Motion Control – Custom Linear Mechanisms

Custom Linear Mechanisms from Steinmeyer …

Welcome to Where Precision Is.  You Can Turn to Steinmeyer for Design and Assembly of Custom Linear Mechanisms for your Precision Positioning Systems
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Modern mechatronic systems consist of numerous precision components that must be assembled in complex configurations. Here, every detail counts.
Steinmeyer Mechatronik, a division of August Steinmeyer GmbH,
offers design and assembly services for a variety of demanding applications.
We have deep experience in medical devices, laboratory instrumentation, optical inspection & semiconductor positioning. Our engineers can implement your finished design or optimize your concept.

For Example …Motion Control Linear Stage

Demanding series production for a medical instrument

The task was to develop a motion unit for a computer tomography scanner which moves tungsten collimators during X-ray source rotation so that the X-ray beam can be adjusted to the minimum radiation dose required. The assembly itself is continuously moved in a circular path around the patient during use. A special challenge was the high acceleration caused by the rotation on a large diameter transverse to the direction of movement. This additional load requires a particularly stable construction with minimal potential for error.

Highest stability and reliability

Since this is used in a durable medical device, the requirements for functional safety and reliability are very high. The positioning system has been tested for three million application cycles and has proven this claim with statistical certainty in an endurance test.

CLICK HERE to see this solution and others from Steinmeyer Mechatronik

Steinmeyer has decades of experience in precision assembly. All of our systems, whether single or multi-axis, are manufactured carefully. Our high standards, monitored continuously through vigorous quality systems, are evident in every assembly we produce. We pay attention to every detail.
Trust Steinmeyer With Linear Mechanism Solutions:
  • We can assemble custom linear mechanisms of all sizes – from miniature actuators using 3 mm linear rails, to 3 m long lifting mechanisms.
  • As an added value, our engineers will offer innovative ideas for optimizing your design.
  • We can quote a completely assembled module, including sourcing of key components!
  • We offer our customers the advantage of a close working relationship, enabling us to provide you with the best possible solution to meet your needs.

Contact Person for Custom Linear Modules

Bruce Gretz

Phone: 781-273-6220

Bruce Gretz   bruce.gretz@steinmeyer.com

About Steinmeyer

In the realm of linear motion control, Steinmeyer is synonymous with precision, innovation, and exacting standards of quality. We are the world’s longest continuously-operating manufacturer of commercial ball screws, our main product line. As an added value, we offer customized linear modules from our highly innovative and experienced Mechatronik division. Designed and manufactured in Germany, our products are used globally in precision positioning for medical devices, lab instruments, and other mechatronic applications. Steinmeyer engineers will work closely with you to customize our offering to deliver a solution that meets your technical requirements and budget.

For further information on Steinmeyer our extensive product portfolio, call 1-781-273-6220 or e-mail Rosemary Belt at rosemary.belt@steinmeyer.com or visit the Steinmeyer FMD group at: www.steinmeyer.com

 

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Motion Control – Powerful Microstepping Drive from Servo2Go!

Applied Motion’s powerful stepper drive costs the same as a competitors drive without a built-in power supply!

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Greenville, DE –— The Motion Control STAC5 microstepping drive provides up to 5 amps per phase from a high bus voltage with sophisticated current control, delivering high torque over a board range of speeds. An advanced anti-resonance algorithm with electronic damping allows for maximum torque utilization and fast settling times.

The STAC5 microstepping drive is available in 120VAC and 220VAC versions, both housed in a compact package.

Applied Motion’s powerful stepper drive costs the same as a competitors drive without a built-in power supply, and features……

  • High performance
  • Built-in power supply & regeneration clamp
  • 120 and 220 VAC models
  • Accepts pulse & direction, streaming commands, stored programming
  • 10/100 MBit Ethernet & EtherNet/IP
  • Advanced anti-resonance
  • Matching high performance motors

All Motion Control STAC5 models include 100Mbit Ethernet communication. The Ethernet interface is used to configure the STAC5 and motor, and also supports the SCL and Q languages over standard Ethernet cabling, addressing and protocols.There are 3 control options available with the STAC5 stepper drives: S, Q and IP.

T• “S” drives can operate in pulse & direction, velocity, and streaming serial (SCL) control modes. To select the control mode, as well as to setup the motor and configure other drive parameters, use the ST Configurator™ software.

• “Q” drives can operate in all of the same control modes as an S drive, plus they have the ability to run stand-alone Q programs stored in non-volatile memory. Q programs are created using the Q Programmer™ software, which provides multi-tasking, math functions, conditional processing, data register manipulation, and more features in a robust yet simple text-based programming language. Like S drives, Q drives must first be setup and configured using the ST Configurator™ software.

• “IP” drives come with built-in EtherNet/IP network communications, the widely used industrial protocol for manufacturing automation applications. With EtherNet/IP users can control, configure and query the drive using an open, standards-based, industrial Ethernet connection at speeds up to 100 MBits/sec. The STAC5-IP drives run all of the same control modes as STAC5-Q drives, with the addition that all drive features can be accessed over EtherNet/IP, including more than 100 commands and 130 registers for controlling motion, I/O, configuration, polling, math, register manipulation, and Q programming. STAC5-IP drives are setup and configured using ST Configurator™, and Q programs are created using Q Programmer™.

An encoder feedback option provides position verification, stall detection and/or stall prevention. Applied Motion’s proprietary stall prevention algorithm monitors rotor lag and automatically reduces speed or acceleration to avoid motor stalls, allowing 100% torque utilization. high torque. These are three-phase brushless motors with hall signals for commutation and velocity loop feedback.

The STAC5 can be purchased with a wide range of high torque step motors, optimized for use with the drive. Three lengths of HT23 are available in single and double shaft configurations: HT23-552, HT23-553 and HT23-554, with holding torque ranging from 84 to 255 ounce-inches. Three lengths of HT34 are also available in single and double shaft configurations: HT34-495, HT34-496 and HT34-497, with holding torque ranging from 550 to 1700 ounce-inches.

For more information on the STAC5 Stepper Drives from Applied Motion Products, click on the link below —

https://www.servo2go.com/product.php?ID=105241&cat

For further information on this new product or others in our extensive product portfolio, call 1- 877-378-02401- 877-378-0240 or e-mail Warren Osak at warren@servo2go.com or visit Servo2Go.com at: www.Servo2Go.com

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Motion Control – ENX 16 RIO Encoder from Maxon Motor!

Motion Control – Maxon Motor presents a top-of-the-range high-resolution encoder. The ENX 16 RIO offers an impressive resolution of up to 65,536 counts per turn in a compact and rugged housing.

Motion Control - Maxon motion ENX 16RIO Motion Control Encoder

 

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Fall River, MA –Motion Control Components – Miniature Encoders – Requirements on encoders are becoming more and more demanding. This applies particularly to positioning applications with precision constant-speed control, where increasingly compact housings need to accommodate an ever greater number of electrical contacts. maxon motor solves this problem with its new ENX 16 RIO optical encoder. It is a mere 16 millimeters in size and offers a resolution of up to 65,536 counts per turn, making it ideal for the precise position and velocity control of DC motors

The new maxon ENX 16 RIO encoder (Reflective, Interpolated, Optical) fulfills all the requirements for a high-resolution optical encoder in a compact design. The resolution can be configured at the factory or online. With 16 millimeters outer diameter and 7 millimeters overall length, the housing is mechanically robust and protected from dust due to its injection-molded construction. The operating temperature range is -40 °C to +100 °C.

Maxon motion ENX 16RIO Motion Control Encoder on Motor

Easily configured online for combinations with maxon motors

The encoder can be combined and configured with matching drives online. It fits the new brushless EC-i 30 motors and the brushed DCX motors (diameters of 16 millimeters and up). The counts per turn and the electrical interface of the ENX 16 RIO encoder are also configurable online. All combination options and detailed product information is available in the maxon online shop: shop.maxonmotorusa.com

Comprehensive documentation and software are included with every delivery, and are also available for you to download from our website at www.maxonmotor.com.


 

 

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Motion Control – High Torque Rotary Voice Coil Actuators!

Motion Control - H2W High Torque Voice Coil Actuators

 

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Santa Clarita, CA —- Motion Control – H2W Technologies has developed several high torque rotary voice coil actuators, otherwise known as a limited angle torque motors or LATs. The model TWR-015-346-2RC was designed to allow for a low moving mass (68 grams per coil) and inertia, as well as dual independent coils to allow for two independent motion profiles or couple the coils together to double the torque output. This rotary voice coil actuator can generate a continuous torque of 185 in-oz [1.29 N-m] and a peak torque of 555 in-oz [3.88 N-m] at a duty cycle of 10% (i.e. 1 second on, and 9 seconds off) in each coil on a 4 inch [102 mm] rotation arm. By coupling the coils together, the continuous torque doubles to 370 in-oz [2.58 N-m] with a peak torque of 1110 in-oz [7.75 N-m] at a 10% duty cycle.

The Motion Control TWR-015-346-2RC has a total angular displacement of 15 degrees [0.26 radians] and a motor constant of 34.4 in-oz/sqrt(watt) [0.24 N-m/sqrt(watt)] per coil or when coupled together the motor constant is 48.5 in-oz/sqrt(watt) [0.34 N-m/sqrt(watt)]. The voice coil motor requires 1.33 amps of continuous current per coil and 4.0 amps of peak current per coil to generate the specified forces. The actuator fits in and envelope of 4.37 in [111.1 mm] x 2.99 in [75.9 mm] x 1.64 in [41.5 mm].

The moving coil design ensures a hysteresis free movement as the coil is wet wound and self-supported, and the non-commutated coil allows for ripple-free motion and no cogging. The voice coil actuator has been designed with mounting provisions in the magnet and coil assemblies. This allows for the integration of a bearing system to maintain the clearances between the coil and permanent magnetic field assemblies. The rotary voice coil actuator is ideal for applications requiring high torque and high-speed applications. Examples of such applications are driving a gimbal axis in scanning applications as well as providing stabilizing torques for image stabilization. More examples of H2W’s Rotary Voice Coils are available on our website: https://www.h2wtech.com/category/rotary-voicecoil-actuators

Technology

Simply stated, a current carrying conductor placed in a magnetic field will have a force (or torque) exerted upon it. This force is proportional to the direction and magnitude of the current and the flux density field. Since the permanent magnet flux density field is fixed, the direction of the rotation depends on the polarity of input current and the amount of torque that is produced is directly proportional to the magnitude of the input current.

Linear Motion Control - H2W High Torque Voice Coil Actuators - Drawing

 

 

 

 

 

 

 

 

 

 

A DC linear servo amplifier is required to provide power to the torquer.

Rotary voice coil actuators are supplied unhoused without bearings.

Coupling the rotary voice coil actuator to your bearing system and a rotary encoder or other feedback device yields a system that is capable of intricate angular position, velocity, and acceleration control.

Low moving inertia of the moving coil assembly allows for high angular acceleration of the payload.

Advantages:

  • No Torque Ripple
  • High Angular Acceleration
  • No Commutation
  • Zero Cogging
  • Brushless
  • Low Profile

Applications:

  • Aerospace
  • Semiconductor
  • Medical
  • Military

Rotary Voice Coil Motor – is an arc segmented multipole permanent magnet stator with a low inertia copper magnet wire rotor. Angular excursions are typically less than 90º. This torquer is supplied with out a shaft or bearing.

TWR Series Limited Angle Torque Motor

The TWR Series is comprised of a stationary, arc segmented, multipole permanent magnet stator assembly with a low inertia wound wire rotor.

Rotor: The rotor is made up of a single coil of bondable copper magnet wire. The coil is wound and preformed into the desired shape. It is held together with the bonding agents in the wire. It can be encapsulated with aluminum or plastic brackets in order to provide a means for mounting the rotor to the bearing system and payload. The maximum angular excursion is less than 90º.

Stator: The stationary stator assembly consists of multipole permanent magnets that are bonded to steel plates. The 2 opposing steel plates are spaced apart to provide a gap using end plates. The coil rotor assembly moves angularly within this gap. There is no magnetic attractive force between the stator and the rotor.

The TWR Series Torquers are available in 2 configurations.

The low profile (Type L) configuration has a smaller overall height which allows it to fit in a more compact space, but has less angular rotation for a given stator arc segment.

The second configuration (Type S) has a larger overall height but has typically twice the angular rotation per given stator arc segment when compared to the Type L torquer.

  • No Torque Ripple
  • High Angular Acceleration
  • No Commutation
  • Brushless
  • Low Profile

For Product Descriptions of High Torque Voice Coil Actuators CLICK HERE

About H2W Technologies, Inc.

H2W Technologies, Inc. is dedicated to the design and manufacture of linear and rotary motion products that are used in the motion control industry. The complete line of linear electric motors includes: Single and dual axis linear steppers, DC brush and brushless linear motors, voice coil actuators, and AC induction motors. Also offered is a complete line of ball screw, lead screw and belt driven positioning stages.

Other motion control products include: Limited angle torque motors for compact, limited angular excursion rotary servo applications, 3 phase brushless rotary servo motors with matching digital servo amplifiers and permanent magnet linear brakes for fail-safe, zero power braking for baggage handling and people moving applications as well as amusement park rides.

With over 75 years combined experience in the linear and rotary motion field, the H2W Technologies team of engineers offers the optimal solution to the most demanding motion control, requirements.

For additional information contact Mark Wilson at H2W Technologies, 26380 Ferry Ct, Santa Clarita, CA 91350; Tel: 888-702-0540, Fax: 661-251-2067, E-Mail: info@h2wtech.com or visit the website at http://www.h2wtech.com

 

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Motion Control – Linear Focus Actuator Features, 20 mm Clear Optical Path, <50 nanometer Repeatability, and <3 miliseconds Response Time!

Sunnyvale, CA –The LFA-2010 Linear Focus Actuator from Equipment Solutions is a high performance compact motion control positioner, specifically developed for optical applications requiring both high precision and high speed positioning over a short to medium stroke. The LFA-2010 actuator has a 10 mm range of motion with <50 nanometer positioning repeatability, and a small step response of time of <3 milliseconds. This high force, low noise voice coil motor is typically configured with an analog position feedback sensor and can be optionally equipped with a 1um resolution digital quadrature feedback element.

Motion Control LFA-2010 Linear Focus Actuator

An important feature of this product is it’s innovative tubular architecture. This allows the 20 mm clear optical path to go directly through the middle of the motor. The patented dual ‘Flexures system’ has zero stiction/friction. For mounting optics a standard C-mount is provided, or an optional 12.7mm diameter lens socket. The C-mount provides options for adapters to common microscope objectives like DIN or M25 or M26. The LFA-2010 Linear Focus Actuator is well suited for optical focusing and other micropositioning applications such as scanning interferometry, surface structure analysis, disk drive testing, autofocus systems, confocal microscopy, biotechnology, and semiconductor test equipment.

The LFA-2010 Linear Focus Actuator can be supplied “Plug-and-Play,” with the SCA814 Servo Controlled Amplifier, a matching power supply, and necessary cabling for easy integration into new and existing applications.

Equipment Solutions, Inc. (ESI) is a provider of engineering and manufacturing services. ESI specializes in the design and production of automation and instrumentation products including motion control components and sub systems. ESI’s products range from galvanometer amplifiers with an integrated arbitrary waveform generator, to high-resolution displacement sensors, voice coil and stepper motor stages, amplifiers and controllers.

For additional information contact Jeff Knirck at Equipment Solutions, 1098 W. Evelyn Ave. Suite #102; Sunnyvale, CA 94086; Tel: 408-245-7161, Fax: 408-245-7160, E-Mail: info@equipsolutions.com or visit the Website at http://www.equipsolutions.com

 

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Motion Control – Checkout the BEMA Series of Large Open Frame XYZ Gantry Systems from Intellidrives!

Intellidrives Motion Control Syncronized Belt Gantry Systems

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Philadelphia, PA, — Motion Control Components and Systems – XYZ Gantry Systems – IntelLIDrives new Syncronized XYZ Gantries BEMA Series are offered in travel length from 300 x 300 mm to 3,000 x 3,0000 mm. With speed up to 2 m/sec, BEMA Gantry Series is perfect for applications in high speed positioning for light-to-medium payloads.

Can be fitted with optional Z third axis module for XYZ configuration

Supplied with self-supporting rigid elevation structure for industrial applications

Can be motorized with stepper motors, brush-less servo motor/encoders or integrated SMART motors. Contact-less end-of-travel limit senors are installed on these systems.

Can be fitted with optional Z third axis module for XYZ configuration.

Supplied with self-supporting rigid elevation structure for industrial applications.

Features:

  • XY plane 2-axes travel from 300 x 300 mm to 3 m x 3 m
  • Optional Z axis stroke 300 mm to 1000 mm
  • Synchronized belt drive
  • Stepper, Servo, SMART motors
  • Repeatable to 50 microns
  • Load 30 Kg

Specifications of X and Y Axes

Actuator

BEMA X,Y Axes

Travel XxY

300×300 mm to 3 m x 3m

Mechanism

belt, lead equivalent 

75 mm

Motor type

stepper

servo/SMART motors

Repeatability

 50 microns

Load capacity

30 kg

Max speed

2 m/sec

motor/driver dependent

Intellidrives Motion Control Z Axis Component with Rotation

Optional Z Axis features vertical travel and bidirectional rotation of the shaft.

Specifications of Z Axis (Linear & Rotary Combination)

Linear Aspect

BEMA-W40

 Spec  Rotary Aspect

RW40

 Spec 
Linear stroke 70, 120, 170,
220, 270,320 mm  
Rotation  unlimited
Load 3 Kg Load 3 Kg
Repeatability  ± 50 Repeatability  ± 60
Resolution  25 Resolution  30
Linear velocity  500 mm/sec Angular velocity  150 rpm
Mechanism belt, lead
equivalent 75 mm
Mechanism  gear 63:17
Motor  stepper Motor  stepper

FOR ADDITIONAL INFORMATION – CLICK HERE

About IntelLiDrives —

IntelLiDrives, Inc. manufactures linear actuators, XY tables and rotary tables for the industry, government, science and research institutions around the world. Our precision rotary actuators, XY stages and linear actuators are used in the applications in medical devices, life sciences, semiconductor and electronic assembly manufacturing, data storage, laser processing, military/aerospace, photonics, automotive and test assembly, research and development and other industries requiring high precision and throughput motion control solutions.

For further information on this new product or others in our extensive product portfolio, call 1-215-728-6804 or e-mail Intellidrives at sales@intellidrives.com or go Intellidrive – Contact Us at: www.intellidrives.com/contact-us

 

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Get a Machine Safety Risk Assessment. Reduce risk and protect your people.

Get a Safety Risk Assessment for a Safer Motion Control Workplace!

Safety-Gotcha Stick

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Hoffman Estates, IL -Motion Control Automation and Safety -Motion Control Components and Systems –

Take the first step to understand your risks and ensure your machines will pass regulatory inspection.

Fill out this form to find out how you can leverage our Global Risk Assessment expertise  to protect the people, and the machines that run your business profitably:

  • Understand your current compliance status
  • Identify and prioritize which equipment presents your greatest risks
  • Develop a strategic plan for compliance
  • Minimize downtime, ensure employee safety and reduce the risk of steep fines

Also – Get The Gotcha Stick for a Safer Motion Control Workplace!

KEEP YOUR WORKPLACE SAFE! – GET A ‘GOTCHA-STICK” CLICK HERE

To Get a Machine Safety Risk Assessment  CLICK HERE

To Down Load the OMRON Machine Safety Risk Assessments Brochure CLICK HERE

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To contact OMRON about this or other industrial products CLICK HERE

 

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Motion Control – XY-Theta Alignment Stage Featuring High Resolution and High Repeatability Is Available from OES!

OES Motorized XY Theta Alignment Stage

 

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Van Nuys, CA – — Motion Control Components – Alignment Stage – The XYR-03-01 Alignment Stage from Optimal Engineering Systems, Inc. (OES) is a high resolution, high repeatability XY-Theta stage for such applications as: Angular glass cutting and grinding, wafer alignment, semiconductor handling, laser cutting and drilling. The linear resolution of the X and Y axis is 5µ (non-micro-step) or 0.125µ (20 micro-steps per step motor driver in use), the repeatability is 1.5µ, and positional accuracy is 5µ. The 1 mm per-turn lead screws and preloaded V-groove and crossed roller bearings add to the high precision and stiffness of the XYR-03-01 alignment stage. The linear travel of the X and Y axes is 50 mm x 50 mm.

The 100 mm diameter theta stage is driven by a precision 90:1 ratio worm gear. The resolution of the theta stage is 0.02O (non Micro-step) or 0.001O (20 Micro-steps per step motor driver in use). Repeatability is 0.005O, positional Accuracy is 0.01O and backlash is 0.005O.

Two-phase stepper motors are standard. The knob for manual adjustments of each axis can be replaced with an incremental encoder for position verification or closed loop operation. These black anodized Aluminum XY-Theta stages are easy to integrate into new or existing systems. Compatible Motion Controllers are available from OES and the XYR-03-01 Alignment Stage can also be ordered as a complete plug-and-play system.

About OES Optimal Engineering Systems, Inc. (OES) is a manufacturer of motion control products including: Stepper motor controllers and drivers, solenoid electronics, and positioning stages and slides. Applications include: Animation, automated assembly systems, automation, CNC machines, flight simulation, inspection systems, linear and rotary stages, machine tools, medical devices, motion control camera boom systems, optical comparators, CMMs, pan-tilt gimbals, PCB assembly & inspection, pick-and-place, positioning stages, robotics, scanners, security cameras, telescope drive mechanisms, time-lapse photography and winders

Some of the industries OES serves are: Aerospace, Astronomy, Chemical, Communications, Educational Institutes, University, Colleges, Government Agencies, National Labs, Manufacturing, Medical, Metrology, Military, Motion Control, Museum, News Agencies, Semiconductor and Test Equipment. Optimal Engineering Systems, Inc’s. competitive advantage is its state-of-the-art in-house manufacturing facility in North America enabling OES to supply clients with custom designed orders or high volume just-in-time deliveries globally.

For additional information contact Customer Service at Optimal Engineering Systems, Inc. (OES) , 6901 Woodley Ave, Van Nuys, CA 91406; Tel: 888-7071-1826, +1 (818) 222-9200, E-Mail: sales@oesincorp.com or visit the website at http://www.oesincorp.com

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Motion Control – Closed-Loop Integrated Stepper Motors feature magnetic or absolute encoder feedback Available from Electromate!

Motion Control - Electromate offers JVL Closed Loop Integrated Steppers

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Vaughan, Ontario, Canada — Motion Control Components — JVL presents a new innovative closed-loop stepper motor technology for its NEMA 23 & 34 integrated stepper motor range from 0,1 to 12 Nm. JVL, the European leader in the development of integrated servo and stepper motor technology, has now again developed a new and unique product in the field of integrated motor control.

New Innovative Technology

JVL closed-loop integrated stepper motors, QuickStep®, provide higher torque, faster acceleration, torque control, stall free operation and quieter movements than traditional step motor systems. QuickStep do this with greater efficiency and less motor heating because motor phase current are regulated up and down according to need. Performance of JVL closed-loop steppers are similar to servo motors, but with higher torque and often without need of gearbox, resulting in a more inexpensive solution. Design safety factors have always been high for stepper motors to ensure stall-free operation – now with QuickStep closed-loop control design can be very close to the limit resulting in even lower costs. QuickStep is a true closed-loop control system that compensates step angle errors during a movement and correct errors within a full step. If load becomes too high speed is lowered and position errors will always stay within two full-steps. Smart digital design and very high update rates (36 MHz) means there is no need of any manual adjustment or setup. It works like a perfect stepper motor benefitting from the servo motor technology.

Advantages compared to open loop stepper motors

  • Position feedback and control
  • Fast and easy commissioning. No tuning needed
  • No stalling. No step losses at all
  • Torque control
  • Much faster positioning and more cycles per second
  • Increased efficiency and thereby much lower temperature
  • Shorter settling time
  • Controls higher inertias than open loop steppers
  • Higher load tolerance
  • More quiet operation (lower acoustic noise)
  • Longer lifetime due to lower temperature
  • Correct positioning without overshoot and oscillation

Advantages compared to servo motors

  • Very high Torque at low speed. Often 3-4 times higher in same motor flange size
  • Very high ratio-of-inertia, often up to 40:1
  • Faster commissioning. No tuning needed
  • Lower price. Same price as open loop steppers
  • Totally stiff at standstill. Full holding torque
  • Direct drive without gearbox (better and more precise torque control)
  • Correct positioning without overshoot
  • No oscillation
  • Very short settling time

Benefit in these application from closed-loop stepper motors

  • Multiple axis applications (RS485, CANopen)
  • Industrial Ethernet: Profinet, EtherNet/IP, EtherCAT, Powerlink, Modbus TCP, SERCOS III
  • Magnetic or Absolute Encoder Feedback
  • Positioning tasks with load changes
  • Applications that require quiet operation, short settling times and precision positioning

Applications include

  • Winding applications
  • Belt drives (start/stop, positioning)
  • Dosing pumps and filler systems
  • Semi-conductor mounting
  • Wafer production
  • Textile machines and industrial sewing machines
  • Robotics
  • Testing and inspection systems

More information on the JVL’s Closed-Loop Integrated Stepper Motors can be viewed at the links below-

NEMA 23 models

NEMA 34 models

About Electromate:

Electromate’s Core Purpose is to help Manufacturers build better machines using differentiated automation technology. They specialize in Robotic and Mechatronic Solutions for the Industrial Automation marketplace. Respected by customers as a premiere source for High Performance Automation and Motion Control Components & Systems, Electromate® specializes in AC & DC Servo and Stepper Motors & Drives, Motion & Automation Controllers, Positioning Systems & Actuators, Feedback Devices, Gearing Products and HMI’s & Operator Displays, all supported via extensive product selection, just-in-timedelivery, dedicated customer service and technical engineering support.

More on Electromate can be found at

Website: http://www.electromate.com

LinkedIn: https://www.linkedin.com/company-beta/209277/

Twitter: https://twitter.com/Electromate

Facebook: https://www.facebook.com/electromateindustrial/

Google+: https://plus.google.com/104057418684128701566

Blog: https://electromate.wordpress.com/

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For more information on the “Best Place to Work”CLICK HERE!

To view Electromate’s new corporate video CLICK HERE

To see all of Electromate’s Products and Application Stories featured on MotionShop.com, enter electromate in the Google custom search box (upper left, above)

For further information on this new product or others in our extensive product portfolio, call 1-877-SERVO99 (737-8699) or e-mail Warren Osak at sales@electromate.com or visit Electromate at: www.electromate.com

 

Motion Control Tutorial – Slotted vs. Slotless Motor Technology

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When first introduced, brushless DC motors, despite their many advantages, were cast as a costly alternative to brush-commutated motors and were typically only specified for low-power applications where long life was the primary desired requirement. Without the mechanical brush-commutator mechanism that would wear and eventually result in motor failure, brushless motors could be relied upon to deliver performance over time. As for other advantages, conventional wisdom held that brushless motors provide high speed and fast acceleration, generate less audible noise and electromagnetic interference, and require low maintenance. Brush-commutated motors, on the other hand, would afford smooth operation and greater economy. In the past decade, though, brushless motors have gained broader appeal and greater acceptance in industry for a wider range of applications previously dominated by brush-commutated products, due in part to dramatic reductions in the cost and size of electronic components and advances in motor design and manufacturing.

At the same time, manufacturers have further sought to challenge conventional wisdom by improving brushless motor design in an effort to combine the traditional advantages of brush-commutated and brushless types. A noteworthy example of how far these innovations have progressed involves the slotless (instead of slotted) construction of the brushless motor’s stationary member, or stator.

The slotless stator design originated with the goal to deliver smooth running performance and eliminate cogging, which is an unwanted characteristic especially in slower-running applications (less than 500 rpm). The absence of cogging is, in fact, the most-often cited reason for selecting a slotless brushless motor.

Slotted Motor Construction

Most brushless motors (slotted or slotless) use electronic commutation, usually Hall-effect sensors and magnets, in place of brushes. The motor’s rotor consists of a steel shaft with permanent magnets or a magnetic ring fixed around the circumference of the shaft. The magnets are responsible for producing torque. As the flux density of the magnet material increases, the amount of torque available from the rotor assembly increases.

In traditional slotted brushless motors, the stator features a group of slotted steel laminations (0.004 in. to 0.025 in. thick), which are fused to form a solid uniform stack and create a series of teeth. Wound copper coils, which produce electromagnetic fields, are then inserted into each of the slots. Together, the laminated stack and wound copper coil form the stator assembly. The return path completing the magnetic circuit consists of the laminated material outboard of the copper windings in the stator and the motor housing.

These brushless slotted motors are especially powerful, because the teeth around which the copper wire is wound place the iron closer to the magnets, so the magnetic circuit is completed more efficiently. As the air gap between iron and magnets is reduced, the torque available for the motor is increased.

However, slotted stators are known to cause cogging, which is attributed to the teeth in their construction. Cogging occurs when the permanent magnets on the rotor seek a preferred alignment with the slots of the stator. Winding copper wires through the slots tends to increase this effect. As magnets pass by the teeth, they have a greater attraction to the iron at the ends of the teeth than to the air gaps between them. This uneven magnetic pull causes the cogging, which ultimately contributes to torque ripple, efficiency loss, motor vibration, and noise, as well as preventing smooth motor operation at slow speeds. A slotless stator offered a solution to the problems experienced with cogging in slotted brushless DC motors.

Advantage of the BLDC Slotted Motor Technology

The main advantages of the slotted technology are:

  • ease of winding customization
  • increased heat dissipation
  • ability to withstand high peak torque
  • high power density

Slotted Motor Applications

The Slotted Motor is ideal for applications such as:

  • Medical Hand Tools
  • Hand held shaver system for arthroscopic surgeries
  • High speed surgical drills for ENT surgeries

Slotless Motor Construction

Instead of winding copper wires through slots in a laminated steel stack as in conventional slotted brushless motors, slotless motor wires are wound into a cylindrical shape and are encapsulated in a hightemperature epoxy resin to maintain their orientation with respect to the stator laminations and housing assembly. This configuration, which replaces the stator teeth, eliminates cogging altogether and results in desired quiet operation and smooth performance.

The slotless design also reduces damping losses related to eddy currents. These currents are weaker in a slotless motor, because the distance between the laminated iron and magnets is greater than in a slotted motor.

Slotless motors are typically designed with sinusoidal torque output that produces negligible distortion, rather then a trapezoidal voltage output. The sinusoidal output reduces torque ripple, especially when used with a sinusoidal driver. Because the slotless design has no stator teeth to interact with the permanent magnets, the motor does not generate detent torque. In addition, low magnetic saturation allows the motor to operate at several times its rated power for short intervals without perceptible torque roll-off at higher power levels.

Compared with slotted motors, slotless construction also can significantly reduce inductance to improve current bandwidth. The teeth in a slotted motor naturally cause more inductance: the coils of copper wire around the teeth interact with the iron in a slotted motor, and this interaction tends to send the current back on itself, resulting in more damping (or dragging) and impacting negatively on slotted motor response and acceleration.

In terms of delivering power, conventional slotted motors used to enjoy the advantage over slotless types, due (as noted) to the proximity of iron and magnets and the reduced air gap.

However, this advantage has virtually evaporated, in large part due to the utilization of high-energy, rare-earch magnets (such as samarium cobalt and neodymium iron boron). By incorporating these magnets, manufacturers of slotless brushless motors have been able to routinely compensate for the greater air-gap distance. These more powerful magnets effectively enable the same (or better) torque performance for slotless products compared with slotted. Eliminating the teeth and using stronger magnets both serve to maximize the strength of the electromagnetic field for optimum power output. Rare-earth magnets, along with the fact that fewer coils, or “turns,” of the wire are required in slotless motors, also help contribute to low electrical resistance, low winding inductance, low static friction, and high thermal efficiency in slotless motor types.

One more important difference between slotless and slotted designs is the rotor diameter. Slotless motors have a larger rotor diameter than slotted construction for the same outside motor diameter and will generate a higher inertia, as well as accommodating more magnet material for greater torque. For applications with high-inertia loads, the slotless product is more likely to be specified.

Slotless Motor Applications

In general, brushless motors are usually selected over brushcommutated motors for their extended motor life. (While motor life is application-specific, 10,000 hours are usually specified.) Other reasons for specifying brushless motors include a wide speed range, higher continuous torque capability, faster acceleration, and low maintenance.

In particular, slotless versions of brushless DC motors will suit those applications that require precise positioning and smooth operation. Typical niches for these motors include computer peripherals, mass storage systems, test and measurement equipment, and medical and clean-room equipment.

As examples, designers of medical equipment can utilize slotless motors for precise control in machines that meter and pump fluids into delicate areas, such as eyes. In medical imaging equipment, slotless brushless DC motors decrease banding by providing the smoother operation at low speeds. Airplane controls supply smoother feedback to pilots. And, by eliminating cogging and resulting vibration, these motors can reduce ergonomic problems associated with hand-held production tools. Other appropriate applications include scanners, robots for library data storage, laser beam reflector rotation and radar antenna rotation equipment, among many others./span)

Customization Options

Slotless brushless DC motors, as with most motors today, feature a modular design so they can be customized to meet specific performance requirements. As examples, planetary or spur gearheads can be integrated on motors for an application’s specific torque and cost requirements. Planetary gearheads offer a higher-torque alternative. Slotless motors can further be customized with optical encoders, which provide accurate position, velocity, and direction feedback that greatly enhances motor control and allows the motors to be utilized in a wider range of applications. As a low-cost alternative to optical encoders, rotor position indicators (ie. Hall Sensors) can be specified.

When using optical encoders, differential line drivers can be utilized to eliminate the effects of electrically noisy environments. Differential line drivers are designed to ensure uncorrupted position feedback from the encoder to the control circuit.

Motor Selection Guided by Application

Despite the overall design and performance comparisons reviewed here for slotless and slotted brushless DC motor types, one should remain cautious in drawing any conclusion that one type is the ultimate choice over the other. There are simply too many variables that must be evaluated, ranging from rotor size and windings to housing and special components. A given application and its requirements should (and will) be the guiding factors in selecting a particular motor type and the customized components to be incorporated.

Some encouraging news in those applications that would clearly benefit from a slotless brushless motor is that costs are coming down to be more in line with those for slotted motors. This is because of new streamlined manufacturing techniques and an increasingly available supply of powerful magnets, which are both beginning to have a positive impact on end-product costs.

Regardless of any cost differential, however, for many applications, slotless brushless DC motors will be the preferred choice to resolve specific requirement issues. While advances in electronics are beginning to be applied that promise to reduce normal cogging in slotted products as a step toward making these motors more smooth running and quiet, the industry is not there yet: slotless motors remain the best alternative where cogging and life are defining performance issues

This Tutorial and other Motion Control Tutorials are available through www.Servo2Go.com

For further information on this new product or others in our extensive product portfolio, call 1- 877-378-0240 or e-mail Warren Osak at warren@servo2go.comor visit Servo2Go.com at: www.Servo2Go.com

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