In this paper, we characterize the performance of and develop thermal management solutions for a DC motor-driven resonant actuator developed for flapping wing micro air vehicles. The actuator, a DC micro-gearmotor connected in parallel with a torsional spring, drives reciprocal wing motion. Compared to the 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. The micro-motor, selected for low weight considerations, operates at high power for limited duration due to thermal effects. To predict system performance, a lumped parameter thermal circuit model was developed. Critical model parameters for this micro-motor, two orders of magnitude smaller than those previously characterized, were identified experimentally. This included the effects of variable winding resistance, bushing friction, speed-dependent forced convection, and the addition of a heatsink. The model was then used to determine a safe operation envelope for the vehicle and to design a weight-optimal heatsink. This actuator design and thermal modeling approach could be applied more generally to improve the performance of any miniature mobile robot or device with motor-driven oscillating limbs or loads.
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