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In this paper, we characterize the performance of and develop thermalmanagement solutions for a DC motor-driven resonant actuator developed forflapping wing micro air vehicles. The actuator, a DC micro-gearmotor connectedin parallel with a torsional spring, drives reciprocal wing motion. Compared tothe gearmotor alone, this design increased torque and power density by 161.1%and 666.8%, respectively, while decreasing the drawn current by 25.8%.Characterization of the actuator, isolated from nonlinear aerodynamic loading,results in standard metrics directly comparable to other actuators. Themicro-motor, selected for low weight considerations, operates at high power forlimited duration due to thermal effects. To predict system performance, alumped parameter thermal circuit model was developed. Critical model parametersfor this micro-motor, two orders of magnitude smaller than those previouslycharacterized, were identified experimentally. This included the effects ofvariable winding resistance, bushing friction, speed-dependent forcedconvection, and the addition of a heatsink. The model was then used todetermine a safe operation envelope for the vehicle and to design aweight-optimal heatsink. This actuator design and thermal modeling approachcould be applied more generally to improve the performance of any miniaturemobile robot or device with motor-driven oscillating limbs or loads.

Characterization and Thermal Management of a DC Motor-Driven Resonant Actuator for Miniature Mobile Robots with Oscillating Limbs