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Investigating static and dynamic characteristics of electromechanical actuators

(EMA) with MATLAB GUIs

Article  in  Computer Applications in Engineering Education · June 2009

DOI: 10.1002/cae.20279

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Investigating Static and
Dynamic Characteristics
of Electromechanical
Actuators (EMA) With
MATLAB GUIs
GURSEL SEFKAT
Faculty of Engineering and Architecture, Mechanical Engineering Department, University of Uludag, Bursa, Turkey

Received 30 January 2008; accepted 21 August 2008

ABSTRACT: This paper deals with the design of an electromechanical device considering
some prescribed performance requirements, and static and dynamic analysis of this device are
carried out. In studying the transient response of such a system, as part of dynamic analysis,
two methods mostly used finite element method (FEM) and finite differences method (FDM).
However, these methods need much CPU time. In this work, a computer simulator program is
developed for an EMA. This technique is implemented in the MATLAB-Simulink environment
and tested for different design tasks such as electromagnetic valves or electromechanical
brakes etc. Furthermore, by using GUIDE tools within MATLAB, a simple useful and user-
friendly GUI structure is developed to provide a visual approach to design and analysis
process. ß 2009 Wiley Periodicals, Inc. Comput Appl Eng Educ 18: 383
396, 2010; Published online in Wiley
InterScience (www.interscience.wiley.com); DOI 10.1002/cae.20279

Keywords: EMA; system dynamics; static and dynamic analysis; MATLAB and MATLAB/GUIs

INTRODUCTION which limited stroke, on/off mechanical movements

Electromechanical actuators are widely used as
switching actuators. They are simple in construction,
rugged, and relatively cheap to produce. They can be
found in many industrial and domestic apparatuses in
Correspondence to G. Sefkat (sefkat@uludag.edu.tr).
ß 2009 Wiley Periodicals Inc.
are required.
Modern applications like cars or control devices
use faster and faster acting and low energy actuators,
which are manufactured in high quantities. Most of
them are electromagnetic actuators that are applied up
to the limits of their capacity. Simulations shorten the
development times of product because they reduce the
number of necessary prototype cycles and they

383
384 SEFKAT
enlarge the parameter spectrum. The simulations have
to become more exact because of lower tolerances
and apply of the actuators at their limits. Another
modern trend is the development of the mechatronic
systems. Different physical effects have to be often
considered simultaneously. Especially at high inte-
gration the functional parts influence each other. That
is why the simulation must allow modeling all parts
together.
Electromechanical devices are often used as
actuators in modern mechatronic systems. They play
a crucial role in the design of these systems such as
injection and braking systems in automotive industry.
Due to increasing demands on the accuracy of these
systems, the switching times of electromechanical
devices must be very small in order to guarantee
the desired performance. The dynamic behavior of
electromechanical actuator shows a highly nonlinear
characteristic due to the nonlinear properties of the
electrical, magnetic and mechanic subsystems. This is
crucial for a wide range of operation. Therefore, in the
design of electromechanical actuator the dynamic
behavior of the magnetic flux through the armature
must be taken into account.
Among the numerous papers on these subjects
some representatives are mentioned in what follows:
In Ref. [1], the design of switching valves with single
and double discs is investigated, and its electro-
magnetic and fluid characteristics are also obtained.
The optimum design of EMA is treated in Ref. [2].
Furthermore, in the same work, it is shown that EMA
is better than mechanical systems regarding system
dynamic performance. The characteristic of pilot
valve with single disc are obtained in Ref. [3]. The
authors of Ref. [4] developed a method for simulation
taking reluctance of electromechanical device’s
dynamic performance into account. Ref. [5] deals
with the using area of electromechanical device, their
characteristics and control. Characteristics and control
of a solenoid valve used in a medical device is studied
in Ref. [6].
Figure 1 Schema of electrical, magnetic and mechanicals subsystems showing basic subsystem
interrelationships.
EMA consist of three distinct and sometimes
strongly coupled subsystems, namely the electrical,
magnetic and mechanical. Figure 1 schematically
illustrates the basic interrelationships among these
three partially represented by the interconnecting
lines; for example the rate of chance of flux leakage,
dl/dt, is not only a function of magnetic subsystem
parameters but also is a function of the armature
position x, the armature velocity dx/dt, and time
derivative of the coil current di/dt. The armature
acceleration, however, is determined by the magnetic
and external forces, which are, in turn, functions of the
armature position, armature velocity, electric current,
and other variables. Clearly, the overall system
behavior is not solely defined by simple expressions
describing the internal behavior of individual,
isolated subsystems [7]. In the following sections,
the governing equations for each of the subsystems are
developed and the coupling between these subsystems
is shown explicitly.
The developed programs are sometimes com-
posed of the graphical user interfaces (GUIs), which
are suitable for the present operating system and make
the programs easy to use. Some languages have GUIs
development package together with their software
such as VISUAL Cþþ, VISUAL BASIC. However,
these languages confine engineering capabilities and
thus, one is interested in package programs such as
MATLAB, MATRIXx. Some researchers have recog-
nized the advantages of these software packages, as
is seen from the previous research [8
11]. This
numerical software also takes a substantial part in
many textbooks [12
14].
In this paper, a computer simulator program for
the design and analysis of a typical (disc, plunger)
electromagnetic actuator is developed. This work
differs from the above mentioned works in that the
technique is implemented in the MATLAB-Simulink
environment. The capability of the technique is shown
in the example of designing a magnetic actuator that
will be presented in the remaining of the paper.
 STATIC AND DYNAMIC CHARACTERISTICS OF EMA
THE DESIGN OF EMA
Magnetic attraction force characteristics of various
types of magnetic circuits differ from each other. The
disc types of magnetic circuits are intended to produce
large force acting through a relatively short stroke
[15]. They are characterized by having a magnetic
circuit of extremely short length and large sectional
area with two working gaps. These gaps, magnetically
in series, are mechanically in parallel and hence
produce a large effective holding surface area. Hence,
in this work, this type of magnetic circuit has been
chosen to design and to study static and dynamic
behavior.
As seen in Figure 2, general structure of an EMA
comprises a core known as moving pole and a
motionless pole including winding circuit. Core and
pole is made from ferromagnetic material. Magnetic
force provided by electric current in winding attracts
core toward pole. Moving part of any device can
easily be controlled by this force.
Force Equation
The magnet must exert an assigned minimum force
throughout an assigned stroke. The magnetic attrac-
tion force between the moving element and the pole,
depending on the variation of the magnetic flux
density, Bh (Wb/m2) in the air gap can be defined as
follows:
z B2h A
Fm ¼ ð1aÞ
2 m
Also depending on the current I applied to the coil and
the distance x between the moving and the stationary
element, the magnetic force can be defined as
mAðNIÞ2
Fm ¼ ð1bÞ
2zðxh
xÞ2
Figure 2 Geometry of EMA (a), electrical model of EMA (b).
385
where z is the number of the working gap (z ¼ 2), A
the effective cross sectional area, xh the total moving
distance, N the number of the turn, m the permeability
of the air gap (4p10
7 H/m). In Equation (1a), the
magnetic saturation is taken into account whereas this
situation cannot be seen explicitly in Equation (1b). In
fact, the variation of the flux density of the air gap
depends on the variation of the distance of the air gap.
Consequently, the effects of electrical voltage applied
to the magnetic circuit and the variation of the air gap
on the magnetic attraction force can be seen more
clearly in Equation (1b).
Magnetic Circuit Equation
The exciting magneto motive force NI, which must
provide the flux required for the given force and
stroke, is determined by the magnetic circuit equation.
This equation is of the following form,
B h xh X
NI ¼ z þ Hi li ð2Þ
m
where z(Bhxh/m) represents the magneto motive force
a density of Bh across
necessary to establish the flux atP
an air gap of length xh, and Hili represents the
magneto motive force necessary to establish the flux
in the iron parts of the circuit and Bh ¼ f(x,i) is the
useful air gap flux density, xh is the total air gap that
includes holding gaps and traveling gap.
Heating Equation

2
r NI
y¼ ð3aÞ
2kf2 ðr2
r1 Þ r4
where y is the final temperature rise of the coil, k the
heat dissipation coefficient, r the specific resistance
for wire, and f2 the space factor which take a standard
value depend on wire diameter [17].
386 SEFKAT

Figure 3 Flow chart for static (a) and dynamic characteristic (b) of electromechanical device.

The coil must have such sectional area and heat-

4rðr1 þ r2 ÞNI
conduction surface as to keep the temperature rise E¼ ð4Þ
within an assigned limit. This equation, which is dt2
depending on sizes given Figure 2, can be defined as where E is the assigned coil voltage (r1 þ r2) the mean
follows [16]: diameter of a turn on the coil winding, and dt is the
rpðr1 þ r2 Þ bare wire diameter.
y¼ ðNIÞ2 ð3bÞ
kAtr ðr4
2mk Þðr2
r1
mk Þf2
where Atr is the surface field for heat transfer, mk is the
coil wall thickness.

Voltage Equation
By applying the Ohm law to resistant equation
including specific resistance, this equation can be
obtained as follows: Figure 4 Simulink model of EMA for dynamic analysis.
 STATIC AND DYNAMIC CHARACTERISTICS OF EMA 387

Figure 5 Submodel for magnetic circuit.

In the four formulas Equations (1)
(4) listed the
following items are usually given in the design data;
Fm is the required force, xh the length of the air gap or
stroke of the magnet, y the required temperature rise,
and E the assigned coil voltage. Of the other design
items, some vary between only very narrow limits
and, hence, can be assumed for the purposes of the
preliminary calculation; the remaining ones must be
evaluated from the equations [17].
At this stage, the electromagnetic dimensions that
depend on produced magnetic force for a constant air
gap are determined. Considering the electromagnetic
device characteristics such as magnetic losses,
saturation of iron material, permeability expression,
and different air gaps in magnetic circuit makes the
design and analysis process more difficult. Therefore,
numeric analysis methods should be employed for this
kind of detailed calculation. Thus, force-displacement
curves that represent static characteristics of electro-
magnetic device will be obtained depending on sizes.
STATIC CHARACTERISTICS OF
FLAT FACE EMA
The mathematical expression of the magnetic force
exerted on this by coil is given in Equation (1a) for
z ¼ 2. The design process can already be started with

Figure 6 Submodel for permeability.

388 SEFKAT

depend on disc displacement, are given by empirical

equations (6) containing flux path sizes and other
sizes [17].
The inner pole fringing permeability is:


r2
r1
Pfi ¼ 3:26m0 r1 þ 4m0 r2 ln ð6aÞ
pxh
The outer pole fringing permeability is:
Figure 7 Submodel for mmf in iron part.

r1
this equation. Giving the magnetic force desired the Pfd ¼ 1:63m0 r3 þ 2m0 r3 ln 1 þ
xh
required cross-section area of the core; hence the core
 ð6bÞ
r2
r1
radius r1 is obtained vie Equation (1a). Then optimum þ 3:26m0 r2 þ 4m0 r2 ln
EMA sizes (Fig. 2) are found considering the pxh
following constraints [16,17]. The useful gap permeability is:
r4 pm0 r12
3 4 Puh ¼ ð6cÞ
r2
r1 ð5Þ 2xh
r12 ¼ r32
r22 ¼ 2r1 r5
The total effective permeance through the armature
where r4 is determined by Equation (3a). Thus, mean between inner and outer pole core is:
flux path sizes lk, ly, and ld are obtained. Then, the
1
permeability which is needed to calculate the flux Pa ¼ ð6dÞ
produced in various parts of magnetic circuit, which ð1=ðPug þ Pfi ÞÞ þ ð1=ðPug þ Pfd ÞÞ

Figure 8 Submodel for coil-disc movement.

Figure 9 Submodel for condition with real state.

 STATIC AND DYNAMIC CHARACTERISTICS OF EMA 389

Finally, the leakage permeability between pole cores

is:


ðr1 þ r2 Þ ðr1 þ r2 Þ pxh
P1 ¼ m0 1:57r4
1

ðr2
r1 Þ 2 ðr2
r1 Þ
ð6eÞ
Using relation ships just given above, flux density
equations for different parts of circuit are obtained as
follows.Flux density in air gap:

Puh
Bh ¼ ð7aÞ
Pa þ P1
Flux density in disc:
Pa
Bd ¼ Bh ð7bÞ
Puh
Flux density in core pole:
2 P1
Bk ¼ Bd þ B h ð7cÞ
3 Puh
According to flux density values, H values are
calculated by interpolation from the B
H magnet-
ization curve for the material to be used. Hence, the
total magneto motive force NI, which must provide
the flux required for the given force and stroke, is
determined by Equation (2).
The accurate solutions of electromagnetic
coupled equations are very difficult owing to the
effects of magnetic leakage and the nonlinear
relationship between magnetic flux and magnetic
intensity in ferromagnetic materials. Therefore, they
cannot be solved in closed form to determine dynamic
characteristics of the electromechanical system.
Approximate solutions of the equations may be
obtained using small perturbation techniques, finite
element methods (FEMs) or numerical computation
methods. In this study the MATLAB/Simulink
environment have been used to solve the system of
nonlinear equations due to its ease of usage.
For this purpose, a MATLAB code is developed
to find the static characteristics of the electromagnets
[15]. The program is based on permanence formulae
and leakage coefficient of the dimensioned magnetic
circuit. The flow chart of the program is shown in
Figure 3a. The program estimates various character-
istics values by using the date taken from the
magnetization curve (B
H curve) of the material of
the magnets. It estimates the necessary magnetic force
at each step of incremental air gap for a given Figure 10 Flow chart of GUIs program.
electrical current. The output of the program can
be organized for various static characteristics of
the magnetic circuits such as force-displacement,
magneto motive force-flux density and also 3D
390 SEFKAT

graphics of displacement-current-flux density charac- where e(t) is the coil voltage, R is the circuit resistance
teristics [18]. and d(Nf)/dt is the voltage occurred in magnet
winding or e.m.f. The use of current or flux in
modeling EMAs as a basic design parameter is
arbitrary as is seen in the relevant literature [19].
DYNAMIC CHARACTERISTIC OF Both current and magnetic flux based models are used
FLAT FACE EMA in this paper.
The current-based model:
An electromechanical device consists of electrical and
mechanical subsystems, coupled by a magnetic
d diðtÞ
subsystem. Dynamic characteristics of such a system eðtÞ ¼ RiðtÞ þ ðLiðtÞÞ ¼ RiðtÞ þ L
dt dt ð9Þ
are governed by two fundamental relationships which
dLðxÞ dx
are briefly explained in the following. þ iðtÞ
dx dt
 
di 1 dLðxÞ dx
Electrical or Electromagnetic Equation ¼ eðtÞ
RiðtÞ
iðtÞ ð10Þ
dt L dx dt
Physical model of the electromagnetic part of system
includes two components in serial, that is, a resistance where L(x) ¼ N2m0A/(lt
x), dL(x)/dt ¼ N2m0A/(lt
x)2
and an inductance. Applying the Kirchhoff law to this and lt is total air gap.
magnetic circuit yields The flux-based model:

dðNfÞ dfðtÞ 1
eðtÞ ¼ RiðtÞ þ ð8Þ ¼ ½eðtÞ
RiðtÞ ð11Þ
dt dt N

Figure 11 Main window of computer aided design for EMA.

 STATIC AND DYNAMIC CHARACTERISTICS OF EMA 391

and dynamic model of EMA is shown in Figure 3b. As is

fðtÞ ¼ BðtÞA ð12Þ
As is seen in the above equations, the permeability is
taken in the flux-based model in to account whereas
the current of circuit is obtained as a function of disc
displacement in the current-based model.
Mechanical Equation
An attractive force occurs between constant pole and
movement pole by the magnetic flux in the air gap.
Generally this force is used to overcome inertia,
spring, damping and other external forces. According
to Newton’s second law the mechanic equation, that
is, the equation of motion is obtained in the following
form
d2 xðtÞ dxðtÞ
Fm ðtÞ ¼ m þb þ kxðtÞ þ Fd ð13Þ
dt2 dt
where Fm is given in Equation (1b). There are four
variables that is x(t), Fm(t), f(t) and i(t) in Equation
(13). The flow chart of the code developed for
seen from Equations (1)
(13), electromechanical
systems are quite complex systems and their funda-
mental equations are highly nonlinear because of
leakage loses, saturation and eddy current effects.
SIMULINK MODEL FOR EMA
As seen in Figure 4, the Simulink model of EMA is
constituted from two main parts, that is, the magnetic
and the mechanical one.
The submodel of magnetic circuit has also
electrical and magnetic components. As seen in
Figure 4, the supply voltage e and the disc position
x used as feedback signal are input variables while
produced magnetic force Fm and current i are output
of the submodel.
The magnetic part of the submodel is shown in
Figure 5. This submodel has two computational
subunits, that is, the permeability computation unit
and the unit for finding magneto motor force (mmf) in
iron part. Flux density is obtained by using electrical

Figure 12 Dynamic analysis window of CAD for EMA.

392 SEFKAT
and fundamental magnetic equations (Eqs. 1, 7
13)
and sent to the permeability unit. In this unit
permeability (Eq. 7) related to different parts of
electromechanical system are computed. Then the
produced magnetic force is found using by flux
density through the air gap (Eq. 1). In the mmf unit the
magnetic field intensity of different parts of electro-
mechanical system is obtained by employing flux
density value, magnetization curve of material
(Figs. 6 and 7). Thus, total mmf created in iron
material and air gaps (Eq. 2), for electromechanical
system is computed. Consequently, electrical current
in the circuit is obtained by dividing total mmf by
number of winding.
The mechanic part of electromechanical system
model is built by using Equation (13) as shown in
Figure 8. The produced magnetic force Fm and disc
position x are given input and output in this submodel,
respectively.
The structural component of the model contain-
ing if-statements associated with the motion is shown
in Figure 9.
Figure 13 Dynamic analysis results from flux-based model.
THE STRUCTURAL OF THE GUI
DEVELOPED
This section is devoted to the description of the
MATLAB based GUI for EMA design and analysis
that is developed in this work. The main goal of this
software is twofold: to make the design of an EMA
easier to user and to quickly observe the effect of
parameters. The flow chart of the computer program is
given in Figure 10.
The main window of this program is separated
into five different sections as illustrated in Figure 11.
The top-left section exhibits a coordinate system for
graphical presentation of the computational results.
The top-right section is allocated for choosing the type
of electromagnets and analyses, and for entering a few
commands related to graphical plots. Bottom sections
of this window are null at the beginning. After the
choice of electromagnet type, some buttons and boxes
in the bottom-left section will be appeared allowing
the desired input parameters to be entered. After the
input of these parameters press the OK button. Then
 STATIC AND DYNAMIC CHARACTERISTICS OF EMA
the computed dimensions (from Eqs. 1 to 5) are given
in the boxes on the bottom-middle section.
In this stage, once the type of analysis is
determined as static, current and step-size for air
gap input boxes will appear in the bottom-
right section, allowing these parameters to be entered.
Afterwards, if the material is selected from tool bar
and the STAN Disc button is pressed the distance-force
curve will be plotting in the top-left section.
When the analysis type is chosen as dynamic, a
new similar window will be opened as shown in
Figure 12. The dynamic analysis window of this
program is separated into three different sections. The
design inputs are entered in the same way as in static
analysis and the OK button is pressed to activate
dynamic analysis process (see Figure 3b). After
executing this program, we can choose the cal-
culated results that we want to see using the buttons
in the top-right section. The selected results will be
presented in the top-left display. In the following it
will be explained by a numerical example of the
Figure 14 Dynamic analysis results from current-based model.
393
design of a flat face disc how to use the program
developed.
The results obtained from static analysis are
magnetic force-displacement curves for different
current values (see Figure 11). The results of dynamic
analysis will be presented and interpreted in the
following section.
SIMULATION RESULTS
First, the dimensions of the EMA are obtained. Using
these values static and dynamic analyses are carried
out. The results are obtained for both the flux-based
and the current-based models. The dynamic results
computed for the flux-based model for various input
voltages are shown in Figure 13. Similar results are
also obtained for current-based model, and are shown
in Figure 14.
For the purpose of comparison the results of these
two models are shown in Figure 15.
394 SEFKAT
Figure 15 Dynamic analysis results compared flux (with permeability) and current (without
permeability) based model.
EXPERIMENTAL TEST RESULTS
Two EMAs were designed by means of the GUIs
program and manufactured to carry out experimental
tests to verify the theoretical results given by the
program. One of these EMAs is an electromechanical
brake [15] while the other is an engine valve [19]. The
switching conditions of the EMAs were investigated
for a number of the different air gaps. The date of
dynamic tests were controlled and recorded with an
Adventech PCL-818H data acquisition board. The
changes in the current of the coils in the EMAs were
measured through the sensing resistance.
The air gap-force curves experimentally obtained
for different models are shown in Figure 16. For
comparison, the simulation results are added to
Figure 16. As can be seen in these results, the static
characteristics of the EMAs are very close to each
other. In addition, the simulation results show a good
agreement with the experimental ones.
Current history curves which are one of the most
important characteristics of dynamic analysis were
obtained for different air gaps from Model 2 and
presented in Figure 17. For comparison, the simu-
lation results are added to Figure 17. As is obviously
seen in these results, the switching times of the
devices are very close to each other. In addition,
the simulation results show a good agreement with the
experimental results.
CONCLUSION
Detailed analysis of the magnetic part is derived by
solving the Maxwell equations. The most realistic
numerical solutions of 3-D Maxwell equations are
obtained with FEM techniques depending on the
geometry of electromechanical system [20,21]. FEM
techniques have some disadvantages in spite of their
advantages. They require a special FEM program and
it is determined that CPU times are quite long despite
the accuracy of design and modeling [22]. Because of
the increasing use of high performance electro-
mechanical systems (EMS), there is a need to develop
a new EMS model for EMS dynamics that is both
 STATIC AND DYNAMIC CHARACTERISTICS OF EMA 395

Figure 16 Static characteristic for different model.

accurate and sufficiently fast for use in design
optimization and control studies.
In this paper, it has been developed a GUIs
program for EMA design and static-dynamic analysis
of as such a device using MATLAB. The computer
simulator program presented here has advantages over
FEM/finite differences method (FDM) software that
are used for transient calculations and therefore need a
lot of time. The model realizes both design and
analysis in a very few time. Besides, GUIs program
provides a visual approach in design and analysis for
EMA. Hence, both effects of design parameter values
can be seen very fast and also a user-friendly
environment is created.
Force-displacement curves as static character-
istics were obtained for different constant current and
presented together with test results. As seen in
Figure 16, simulation and test results are in a very
good agreement. The reason of the small differences is
that the B
H date of the material used in this work is

Figure 17 Current history for different models.

 396 SEFKAT
taken from the relevant literature (Mild Cold-rolled
steel, S.A.E 10-109 [17]) instead of experimentally
finding.
Current curves being one of the most important
dynamic characteristics for EMA are obtained using
both the flux based and current based electromagnetic
models (Eqs. 10
12). These curves are illustrated in
Figure 15. According to simulation and test results for
dynamic analysis, the flux-based model is found to be
better than current-based model.
The program is also suitable for further develop-
ment. For instance, other types of EMAs full-conical
plunger can be designed by easily adding some new
type buttons in the main window.
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BIOGRAPHY
Gursel Sefkat received his BSc, MSc, and
PhD degrees in mechanical engineering from
the University of Uludag, Bursa, Turkey, in
1991, 1993, and 2000, respectively. He is a
lecturer at the same university. He is studying
the design and control of electromechanical
actuator. His research interests include slid-
ing mode control, electromechanical actua-
tors, automatic control and system dynamics.
View publication stats
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