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Best Practices for Motion Control: Stepper Motor and Encoder Selection

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Lin Engineering and US Digital present stepper motor and encoder feedback selection considerations for motion control applications. We’ll share a case book example highlighting a medical application …

Lin Engineering and US Digital present stepper motor and encoder feedback selection considerations for motion control applications. We’ll share a case book example highlighting a medical application that required a high torque step motor utilizing an encoder for position feedback. Details of stepper motor and feedback options will be presented along with common terms and a guide to selection and integration.

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  • 1. •  •  •  •  •  Selec%ng  a  step  motor   Common  step  motor  enhancements   Case  History   Benefits  of  an  encoder   Encoder  selec%on  
  • 2. 1.  Maximum  Efficiency     Torque  at  Speed   2.  Power  Available     Voltage  &  Current   3.  Common  Issues     Resonance     Accuracy  
  • 3. •  Vary  the  voltage  or   the  current   •  Find  an  opera%ng   speed   •  Motor  supplier  will   back  calculate   required  torque  
  • 4. Maximizing  Torque  @  OperaOng  Speed   24VDC,  2.0  Amps/Phase,  Full  Stepping   80   Lin  Motor   ExisOng  Motor   Pullout  Torque  (oz-­‐in)   70   60   50   OLD   Opera%ng  Speed   NEW   40   Opera%ng  Speed   30   20   10   0   200   400   600   800   1000   Speed  (pps,  1  pulse  =  1.8  degree)   1200   5  
  • 5. (Varied by motor winding and power) 80   We  design  motor’s  max.  efficiency  at  your  opera%ng  speed   Efficiency  (%)   70   60   50   40   30   20   10   0   0   2   4   6   8   10   12   14   16   Speed  (RPS)   6  
  • 6. Tips  to  reduce  resonance   •  Change  Voltage  and  Current   •  Change  Iner%a  of  the  load   •  Change  microstepping   •  Change  to  a  different  motor  
  • 7. Vibration Amplitude Vibration Amplitude                               3709  vs.       Standard  0.9  
  • 8. •  Vary  Current  or  Voltage  to  find  torque   •  Every  motor  can  be  maximized  for  best   performance  for  max  efficiency   •  Reduce  resonance  by  changing  voltage,   current,  microstepping  or  load.  
  • 9. •  Lower  Speeds  and/or  Higher  Torque-­‐  Gearboxes   •  Reduce  Resonance-­‐  Dampers   •  Posi%on  Verifica%on  and  Correc%on-­‐  Encoders  
  • 10. •  When  posi:on  of  motor  must  always  be   maintained   •  If  a  motor  stall  detec:on  and  ac%on  is  required   •  Typical  Industries:   •  Medical   •  Solar   •  Semiconductor  
  • 11. Background:   •  Medical  device  used  to   remove  mucus  from  pa%ent   airways   Requirements:   •  High  holding  torque   •  Accurate  posi%oning   •  Posi%on  feedback  
  • 12. •   Mechanical     •   Resolu%on   •   Index   •   Differen%al  vs.  Single  Ended  Output  
  • 13. •   Frame  Size   •   Shac  Diameter   •   Moun%ng  Bolt  Circle   •   Environmental  Considera%ons  
  • 14. One  Cycle   1   2   3   Quadrature  States   4  
  • 15. •   CPR  -­‐  Cycles  Per  Revolu%on   •   PPR  -­‐  Pulses  Per  Revolu%on   •   Example  -­‐  100  CPR  =  400  PPR  
  • 16. Output  A   Output  B   A  Leads  B  
  • 17. Output  A   Output  B   B  Leads  A  
  • 18. •  Provide  Direc%on  of  Shac  Rota%on   Informa%on   •  Enable  4x  Resolu%on  Increase  Over  Disk  CPR   •  Standard  Signals  Regardless  of  Encoder   Mechanical  Package  
  • 19. Output  A   Output  B   Index  
  • 20. Index  Paeern  
  • 21. •  Once  per  360  Degree  Rota%on   •  Gives  a  Single  Absolute  Loca%on   •  Typically  Used  for  Home  or  Zero  Loca%on  
  • 22. A   A’   B   B’  
  • 23. A       A’       Index       Index’      
  • 24. •  High  Electrical  Noise  Immunity   •  Transmijng  Encoder  Signals  Over  a  Long   Distance   •  Requires  Differen%al  Receiver    
  • 25. Output  A   Output  B   Index  
  • 26. •  Simple  Interface  Requirements   •  Most  Common  Form  of  Encoder  Output   •  Short  Distance  Signal  Transmission  
  • 27. •  •  •  •  •  Mechanical   Resolu%on   Index     Differen%al  vs.  Single  Ended  Output   Final  Step  -­‐  Decision  
  • 28. •  •  •  •  •  Short  Lead  Times   Personal  Customer  Service   Great  Value   Reliability   Custom  Mo%on  Control  Solu%ons  

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