theory, application & operation of frameless motor technology webinar 02 23-2016

February 23, 2016

Theory, Application & Operation of Frameless Motor Technology

Tom S. Wood Motor Product Specialist

Kollmorgen ELECTROMATE

Toll Free Phone (877) SERVO98Toll Free Fax (877) SERV099

[email protected]

Sold & Serviced By:

Speakers Texas Instruments & Ethernet POWERLINK Standardization Group


Kollmorgen

Meet The Presenter

ELECTROMATEToll Free Phone (877) SERVO98

Toll Free Fax (877) SERV099www.electromate.com

[email protected]

Sold & Serviced By:

Thank You To Our Exclusive Sponsors



[email protected]

Sold & Serviced By:

4

Why Direct Drive Frameless ?

Direct Drive Frameless Story

This could be a Belt/Pulley, Planetary Gearhead, Rotating Nut or Driven Ballscrew



[email protected]

Sold & Serviced By:

5

Why Direct Drive Frameless ?

Direct Drive Frameless Story

This could be a Belt/Pulley, Planetary Gearhead, Rotating Nut or Driven Ballscrew



[email protected]

Sold & Serviced By:

Why Direct Drive ? • Clean mechanical assembly

– Lower parts count – Reduce assembly time

• Improved servo performance – Increase accuracy up to 50 times – Greater servo performance and higher bandwidth – No need for inertia “matching”

• Zero maintenance – No Belts to tighten or adjust – No gears to lubricate or leak

• Reduce machine down time – no mechanical transmission parts to break

• Hollow shaft option – Through-bore for process air or tooling

• Quiet performance…up to 20db noise reduction



[email protected]

Sold & Serviced By:

Housed Direct Drive Motor

Housed Direct Drive Motor 250 Lb-ft Continuous 989 Lb-ft Peak

Customer Load Wheel 4 Feet Diameter 250 Pounds

96 Steel pegs 3.75 degrees per peg Total Inertia 15 lb-ft-s2



[email protected]

Sold & Serviced By:

Single Peg Index Velocity Profile Single Peg Index (3.75 Degree Move)

Velocity Profile

Total Move Time 97 ms

Settling Time 13 ms



[email protected]

Sold & Serviced By:

Bar Clamped to Table

Indicator 1 Thousandth Inch / Number 1 Ten Thousandth Inch / division 0.8 Arc Seconds / division

26 inch radius from center

Repeatability Test



[email protected]

Sold & Serviced By:

Repeatability Test



[email protected]

Sold & Serviced By:

11

Embedding Frameless Motors



[email protected]

Sold & Serviced By:

12

Applications • Applications

• Collaborative Robots • Surgical Robots • Semi Wafer-handling Machines • Manufacturing Automation • Machine Tools • Unmanned Autonomous Vehicles

• Trends • Machines need to be smaller smaller solutions explore Direct Drive

• Electric motors replacing hydraulics Reduces weight (operating costs) Reduces maintenance cost in environmentally sensitivity



[email protected]

Sold & Serviced By:

13







[email protected]

Sold & Serviced By:

14







[email protected]

Sold & Serviced By:

15

Robotics: NREC Robot • DARPA Robotics Challenge is a competition to create

robots capable of assisting humans in a disaster • Benefits provided by frameless motor integration:

• Small, compact integrated motor and gearing actuate the robot’s 50 degrees of freedom



[email protected]

Sold & Serviced By:

16

Frameless Motor Mounting Video Frameless Motor Mounting Video – Customer Application



[email protected]

Sold & Serviced By:

17

Frameless Motor Mounting Video



[email protected]

Sold & Serviced By:

18

Classic ‘Torquer’ Motor Shape

KBM 10-35 ‘Servo’ Motor Shape

Stationary wound armature Rotating permanent

magnet field

Stationary wound armature

Rotating permanent

magnet field

Frameless Motor Form Factor



[email protected]

Sold & Serviced By:

19

Frameless Motor Form Factor

D2L Rule Continuous Torque Capacity is Directly Proportional to Length:

2 x Length = 2 x TC

But …

Doubling the Diameter (Moment Arm) Squares the Continuous Torque Capacity

2 x Diameter = (TC)2

From

From

To

To

2x

2x



[email protected]

Sold & Serviced By:

20

Frameless Motor Optimization Data to Consider Torque / Speed Load

Point(s) Duty Cycle / Temp Details Drive Amplifier Details • Current & Voltage • Sine vs. 6 Step

Mechanical Envelope • Max Available Diameter • Max Available Length • Through Bore data • Mounting concept

Design Elements Choose Largest Practical Diameter • Low speed / higher torque suggests a larger

diameter - D2L rule

Stack Length Change • Wattage increases with stack length • Tc / Tpk will vary proportional to stack length

Optimize Winding Parameters • Increase system efficiency • Bus voltage will drive the winding choices based

on max speed needed

Water Jacket Cooling • Channel features on stator sleeve

• Tubing integrated into back-iron design



[email protected]

Sold & Serviced By:

21

Position Feedback Considerations Electrical and Control Considerations

• Add feedback device [Frameless or shaft mounted]

• Same type of feedback as conventional servos; Encoder, Resolver, Absolute, Incremental available for system use.

• Often a Size 31 or 55 thru-bore resolver will easily adapt to the mechanical system.

• Resolvers rated to a standard 200 degree C level

• Rated for high shock and vibration applications



[email protected]

Sold & Serviced By:

22

System Design Feedback Options

Harowe large through-bore

Resolver

Up to 140mm OD with

93mm max Bore



[email protected]

Sold & Serviced By:

23

System Design Feedback Options

Typical large through-bore

Encoder

Up to 390mm Bore



[email protected]

Sold & Serviced By:

24

Mounting Considerations …

Embedded Motion Technology - Frameless Mounting Considerations

• The benefits of Improved System Performance, Reduced Maintenance, Smaller Mechanical Footprint, Higher System Efficiency are understood

• Customer still has a key question in mind …

I like the frameless design concept but how do I mount the motor components into my machine?



[email protected]

Sold & Serviced By:

25

Mounting Considerations … Mechanical Mounting Considerations • Customer’s own bearings

• Customer’s shafting / drivetrain

• Bearing precision and machining tolerances are dependent more on customer machine requirements than frameless motor mounting requirements

• Run-out more dependent on customer requirements

• Air gap of 0.015” – 0.075” (0.38 mm – 1.9 mm) each side of rotor needed for frameless motor

• Mounting; Bonding, Clamping, and Bolting options are discussed in some detail in the KBM Selection Guide



[email protected]

Sold & Serviced By:

26

Radial Running Clearance – “AirGap”

Source: KBM Selection Guide p.89 – KM_SG_00073_RevE_EN



[email protected]

Sold & Serviced By:

27

Customer Through-bore type Encoder

Customer Duplex Bearing

Customer Machine Shaft

Customer Housing

KBM-43X03 Stator

KBM-43X03 Rotor

KBM-43X03 Mounting Example Bonding



[email protected]

Sold & Serviced By:

28

Customer Housing with Stator embedded

Customer Shaft with Rotor




[email protected]

Sold & Serviced By:

29

Customer Housing

Customer Shaft

KBM Rotor

KBM Stator




[email protected]

Sold & Serviced By:

30

Customer Housing

KBM Stator

Housing / Stator Exploded View




[email protected]

Sold & Serviced By:

31

3D to 2D

Housing / Stator Assembly

See Detail A




[email protected]

Sold & Serviced By:

32

Insert Stator

2 mm min. end turn to

housing clearance

0.10/0.05 mm gap per side,

“slip fit”

0.26/0.13 mm additional adhesive

groove, 50+% of surface

Depth stop

shoulder feature

Recommended Structural Epoxy 3M Scotchweld 2214 Hysol EA934NA

Detail A – Stator / Housing KBM-43X03 Mounting Example Bonding



[email protected]

Sold & Serviced By:

33

KBM-43X03 Mounting Example Bonding • Recommended for KBM Frame size 118XX and smaller

• Recommended Structural Epoxy:

• 3M Scotchweld 2214 • Hysol EA934NA

• Design Recommendations

• Cylindrical cup shape customer housing • Locating shoulder for precise location • Lead in chamfer to aid in assembly operation • Maintain clearance over potted winding surfaces > 2 mm • Slip fit with housing of 0.1-0.2 mm over stator OD max • Adhesive grooves with extra slip fit gap of 0.13-0.26 mm • Parts will “self-center” during cure by orienting in vertical axis • Maximum Cure temperature of 155 C to prevent insulation damage

• Please Note that: • Adhesive manufacture guidelines should be followed • Other adhesives can be used • Customer ultimately responsible for proper design of:

• Housing dimensions accounting for thermal effects • Proper surface preparation and application of adhesive



[email protected]

Sold & Serviced By:

34

Customer Shaft

Rotor

Rotor / Shaft Exploded View




[email protected]

Sold & Serviced By:

35

3D to 2D

Rotor / Shaft Assembly

See detail B




[email protected]

Sold & Serviced By:

36

Detail B – Rotor / Shaft Assembly


“precise location slip fit”

No adhesive grooves with Retainer Compound mounting configuration

Recommended Retaining Compound: Loc-Tite 640

Bolt-on Mounting also practical for removable rotor

Fit depth to shoulder

Rotor

Shaft




[email protected]

Sold & Serviced By:

37

Mounting Considerations … Bonding with Structural Adhesives • Bearing precision and machining tolerances are dependent

more on customer machine requirements than frameless motor mounting requirements

• Structural adhesives represent a cost-effective, industry proven, and mechanically sound approach to frameless motor mounting

• Several mounting options; Bonding, Clamping, and Bolting options are discussed in some detail in the KBM Selection Guide

ELECTROMATE


[email protected]

Sold & Serviced By:

38

KBM-43X03 Mounting Example Clamping & Bolting

Customer Through-bore type Encoder

Customer Duplex Bearing

Customer Machine Shaft

Customer Housing

KBM-43X03 Stator

KBM-43X03 Rotor



[email protected]

Sold & Serviced By:

39

Customer Housing

Rotor Bolt Flange

KBM Rotor

KBM Stator

Customer Shaft

Stator Clamp Ring




[email protected]

Sold & Serviced By:

40

Customer Housing

KBM Stator

Stator Clamp Ring




[email protected]

Sold & Serviced By:

41

Customer Housing

KBM Stator Stator Clamp Ring w/ 12

evenly spaced bolts Actual number may vary with

motor and load conditions




[email protected]

Sold & Serviced By:

42


3D to 2D

Housing / Stator / Clamp Ring Assembly



[email protected]

Sold & Serviced By:

43 Insert Stator

2 mm min. end turn to

housing clearance



Clamp ring needs to have gap behind to

allow compression of stator shoulder

Depth stop

shoulder feature

Detail A – Stator / Housing

Clamp ring with bolts, must engage at least half of stator shoulder,

with 2mm gap to endturn encapsulation

KBM-43X03 Stator Clamping Example



[email protected]

Sold & Serviced By:

44

Clamping • Recommended for KBM Frame size 118XX and smaller

• Designed for easy removal or maintenance access

• Design Recommendations • Cylindrical cup shape customer housing • Locating shoulder for precise location • Lead in chamfer to aid in assembly operation • Maintain clearance over potted winding surfaces > 2 mm • Precise Location Slip Fit with housing of 0.10-0.05 mm over stator OD typical • Maintain gap behind clamp ring to allow for compression on stator • Engage at least half of the stator shoulder with the clamping ring

• Please Note that: • Engineering Best Practices should be followed for determining the number and size of

clamping ring bolts as required for the torque capacity of motor ELECTROMATE


[email protected]

Sold & Serviced By:

45

Customer Shaft

Rotor

Rotor / Shaft Exploded View




[email protected]

Sold & Serviced By:

46

3D to 2D

Rotor / Shaft Assembly

See Detail B




[email protected]

Sold & Serviced By:

47

KBM-43X03 Rotor Bolting Example Detail B – Rotor / Shaft Assembly



Bolt-on Mounting practical for easily removable rotor

Fit depth to shoulder

Rotor

Customer Shaft

Bolt-on Mounting from either side of rotor



[email protected]

Sold & Serviced By:

48

Mounting Considerations … Clamping & Bolting : • Bearing precision and machining tolerances are dependent

more on customer machine requirements than frameless motor mounting requirements

• Clamping and bolting represent a cost-effective, easily removable, and mechanically sound approach to frameless motor mounting

• Several mounting options; Bonding, Clamping, and Bolting options are discussed in some detail in the KBM Selection Guide

ELECTROMATE


[email protected]

Sold & Serviced By:

49

What do you do when the frameless motor application needs are outside the range of the standard catalog motor offering?

Frameless Motor Sizing Considerations



[email protected]

Sold & Serviced By:

50

Frameless Motor Sizing Considerations

What do you do when the frameless motor application needs are outside the range of the standard catalog motor offering?

What do we do when the application requires a motor rating [derating] at a specific ambient temperature or amplifier capability?



[email protected]

Sold & Serviced By:

51

• Winding Changes

• Amplifier Variations

• Ambient Temp Variation

KBM/TBM Performance Curve Generator (Coming Soon) Frameless Motor Sizing Considerations



[email protected]

Sold & Serviced By:

52

Motioneering Online Motor Sizing Tool Frameless Motor Sizing Considerations



[email protected]

Sold & Serviced By:

Questions? Joanna Keel

Marketing & Membership Manager Motion Control & Motor Association

[email protected] +1-734-994-6088

Thank you to our exclusive sponsors:


Kollmorgen [email protected]

+1-540-250-0399

Electromate Contact 1-877-737-8698

[email protected] www.electromate.com



[email protected]

Sold & Serviced By: