KBM frameless kit brushless motors

What is direct drive technology?
With direct drive technology a torque motor is coupled directly to the driven load. This provides a very stiff mechanical connection to the load, eliminating problems associated with couplings, belts and gearboxes.

Kollmorgen KBM
KBM™ Series frameless kit brushless motors are designed to be embedded in your machine. The rotor is supported by machine’s own bearings.
A large selection of standard motors are available or alternatively a bespoke solution incorporating your specific modifications can quickly and cost-effectively create a an exact fit motor which will provide the highest performance and longest life in the most compact space.
Designs, which include special winding configurations, tailored mounting features, diameter and stack length dimensional adjustments, or material variations, are all possible.

Simplified Machine Design.
With a Kollmorgen KBM Solution from Micromech, your machine design is simplified. Noisy mechanical transmissions are eliminated as are the performance limitations associated them.

The direct coupling of a torque motor to a load provides improvements to a machine, unachievable with a more compliant mechanical transmission. Furthermore, expensive maintenance is greatly reduced as the need to adjust belts or pulleys or to lubricate gearboxes is eliminated.

Direct drive frameless vs Conventional Motor Systems
Conventional servo systems with mechanical transmissions limit servo performance and reliability. Typically designs consume more space due to use of transmissions, belt / pulley arrangements and couplings. Additionally maintenance is more extensive. This all adds unnecessary machine down time and costs.

Integration Costs

  • Positional inaccuracies from transmission compliance
  • Mounting and alignment of gearbox / belt / bracket
  • Servo tuning difficulties caused by compliance and backlash
  • Pulley installation and tensioning
  • Oversize motor for inertia matching
  • Extra components – clutch, output shaft feedback device
  • Motor / gearbox mounting Bracket
  • Purchasing and BOM
  • Inventory and Inspection
  • Coordinate multiple lead times

Life Cycle Costs

  • Machine maintenance
  • Belt tensioning and replacement
  • Gearbox lubrication and replacement
  • Increasing backlash due to wearing gears
  • Costs to support field failures
  • Unscheduled down time
  • Belt breakageBelt slippage
  • Gearbox failure
  • Reduced throughput due to compliance and settling

Micromech engineers have assisted many of our customers with specification of a KBM frameless motor solution. Contact us for further information on the wide variety of pre-engineered options and configurations available or send us your exact requirements for a custom solution for your application.

Tel 01376 333333 or Email sales@micromech.co.uk.

Choosing the Right Rotary Servo Motor Feedback Device – Part 2

Article Posted by Electromechanical Team on Tuesday, April 4, 2017, on the Parker Motion & Control Technology Blog

ParkerEnvironmental factors, performance requirements and communication protocols all factor into selecting a feedback device for your rotary servo motor application. In this post, we’ll look at some of those factors, provide examples, and give you some helpful formulas to make things easier.

Before getting started, you may find it helpful to review our earlier post on basic operational theory for three types of feedback devices: resolvers, optical absolute encoders and optical incremental encoders.

Environmental factors

Consider the operational environment for your application when selecting a feedback device. The ambient temperature and shock/vibration ratings required for your application can quickly determine if you need a resolver or if an optical encoder will suffice.

  • Ambient temperature – Optical encoders are typically rated for up to 90 degrees C while resolvers can be rated for up to 200 degrees C
  • Shock and vibration – Optical encoders are typically rated for up to 100g of shock and 30g of vibration; resolvers can be rated for up to 200g of shock and 40g vibration

Performance factors

Speed control, position control and torque control are performance requirements that factor into selecting the right feedback device for your application.

Speed control – The resolution you choose will be influenced by the update rate (velocity loop) and input frequency of your control.

For instance, if you are operating at a very slow speed, you need to make sure that your resolution is not too coarse or the control update may occur prior to your next count.

Example – slow speed operation

  • Velocity loop of Drive = .000125 seconds
  • Motor RPM = 50
  • 50 rpm = .83 rev/sec = 300 deg./sec
  • 300 deg./sec x .000125 sec = .0375 deg. of shaft rotation for every update by the control
  • Resolution = 1,000 counts/rev
  • 1,000/360 = 2.8 counts/deg. = 1 count every .357 deg.

Result – Your control will look for an update when your shaft has rotated .0375 deg., but your next feedback count will not appear until you reach a shaft rotation .357 deg. This can create instability and velocity ripple in your application.

On the other hand, if you are operating at a very high rpm, you need to make sure that your drive can process all of the feedback device resolution relative to its input frequency.

Example – high speed operation

  • Input frequency of Drive = 20 Mhz = 20,000,000 counts/sec capability
  • Motor RPM = 2,000 = 33.33 rev/sec
  • 20 bit encoder = 1,048,576 counts/rev
  • Resultant counts = 33.33 x 1,048,576 = 35 million counts/sec

Result: Your drive will not be able to keep up with the resultant counts/rev, which can cause your drive to fault, or prevent you from getting to your required rpm.

Formulas for speed performance requirements

  • Minimum resolution (pulse/rev) for low speed requirement

  •  Maximum resolution (pulse/rev) for high speed requirement

Position control – The optimum location for a feedback device is at the location where the controlled motion is required. When using a motor mounted feedback device, it is important to determine the amount of error that will be acceptable for your application. Your feedback resolution will determine how precisely you can control the rotation of your motor shaft.

For instance, a 5,000 pulse/rev. encoder will allow you to control your motor shaft to .07 deg of rotation. If your encoder’s accuracy is .07 deg then your resultant level of shaft control is .14 deg.

After that you need to take into account the accuracies of the components that your motor is driving. If you are now adding a gearhead with .08 deg. of backlash to your motor with the 5,000 pule/rev. encoder, then your resultant level of shaft control at the output of your gearhead is .14 deg. .08 deg. = .22 deg.

As with speed control, you need to look at the update rate (position loop) of your control device.

  • Slow speed operation – If you are running at a very slow rpm, and your resolution is too coarse, your controller will see this as an error and will try to correct.
  • High speed operation – If you have a high speed application and you choose too much resolution relative to your controller input frequency, you will cause your controller to fault.

Torque control – To control torque, your feedback device provides the means for the motor to commutate. Commutation refers to the action of steering currents or voltage to the proper motor phases to produce optimum motor torque and motor shaft rotation. Knowing the motor rotor/shaft position via the feedback device allows your controller to do this.

Communication protocols

Here are a few considerations to help you choose between BISS, EnDat and Hiperface communication protocols.

  • If you are designing your own drive and controls you may want to investigate which protocol offers the best performance relative to clock frequencies, transmission rates, etc.
  • From a motor manufacturer viewpoint, we look at resolution, permissible speed and ease of integration.
  • From an end user standpoint, make sure the communication protocol of your motor feedback device is a match to your controller, especially when you mix and match components from various manufacturers.

Formulas for screw or belt driven linear stages

These formulas and examples show what your minimum pulse/rev (PPR) feedback resolution should be when using a screw or belt driven linear stage. Round the value up to the closest standard resolution offered by your feedback device. Remember to understand your controller update rate and input frequency relative to the speed that you want to run your motor at.


PPR = Screw Lead/Move Requirement
Lead = 10mm
Move = .00254mm
PPR = 10/.00254 = 3937 PPR

Belt driven stage

PPR = Circumference of Pulley/Move Requirement
Pulley circumference = 15.7 inch
Move = .008 inch
PPR = 15.7/.008 = 1,962 PPR

Learn more

Watch this video to learn more about the features of our SM slotless servo motor. Consider how environmental and performance requirements will apply to the feedback choices offered for this servo motor.

Acknowledgement

Article contributed by Jeff Nazzaro, gearhead and motor product manager, Electromechanical and Drives Division, Parker Hannifin Corporation.

Disclaimer
Licensing for these images came with permission from the Parker Hannifin Media Manager collection.
Article reposted with Parker Hannifin’s permission.

All your motion control requirements from one supplier ‘MICROMECH’ the UK’s premier mechatronic specialist.

In addition to supplying and supporting cutting edge electro mechanical products from some of the biggest names in motion control, Micromech provides a complete service to OEMs machine builders and end users.

Application engineering and product specification:
Send us details of your application and our engineers will specify the optimum cost-effective solution at the best possible price. From simple components to complete bespoke motion control systems we can help. In many cases products can be modified or adapted to create an exact fit for your machine.

System engineering:
Our systems division engineers are experts in bespoke motion control systems. From standard single axis stepper and servo systems to multi axis systems with HMI or PC front ends, we can provide a comprehensive service for end users upgrading a machine, special purpose machine builders or OEM’s. We can also provide a mechanical design and manufacture service and have experience with mechanical sub assemblies and small special purpose machines.

Our capabilities include:
Electrical design (AutoCad).
Mechanical design (Solidworks 3D).
Software design including Labview, Visual basic, Trio Motion Perfect, Parker motion software, Kollmorgen motion software IEC61131 languages.
Control panel wire and assembly.
Mechanical manufacture and assembly.
Installation and commissioning.

Testimonial’s:

“I have had a long relationship with Micromech and always found them friendly, helpful and ready to turn an idea into a reality by listening to what is required, then by us working together bringing that idea to fruition. Special thanks go to Mick Stone and Mark Hall together with Dave Whitmell and Phil Farnworth who not only create fine workmanship but also brilliant entertainment.”

“Micromech is a company in which you can trust. Since 2005 Micromech is a good supplier of Nortemecánica.”

“It was a pleasure working with Micromech throughout our project. Stirling, Mick and everyone else we dealt with were very professional, but also very flexible and friendly. We always felt we were getting good advice and good service.”

Suppliers include:

For all motion control and automation requirements:
Call our sales team on 01376 333333 or Email sales@micromech.co.uk

The new GA700 AC drive from Yaskawa the only drive you need! Available from Micromech AC Drives

The GA700 is the first of a new generation of inverter drives from YASKAWA. Boasting a host of new features designed to make installation and setup as simple as possible coupled with it’s compact design, the GA700 is the perfect choice for industrial use in almost any application.

Yaskawa GA700

Features:

The GA700 provides many important features ensuring the flexibility to fulfil a wide range of requirements with just one type of inverter drive.

  • Large power range up to 630kW, for constant and variable torque
  • Control of Induction, Permanent Magnet and Synchronous Reluctance motors without the need for motor data tuning
  • Easy network integration with cost effective 1-to-5 gateway function
  • DriveWorksEZ block programming for application adaptation without external controllers
  • Tactile keypad with multi-lingual graphical display, auto-backup, real-time clock, copy function and data logger, optional Bluetooth
  • Built-in startup wizard for guided parameter setup without manuals
  • DriveWizard Mobile smartphone app for drive setup, monitoring, guided trouble shooting with connection to YASKAWA Drive Cloud service for data backup and online documentation
Yaskawa GA700

Benefits:

As with all Yaskawa products the GA700 is designed to be installed and forgotten, giving long trouble free operation.

  • Coated PCBs as standard
  • Designed for 10 years of maintenance free operation
  • Built-in functional safety features, EMC filter, DC choke, braking chopper and more to save space and cost for external components while improving the application reliability

Click here for more information on the Yaskawa GA700 or contact Micromech on 01376 333333 or Email sales@micromech.co.uk

 

For more information on the services offered by Micromech visit our systems section or contact Micromech on 01376 333333 or Email sales@micromech.co.uk

Unique new stepping motors with integrated drives and EtherCat from RTA…Buy now from Micromech

RTA Mini Step Stepper Drive

This new and innovative stepping motor from RTA features an integrated mini step stepper drive, incremental encoder and EtherCat connectivity providing a complete basic motion control system in one very neat package.

The HI-MOD ET motor comes in 34 frame size. The compact drive is housed in a metal enclosure mounted on the rear of the motor and includes connectors for all electrical interfacing for ease of installation.

Key Features:
  • EtherCat communications.
  • Profile, Position and CSP modes of operation.
  • Various homing routine options.
  • Input for proximity sensors.
  • Motor current overboost.
  • Intelligent management of the current profile.
  • 32-75vdc operating range.
  • Protection against:
    Under and over voltage.
    Motor output short circuit.
    Over temperature.
  • Electronic damping facility providing excellent noise and vibration reduction.
  • Homing command.
  • Motor stall and position error feedback via integrated incremental encoder.
Click here or details of the full R.T.A. range or for technical help call 01376 333333.

RTA Logo

AC & DC motor controls from the biggest and best.



Add Micromech’s support and application knowledge and you have a winning formula.

  • Both our lead suppliers manufacture in the UK.
  • The world’s largest manufacturer of drives.
  • Power for power the smallest drive on the market.
  • An industry leading manufacturer with a large portfolio to suit every different drive application.
  • Enclosure ratings from IP00 through to IP66
  • Fast deliveries.
  • Large powers available on short lead times up to 2Mw.
  • A wide range of input voltages 110v to 690v.

So, if you want an inverter in an enclosure…
….you know who to call.

Non standard designs are available and we have a “Fanless – Cold Plate Design” inverter that is ideal for Atex Zone 1 Enclosures.

Micromech provide full support from system design, manufacture and software engineering to installation and commissioning.

We are fully accredited and can certify CE and UL control systems in house.

Our qualified engineering team can help you with selection and sizing and our partnership with TEC Motors enables us to provide and take responsibility for your complete transmission system.

Call Andy Donaldson on 07711 451676 or email adonaldson@micromech.co.uk

Create the perfect XYZ gantry system for your application with Parker Origa OSPE Belt driven actuators and a little help from Micromech.

Parker OSP-E

Using the OSP-E…BHD and BV belt driven actuators from the Parker Origa System Plus modular concept actuator range, Micromech have created a standard XYZ gantry assembly configurable to suit many applications.

Max Stroke X and Y 5000mm*
Max Stroke Z 1500mm*
Max velocity 5m/s*
Max payload 100kg*
Max acceleration 50m/s2

* Subject to application

The Actuators:

The OSP-E..BHD series belt driven actuator with integrated guide combines robustness, precision and high performance. The aesthetic design is easily integrated into any machine constructions by virtue of extremely adaptable mountings.

Advantages

  • Accurate Path and Position Control
  • High Force Output
  • High Speed Operation
  • High Load Capacity
  • Easy Installation
  • Low Maintenance
  • Ideal for Multi-Axis Applications

Features

  • Integrated Ball Bearing Guide or Integrated Roller Guide
  • Diverse Range of Multi-Axis Connection Elements
  • Diverse Range of Accessories and Mountings
  • Complete Motor and Control Packages
  • Optional Integrated Planetary Gearbox
  • Special Options on Request
  • IP 54 environmental protection

Parker OSP-E

The OSP-E..BV vertical belt actuator with integrated ball bearing guide has been specially developed for lifting movements in the Z-axis.

The especially low vibration OSP-E..BV vertical actuator in combination with the heavy duty series OSP-E..BHD meets the highest demands in portal and handling applications.

Advantages

  • Fixed Actuator Head for Low Moving Mass
  • Integrated ball bearing guide for high bending moments
  • Magnetic Sensor set for contactless position sensing
  • Easy to install
  • Low Maintenance

Features

  • High Acceleration and Speed
  • Drive Shaft Versions with Clamp Shaft or Plain Shaft
  • Power Transmission by Belt
  • Moving Axis Profile
  • Complete Motor and Control Packages

Parker Origa actuators are available with a wide range of standard options and accessories including:

  • Input shaft variants
  • Integrated gearboxes
  • Dual carriages
  • Actuating direction
  • Bi-parting versions
  • Various motor mountings
  • Various profile mounting options
  • Contactless limit/home sensors

In addition to the many options offered with Parker Origa OSP-E actuators, Micromech can provide

  • Custom XYZ configurations
  • 3D models of you chosen gantry design
  • Cable management
  • Custom motor/gearbox mounting
  • Mechanical limit/home sensors
  • End effector brackets
  • Control systems

Parker OSP-E

For more information on the Parker Origa actuator range click here or contact Micromech on 01376 333333 or Email sales@micromech.co.uk

For more information on the services offered by Micromech click here (link to systems page) or contact Micromech on 01376 333333 or Email sales@micromech.co.uk