Selection of precision micro drives

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1 Selection of precision micro drives Systematics of the drive selection Situation analysis, boundary conditions How is the integration into the environment? Preselection Determining the load requirements Result: key data for load characterization 2017 maxon motor ag, Sachseln, Switzerland

2 Media The Selection of high-precision microdrives maxon Formulae Handbook formulaehandbook.maxonmotor.com maxon catalog epaper.maxonmotor.com Presentation hand-outs support.maxonmotor.com academy.maxonmotor.com

3 The Components of a Drive System to other system components Field bus Electr. Supply power supply battery / accu Motion Controller Host System / Master (PLC / PC) commands set values v(t), F(t) I/O Motor Gearhead Sensor Encoder Tacho Load

4 Systematic selection process Step 1 overview situation power ambient condition communication step 2 step 3 step 4 step 5+6 step 7 load drive gear- motor type sensor head winding controller

5 Step 1: Gain an overview analyze problem recognize dependencies mechanics operating mode power control concept motion profile checklist control accuracy operating points boundary conditions

6 Drive system as a black box task set values commands electrical power current voltage environment temperature, atmosphere impacts, vibration boundary conditions dimensions service life quality, accuracy resolution mech. play mechanical power force, torque velocity, speed emissions electro magnetic heat noise

7 Operating mode What is a operating cycle? How often is it repeated? How long are the breaks? mode: continuous operation load time mode: working cycles time mode: short term operation time

8 Control concept pre-selection What kind of communication? communication with higher level host system set value range inputs and outputs Controlled variable torque, current speed, velocity position feedback sensor Controlled range, accuracy? position resolution speed stability

9 Step 2: Load Requirements Step 1 overview situation power ambient condition communication step 2 step 3 step 4 step 5+6 step 7 load drive gear- motor type sensor head winding controller

10 Step 2: Definition of the load requirements motion profile and speed, operation points Key values forces and torques v(t), F(t) n(t), M(t)

11 Motion profile and operating points speed n time t speed n velocity v 2 extreme operating point torque M force F (M 1,n 1 ) acceleration friction and acceleration (M 2,n 2 ) const. speed friction only (M 3,n 3 ) deceleration friction helps during deceleration (M 4,n 4 ) dwell 0?

12 Key load data for characterization maximum load average effective load (RMS) F / M F max / M max F RMS / M RMS M RMS 1 t tot t 1 M 2 1 t 2 M 2 2 t 3 M Δt max t tot t max. velocity or speed duration of the maximum load duration of a load cycle required position resolution required speed accuracy v max / n max Δt max t tot Δs Δn

13 Example: Conveyor belt for paint cans pulley diameter 100 mm maximum mass on belt 15 kg coefficient of friction on support approx. 0.2 friction force (empty belt) approx. 30 N feed velocity 0.5 m/s supply voltage 36 V

14 Conveyor belt: load data Maximum load speed feed force v L = 0.5 m s F L = F R + μ m g = 30N kg 9.81 N kg 60N acceleration max. force: F a = m v L t = kg 0.5 m s 0.5 s = 15(+5) N F max = F L + F a = 60N + 15 (+5) N = 80N power P L = v L F L = 0.5 m s 60N = 30W

15 Conveyor belt: Key values load Looking for a drive that can accomplish the following: maximum velocity v max 0.5 m/s average force F eff ~ 60 N maximum force F max ~ 80 N duration of F max Δt max 0.5 s v 0.5 m/s 60 N 80 N F

16 Step 3: Drive Step 1 overview situation power ambient condition communication step 2 step 3 step 4 step 5+6 step 7 load drive gear- motor type sensor head winding controller

17 Load types and mechanical drives

18 Conveyor belt: Key values load Looking for a drive that can accomplish the following: maximum velocity v max 0.5 m/s average force F eff ca. 60 N maximum force F max ca. 80 N duration of F max Δt max 0.5 s 0.5 m/s v 60 N 80 N F

19 Conveyor belt: load data gear maximum speed n G = 30 π ω = 30 π v L d 2 average torque maximum torque M G,max = d 2 F max = 30 π 0.5 m s 0.05m 100rpm M G,eff = d 2 F L = 0.1m 2 60N = 3.0Nm = 0.1m 2 80N = 4.0Nm

20 Conveyor belt: Key values gearhead Looking for a gearhead that can accomplish the following: maximum speed n G,max 100 rpm average torque M G,eff ca. 3.0 Nm maximum torque M G,max ca. 4.0 Nm duration of M max Δt max 0.5 s n 100 rpm 3 Nm 4 Nm M

21 Step 4: Gearhead selection Step 1 overview situation power ambient condition communication step 2 step 3 step 4 step 5+6 step 7 load drive gear- motor type sensor head winding controller

22 Gearhead power conversion load output power motor input power high load torque > mnm characteristic: reduction ratio i losses: efficiency h recommended gear input speed ~ 8000 rpm high motor speed > 5000 rpm low load speed < 1000 rpm Gearheads for operation at high torques and low speeds low torque < 500 mnm

23 Step 4: Gearhead selection Looking for a drive that can accomplish the following: maximum speed n G,max 100 rpm average torque M G,eff approx. 3.0 Nm maximum torque M G,max approx. 4.0 Nm duration of M max Δt max 0.5 s?

24 Conveyor belt: Gearhead selection planetary gearhead GP 32 C continuous torque 3 Nm (max. 4 Nm) => at least 3 stages max. input speed 8000 rpm max. reduction selected reduction i 79:1 efficiency η G 70 % requirements motor (key values) speed n mot = n G i = 100rpm 79 = 7900rpm torque i < n max,in n max,l = M eff = M G i η G = 3.0Nm 79 70% = 54mNm M max = 72mNm 8000 rpm 100 rpm = 80: 1

25 Conveyor belt: Key values motor Looking for a motor that can accomplish the following: maximum speed n max 7900 rpm average torque M eff 54 mnm maximum torque M max 72 mnm duration of M max Δt max 0.5 s n 7900 rpm M [mnm]

26 Step 5 and 6: Motor selection Step 1 overview situation power ambient condition communication step 2 step 3 step 4 step 5+6 step 7 load drive gear- motor type sensor head winding controller

27 Motor type selection Combination with selected gearhead Motor limitations: Nominal torque (max. continuous torque) max. torque max. permissible speed n continuous operation deceleration M RMS < M N M N short term operation acceleration n max M

28 DC motor designs DC motors BLDC motors ironless winding ironless winding conventional, iron-cored winding iron-cored winding, internal rotor iron-cored winding, external rotor

29 Low power motors with permanent magnets DC motors BLDC (EC) motors 2017, maxon motor ag, Sachseln, Switzerland

30 DC motor designs conventional, slotted e.g. Dunkermotor coreless e.g. maxon

31 maxon DC motor variants precious metal brushes A-max motor with AlNiCo magnet ball bearing graphite brushes DCX motor with NdFeB magnet sintered sleeve bearing

32 Brushless DC (EC) motor main advantages: higher life higher speeds names: EC motor BLDC motor motor behavior similar to DC motor design similar to synchronous motor (3 phase stator winding, rotating magnet) the powering of the 3 phases according to rotor position

33 maxon EC motor families features in common

34 commutation logics Block commutation commutation electronics + power stage (MOSFET) EC motor (magnet, winding, sensor) Phase 1 HS1 Phase 3 rotor position feedback HS3 Phase 2 HS2 Video: academy.maxonmotor.com

35 DC and EC motor: Comparison DC motor + simple operation and control, even without electronics + no electronic parts in the motor brush commutation system limits motor life max. speed limited by commutation system EC motor + long life, high speeds preloaded ball bearings + no brush fire iron losses in the magnetic return needs electronics to run more cables more expensive electronic parts in the motor (Hall Sensor)

36 maxon motor data and operating ranges operating ranges Motor behaviour: speedtorque line, current P el = U I P mech = π n M 30 P J = R I , maxon motor ag, Sachseln, Switzerland

37 Application: Load operating points speed n e.g. operation at high speed and low torque e.g. continuous operation at constant speed and friction torque e.g. maintaining a position against gravity e.g. high torque needed for short-term acceleration torque M

38 Application: Load key values Key load data speed n RMS average load torque (continuous) Extreme operation point: max. load speed and load torque (limited time) torque M

39 1) The limits of the operation ranges speed n n max M L,RMS Continuous operation Motors have speed limits Based on bearing and brush life Motor torque and current are equivalent Torque constant k M Motors have torque limits Continuous => Nominal torque, current Short term => limited duration M N I N M = k M I mot torque M current I

40 How long is short term operation? speed n Time scale: (19) Thermal time constant winding t W Typically a few seconds overload 2.5 times M N => duration approx. t W = 3.5 s Continuous operation Short term operation torque M Overload M N 2 M N 3 M N Duration approx. 5 t W 0.3 t W

41 2) The speed-torque line Motor behavior at fixed motor voltage U mot speed n (13) (14) n = k n U mot n M M Dn DM Stronger, larger motor => flatter line torque M current I

42 How about voltage? Motor behavior at variable motor voltage U mot speed n n = k n U mot n M M torque M current I

43 Nominal voltage U N The voltage at which the motor is specified. speed n No-load operation Observe: The motor can be operated at any voltage lower or higher than U N! Nominal operation At stall, at start torque M current I

44 At no-load Operation without output torque but with internal losses (friction, iron losses) speed n 2) No-load speed n 0 No-load speed and motor voltage n 0 k n U mot Torque losses (3) No-load current I 0 torque M current I

45 3) Winding series: Speed and torque low resistance winding Speed constant decreases high resistance winding Output speed Voltage increases Currents decrease Output torque Torque constant increases

46 Winding series: At fixed voltage 24V speed n 12'500 rpm 2.7 A 1.8 A 1.4 A 0.87 A 0.71 A 23 mnm Remember for the selection: Speed constant high enough! but not too high => keep the currents small. torque M current I

47 Winding series: Limits and nominal voltage Nominal torque (5) and no load speed (2) : Speed-torque gradient (14) at nominal voltage: almost the same almost the same speed n 12'500 rpm Remember: Mechanical behavior and limits are essentially identical! 23 mnm torque M current I

48 Tolerances speed n n Sources winding resistance ± 7 % magnetic properties ± 8 % friction and iron losses Results general tolerances 5 to 10 % tolerance in I 0 ± 50 % tolerance in n 0 ± 10 % weaker motor Steeper speed-torque line enhanced n 0, lower M H I torque M current I

49 Conveyor belt: Key values motor Looking for a motor that can accomplish the following: maximum speed n max 7900 rpm average torque M eff 54 mnm maximum torque M max 72 mnm duration of M max Δt max 0.5 s n 7900 rpm M [mnm]

50 Step 5: Motor type selection Motor type according to modular system RE 25 RE 30 RE 35 A-max 26 A-max 32 RE-max 29 EC 32 EC-max 30, 40W EC-max 30, 60W EC-4pole 22 EC flat 32 EC-i 40 (70W) continuous operation M N Nominal torque M N > 54 mnm max. permissible speed > 7900 rpm short term operation M

51 Conveyor belt motor type Motor type according to modular system Nominal torque M N suitability RE 25 < 30 mnm Too weak, with brushes RE 30 ca. 90 mnm OK, but with brushes RE 35 ca. 100 mnm strong, but with brushes A-max 26 < 18 mnm too weak, with brushes A-max 32 < 45 mnm too weak, with brushes, n max = 6000 rpm RE-max 29 < 30 mnm too weak, with brushes EC 32 < 45 mnm too weak EC-max 30, 40W < 34 mnm too weak EC-max 30, 60W < 63 mnm perfect EC-4pole 22 < 64 mnm OK, only 120W version, builds long EC flat 32 < 23 mnm too weak EC-i 40 (70W) < 70 mnm OK, builds short, cost effective

52 Step 6: Winding selection Goal: Reach the required speed at maximum possible motor voltage under maximum load for a given motor size (motor type) this means: sufficiently high speed constant n 0,theor = n mot + n M M max speed n n 0,theor n mot, M mot k n > k n,theor = n 0,theor U mot n mot speed-torque line too low for the required load speed M mot speed-torque line high enough for the required load speed torque M

53 Example: Conveyor belt for samples n [rpm] 9300 n 0,theor = n mot + n M M max = rpm k n > k n,theor = n 0,theor U mot = 9300rpm 33V 7900 select motor : speed constant k n = 393 rpm/v needed current with torque constant k M = 282 rpm V 72 mnm M I max = M max + I k 0 M = = 3.2 A 24.3

54 Step 7: Sensor and controller Step 1 overview situation power ambient condition communication step 2 step 3 step 4 step 5+6 step 7 load drive gear- motor type sensor head winding controller

55 Summary What we have done The parts of a drive system The properties and limitations. How to select them systematically.

56 Thank you for your visit! and good luck in solving your drive task!

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