduction of these motors will be in the field of FRC. |
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The voltage drop on the lead-acid battery over time might also be too much for ESCs. ESCs are actually pretty cheap. Because they are often just SMD parts, I've noticed even cheap ones from places such as ebay work just fine due to the lack of manual work. If you wanted US-made ones though it could cost a bit more. They are usually cheaper than the controllers we use though. |
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They really wouldn't be much better than brushed motors, just more efficient. Since most of those drives are sensorless in the affordable price points, teams would see issues with cogging as most wouldn't know how to properly size them. Most of the lower cost controllers handle direction change awful as well, and would only be suitable for flywheels, etc... The true benefit of brushless motors for FRC would be when we get current control, which is a higher price point controller. We could do some REALLY cool control stuff at that point though, very smooth motion. If hobby grade brushless motors became available for FRC, it's unlikely we would use them (reliability, the potential cogging issue). I reserve the right to change my mind after testing though. If anything we'd reserve them for applications that never see high stall loads and we can take advantage of their high power and efficiency in the faster range. |
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Power density might also help. The SSS 5940, which I was looking at for a go kart, has exactly the same dimensions as a cim, but it has a peak rating of 10000 watts versus the cim's 1600. I'm not sure if that's just the motor specifically or a property of all brushless motors. Well, it has a stall current of 180 amps, but a voltage capacity of around 60v. What is cogging? I've never heard that term before. |
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That 10kw number is likely peak electrical, MOST cheaper brushless motors (RC grade stuff) is vastly overrated in power because they spec peak electrical power, and the motor would burn up at that operating point anyway. As you pointed out, this big power comes at higher voltage in most cases. You won't find an RC grade brushless motor at 12V pushing more than 1kw (if that) commonly. If we were to go to brushless, I think the right move would be a custom controller adapted from industry to be cost effective, and possibly a modified RC brushless motor that is fully sensored. Industrial brushless motors are just too expensive for FRC currently. |
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https://fbcdn-sphotos-e-a.akamaihd.n...304680_o.j pg :cool: |
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In the RC community the word cogging is used, and it's a misnomer. It refers to a non-sensored motor being able to start due to the static load being too high. These ESCs generally chase through the phases and assume the motor starts then measure back EMF to com mutate after. If the motor was sensored and properly communicated through this time it'd be capable of starting. The actually definition of cogging is the torque ripple from the specific arrangement of the magnets. |
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If you want more information check out: http://www.instructables.com/id/Chib...iature-Electr/ |
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Going back into my mental archive, CIMs were first in the 2004 KOP. The 2003 KOP was the first "KITBOT" chassis with the large aluminum tubes and still had the drill motors because of the funky injection molded black plastic drill motor mount.
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I'm not sure about before 2003 since I wasn't on the team before then and they weren't on the previous year's robots my team had built. |
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Isn't the "Chiaphua motor" the CIM by a different name? I seem to recall seeing CIMs referred to by this name in a lot of older documents, like Dr. Joe's "Nothing but Dewalts" paper, for example.
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Here is the debate from 2003. http://www.chiefdelphi.com/forums/sh...ad.php?t=21339 Anyone still calling them Atwood motors? |
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I'd forgotten about that.
Here's the 2001 KOP checklist. Please check it, but I don't see the Chip listed. 2001 |
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Back in the day we called them "Chalupas". Please remember that these are designed as intermittent duty motors for lifting trailer tongues onto hitches. They are sealed to provide some weather proofing. The drill motors were discontinued because they were replaced with another design.
Magnets, Rich is a motor guy by day and my motor reference person. when he speaks, listen. I am thinking we ran two CIM and two FP motors on that drive system. They were obviously geared differently. At that time, both the drill and FP motors suffered from low RPM, high current designs. What complicated things, as the temperature began to rise, the fan actually fell off the shaft or simply melted. Then it was a simple matter of thermal runaway. For some reason, drill motors also had a nasty habit of emitting flame when they failed. |
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Since they've been brought up, how well do brushless motors work at stall torques and low RPMs?
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Sensored industrial brushless motors work great. |
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And there have been instances of lower cost, higher production quantity brushless permanent magnet motors -- their application in automobile power steering systems is a good example. That application first went to serial production more than fifteen years ago, and is now made by several of the world's most capable suppliers. For many years I have thought that the FRC kit of parts is one of the best showcases for introducing new components with good potential to displace legacy technologies. Low cost brushless motors and their associated controllers have that potential. ---- @Michael: motors are electromechanical devices. Their proper operation requires containment of BOTH smoke and noise -- if either of these escapes the motor, bad things happen. ;) |
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Have any of you used the snowblower motor this year? I saw that it was added, but I hadn't heard much about it.
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It seems that many teams chose other motors since only one snowblower motor was allowed. I did inspect some robots with the motor, but I would put it in the less than 5% range.
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Snow blower motors. We all should clearly absolutely totally use those.
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First Post
Ok, so I have gone through the search for over 20 mins and have also read last years rules and I cannot find where it prohibits using a DC/DC converter to raise the voltage to 18vdc to run a RS-775-18 at 18vdc. Wouldn't this be covered under custom circuits? Whether or not that would be advisable is a different question. Thanks in advance for your patience ;) |
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The PDB will only supply 40A (at 12 volts) to a motor, or the individual breaker will reset. That means that only 480 electrical watts can run through your motor anyways. Stepping up the voltage to 18V drops your maximum amperage to just 26.6 amps. I haven't looked at the specific motor torque/rpm/current curves, but barring inefficiency, they can only operate at the same maximum power |
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Raging,
R53 CUSTOM CIRCUITS shall not directly alter the power pathways between the ROBOT battery, PD Board, motor controllers, relays, motors, or other elements of the ROBOT control system (items explicitly mentioned in R64). Custom high impedance voltage monitoring or low impedance current monitoring circuitry connected to the ROBOT’S electrical system is acceptable, if the effect on the ROBOT outputs is inconsequential. |
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Operating at higher voltage makes the motor much more efficient. The output shaft mechanical power at 18 volts and 26.6 amps is much greater than the power at 12 volts and 40 amps. |
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There's also the question of motor speed. To get the higher output mechanical power, the motor would be operating at a higher speed, thus (potentially, depending on the application) requiring another stage of gear reduction with the attendant additional inefficiency. But the point is, the RS-775-18 was designed for 18 volts, and it is far more efficient at that higher voltage. |
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Ether
Thank you for that document. That is exactly why I was thinking about this. V=IxR. So if the voltage increases the amps go down. Less heat, more efficient and as shown more power. But from reading the rules a bit closer it appears it is a no no. Thanks for all of your help:) |
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I concur that there is plenty of leeway in the breakers before they pop. |
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So why allow an 18v motor if we can't effectively use it???
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Making your own would just be a coupld $2 transistors rated for 60+ amps, a heatsink, and a large inductor. The inductor would be the hardest to source, as high-current high-inductance coils are expensive. It wouldn't need to be adjustable as long as the motor controller can support the voltage, as you can place the controller after the boost converter. |
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Of course, a continuously running mechanism that is also likely to stall should be powered with a CIM rather than a 775-18. |
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Ok
So I have read every word in the Motor section, power distribution and command and control, command & signals system from last years rules and NO where does it expressly prohibit an 18vdc motor being ran by 18vdc. If someone can find any differently I would be surprised. Here is the caveat that I feel would allow it. 4.8.10 R40 Any active electrical item not explicitly listed in R29 or R67 is considered a CUSTOM CIRCUIT. CUSTOM CIRCUITS may not produce voltages exceeding 24V when referenced to the negative terminal of the battery. Since R29 references the motors it does not apply to custom circuits. Also the speed controllers are rated up to 30vdc so they can handle 18vdc Whether or not this is feasible/recommendable etc etc is a different question. I am only after the legality of the question right now. |
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And yes, this booster IS a custom circuit. R29 is the motor list. R67 covers the Jaguar/control system interface. A voltage booster is not listed in either. You can also reference the definition of Custom Circuit--no voltage booster listed, therefore, it's a custom circuit. Because it's a custom circuit, it cannot alter the power pathways. I would consider boosting the voltage, either before or after the speed controller, to be an alteration of the power pathway, and thus illegal. |
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Basically, unless a CUSTOM CIRCUIT is also a non-functional decoration, it can only be an input*.
*Under the 2014 rules. |
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Hopefully things will change in 2015. Seems a shame to have the ability for an 18vdc motor and not use it to its full potential:(
Thanks for all of your help. Cheers :D |
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Back in 1996 we used to play with 12V drill batteries, two to a 'bot IIRC. The step up to the 12V sealed lead acid UPS/scooter batteries came a few years later. The average FRC robot today is much more powerful, and much more robust, compared with those early years. Is the FRC ready for another step up in electrical storage? |
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Get a battery company to donate enough 12V 25~30Ah LiFePO4 batteries for every team to have at least 4 and I don't think FIRST will have any choice but to change batteries**. *2013 & 2014 rules. **This applies to any electronic component you want to use. If enough is donated, the GDC will make it legal. |
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All that adding more motors will do increase the energy available to each bot, causing more damage and collisions and safety concerns. As it stands, we have enough motors to drive about as fast as a driver can handle. Main breaker blows are the exchange for that kind of speed. Making it bigger would make drivers drive more dangerously. |
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the motor must be designed to operate at the higher voltage and speed. the RS-775-18 is designed to operate at 18 volts, and the speeds associated with that higher voltage. can the same be said for the 12V FRC motors? who knows. |
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But I strongly suspect that CIM motors, which are designed for 1000 hours mininum life when run at ~17% duty (3 minutes on CW 2 sec off 3 minutes on CCW 30 minutes off, repeating) with 64 oz-in load torque and 12V supply, would not survive that long if tested the same way at 18V supply. Maybe the reduced life would be sufficient for FRC application. I wonder if CCL can be induced to provide life test data for the CIM at 18V? |
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Power management is a good exercise in proper engineering. Just because we have 30 motors available to us doesn't mean we should use 30 motors. A limited supply of electrical energy forces teams to budget their available energy. Just another challenge. DL |
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