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StepSERVO™ Technology: Bridging the gap between cost effective and high performance motion

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Servo motor technology has been the backbone of high performance motion systems in automated machinery for many years. Applications include packaging equipment, high speed labelling machines, automated assembly, food and beverage, smart linear actuators and many more. At the same time, step motor technology has been used for motion axes where cost effectiveness has been a primary consideration.

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StepSERVO™ Technology: Bridging the gap between cost effective and high performance motion

  1. 1. #DWwebinar StepSERVO Technology: Bridging the gap between Cost Effective and High Performance Motion Control
  2. 2. #DWwebinar q  This webinar will be available afterwards at www.designworldonline.com & email q  Q&A at the end of the presentation q  Hashtag for this webinar: #DWwebinar Before We Start
  3. 3. #DWwebinar Miles Budimir Senior Editor – Moderator Design World Eric Rice Marketing Director Applied Motion Products, Inc. StepSERVO Technology: Bridging the gap between Cost Effective and High Performance Motion Control Meet your Speakers
  4. 4. #DWwebinar
  5. 5. #DWwebinar
  6. 6. #DWwebinar 1978 Applied Motion Products, Inc. is founded in 1978 in California to design, market and manufacture motion control solutions for the automation industry.
  7. 7. #DWwebinar 1978 1992 In 1992, Applied Motion designs and markets its first of many standard stepper drives, the 2035 full/half step drive.
  8. 8. #DWwebinar 1978 1994 1992 Shanghai Moons’ Electric is founded in 1994.
  9. 9. #DWwebinar 1978 1994 19971992 In 1997, Shanghai Moons’ Electric begins manufacturing stepper motors.
  10. 10. #DWwebinar 1978 1994 1997 20071992 In 2007, Applied Motion and Moons’ form Shanghai AMP&MOONS Automation (AMA), a joint venture dedicated to the development and manufacture of motor drives and integrated motors. AMA
  11. 11. #DWwebinar 1978 1994 1997 20071992 Moons’ acquires Applied Motion Products in 2014 to combine the strengths of all three companies into a global automation solutions provider. AMA 2014
  12. 12. #DWwebinar 1978 1994 1997 20071992 Moons’ acquires Lin Engineering in 2015, adding to the strength of Moons’ Industries globally. AMA 2014 2015
  13. 13. #DWwebinar
  14. 14. #DWwebinar Moons’ Industries Headquarters and Manufacturing in Shanghai, China Moons’ Industries Support center in Milan, Italy Moons’ Industries Support center in Chicago, USA Applied Mo1on Products Watsonville, CA, USA Lin Engineering Morgan Hill, CA, USA
  15. 15. #DWwebinar Auto-lamination Line Stator Coating Shaft Production Rotor Assembly Final AssemblyMachining Centers Produc'on capacity > 14 million step, servo and BLDC motors annually.
  16. 16. #DWwebinar The Value of Applied Motion Products Our Sales and Technical staff have an average of 23 years of experience in Motion Control. Both at Applied Motion and these other companies…
  17. 17. #DWwebinar The Value of Applied Motion Products 42 patents 30 patents 9 patents 3 patents President, Don Macleod Founder, Kenneth Kordik (ret.) Chief Technical Office, Jeff Kordik
  18. 18. #DWwebinar Closed Loop Stepper Technology
  19. 19. #DWwebinar WHAT IS StepSERVO? • TECHNOLOGY for implemen1ng closed loop servo control of 50- pole permanent magnet brushless DC motors, AKA “step motors”. • A RANGE OF PRODUCTS consis1ng of integrated motors in NEMA frame sizes.
  20. 20. #DWwebinar How does StepSERVO compare to tradi1onal open loop technology?
  21. 21. #DWwebinar Input Drive/ Controller Step Motor Output: Rotor Posi1on Tradi1onal Step Motor System is Open Loop Pros of Open Loop Systems: •  Low cost •  Simple to use; no tuning required •  Simple to control with digital pulse and direc1on signals •  Precise posi1oning Cons of Open Loop Systems: •  Resonance at certain speeds can lead to vibra1on and loss of torque •  Can stall without warning if torque demand is too high •  Motor consumes current regardless of load •  Can be noisy (audible)
  22. 22. #DWwebinar Pros of Closed Loop Systems: •  Addi1onal peak torque range •  Full closed-loop control, e.g. torque control •  Motor draws only the current that it needs Input Drive/ Controller Step Motor Output: Rotor Posi1on StepSERVO System is Closed Loop Sensor PID servo control loop •  Be_er overall system accuracy because drive/controller always knows the posi1on of the rotor
  23. 23. #DWwebinar Input Drive/ Controller Output: Rotor Posi1on Sensor Step Motor •  50-pole brushless motor (AKA step motor) •  5000 line incremental encoder (20,000 counts/rev) Note: 1024 line encoder used on smallest NEMA 11 motors only •  Integrated drive and control electronics •  Closed loop PID servo control
  24. 24. #DWwebinar Servo Motors Open Loop Step Motors Mo1on Control Market Space Cost $$$ $ Posi1on Loop Bandwidth Speed, Efficiency, Noise StepSERVO Motors Performance
  25. 25. #DWwebinar 1.  ACCELERATION 2.  EFFICIENCY 3.  HEATING 4.  AUDIBLE NOISE 5.  COST Side-by-Side Comparison: StepSERVO vs. Open Loop
  26. 26. #DWwebinar 1. ACCELERATION: For short, fast moves StepSERVO motors are best.
  27. 27. #DWwebinar 0 50 100 150 200 250 300 0 5 10 15 20 25 30 35 40 Torque (oz-in) Speed (rev/sec) Open loop max torque Open loop usable torque Max torque Usable torque Open loop speed-torque curve
  28. 28. #DWwebinar 0 50 100 150 200 250 300 0 5 10 15 20 25 30 35 40 Torque (oz-in) Speed (rev/sec) StepSERVO peak torque StepSERVO con1nuous torque Con1nuous torque Peak torque Up to 50% higher torque StepSERVO speed-torque curve
  29. 29. #DWwebinar 0 50 100 150 200 250 300 0 5 10 15 20 25 30 35 40 Torque (oz-in) Speed (rev/sec) StepSERVO peak torque StepSERVO con1nuous torque Open loop usable torque StepSERVO Closed loop torque StepSERVO Closed loop torque Open loop torque Comparison of Open loop and StepSERVO speed-torque curves Up to 85% more torque than open loop.
  30. 30. #DWwebinar 0 5 10 15 20 25 0 0.02 0.04 0.06 0.08 0.1 0.12 Speed (rev/sec) Time (sec) Open loop move profile Fastest open loop move profile
  31. 31. #DWwebinar 0 5 10 15 20 25 0 0.02 0.04 0.06 0.08 0.1 0.12 Speed (rev/sec) Time (sec) Fastest StepSERVO move profile Comparison of Open loop and StepSERVO move profiles 45% shorter move time than open loop. Almost 2X the number of cycles per minute. Fastest open loop move profile
  32. 32. #DWwebinar 2. EFFICIENCY: StepSERVO motors consume less power.
  33. 33. #DWwebinar 0 2 4 6 8 10 12 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 Speed (rev/sec) Time (sec) Open loop stepper StepSERVO Closed loop stepper 43.8 WaKs 14.2 WaKs Side-by-side comparison: Same move profile for both motors… •  Accel = 100 rev/sec2 •  Decel = 100 rev/sec2 •  Speed = 10 rev/sec •  Distance = 5 rev •  Dwell 1me = 0.1 sec Average Power Consump'on: More efficient!
  34. 34. #DWwebinar 3. HEATING: StepSERVO runs cooler.
  35. 35. #DWwebinar Ploss = i2R A large por1on of the losses in a motor (Ploss) is equal to the square of the current (i2) 1mes the winding resistance (R). Losses generate heat.
  36. 36. #DWwebinar •  StepSERVO motors only draw the current they need to move the load. •  Open loop motors draw the same amount of current whether it’s required to move the load or not. IMPORTANT !
  37. 37. #DWwebinar 0 2 4 6 8 10 12 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 Speed (rev/sec) Time (sec) Open loop stepper StepSERVO Closed loop stepper 76.0 °C 36.9 °C Side-by-side comparison: Same move profile for both motors… •  Accel = 100 rev/sec2 •  Decel = 100 rev/sec2 •  Speed = 10 rev/sec •  Distance = 5 rev •  Dwell 1me = 0.1 sec Motor Case Temperature, aZer 30 minutes: Runs cooler!
  38. 38. #DWwebinar 4. AUDIBLE NOISE: StepSERVO runs quieter.
  39. 39. #DWwebinar Motor Under Test (MUT) Microphone
  40. 40. #DWwebinar 0 10 20 30 40 50 60 70 80 90 0 5 10 15 20 25 30 35 40 Audible noise (dBA @ 12") Speed (rev/sec) Open loop StepSERVO™ closed loop From 0 to 1700 rpm, StepSERVO is no1ceably quieter. From 1700 to 2000 rpm, There is not much difference. Step motors are not generally recommended above 2000 rpm.
  41. 41. #DWwebinar 5. COST: StepSERVO offers great value.
  42. 42. #DWwebinar Open Loop Open Loop w/ encoder StepSERVO Closed Loop 1X 1X 1.2X 1.38X Rela've Cost Comparison: Integrated Stepper Motors Only 38% more than open loop Only 15% more than open loop w/ encoder! Start at $257 1.15X 1X
  43. 43. #DWwebinar SPECIFICATIONS: TSM SSM TXM
  44. 44. #DWwebinar TSM Specifica+ons •  DC input voltages up 70 VDC •  RS-232, RS-485 •  8 DIN, 4 DOUT, 1 AIN •  Step & Direc1on, Analog Velocity/ Torque/Posi1on, Streaming Commands, Stored Program Execu1on, Fieldbus: •  NEMA 11, 17 and 23 frame sizes
  45. 45. #DWwebinar •  DC input voltages up 70 VDC •  Ethernet •  3 DIN, 1 DOUT, 1 AIN •  Step & Direc1on, Analog Velocity/Torque/Posi1on, Streaming Commands, Stored Program Execu1on, Fieldbus: •  NEMA 23 frame size SSM Specifica+ons
  46. 46. #DWwebinar TXM Specifica+ons •  DC input voltages up 70 VDC •  RS-232, RS-485, Ethernet •  3 DIN, 1 DOUT, 1 AIN •  Step & Direc1on, Analog Velocity/ Torque/Posi1on, Streaming Commands, Stored Program Execu1on, Fieldbus: •  NEMA 24 frame size •  IP65 rated, M12 connectors
  47. 47. #DWwebinar TSM SSM TXM • IP65 • NEMA 24 • RS-232, RS-485, Ethernet • IP40 • NEMA 11, 17, 23 • RS-232, RS-485 • IP40 • NEMA 23 • Ethernet • Step&Dir, Velocity, Streaming Commands, Stored Program, Fieldbus
  48. 48. #DWwebinar What StepSERVO IS… •  Technology for closed loop control of brushless motors. •  A motor for precise and accurate posi1oning applica1ons with… •  More torque. •  Higher accelera1on rates. •  Be_er overall system accuracy. •  Less wasted energy and heat. •  Be_er efficiency. •  Less audible noise.
  49. 49. #DWwebinar What StepSERVO IS… •  An excellent solu1on for velocity control applica1ons. •  An excellent solu1on for torque control applica1ons. •  An excellent solu1on for all kinds of applica1ons, including… •  Labelling •  Material handling •  3D prin1ng •  Automated assembly •  Pressing •  Capping, screwing •  Linear applica1ons with ballscrews, lead screws and belt actuators •  Medical devices •  Laboratory equipment •  Semiconductor machinery •  CNC machining •  And many, many more…
  50. 50. #DWwebinar What StepSERVO IS NOT… •  A low-pole count servo motor (e.g. 4, 6 or 8 poles). •  Recommended for speeds above 2000 rpm.
  51. 51. #DWwebinar Resources Product Informa1on: www.applied-mo'on.com •  Applica1on Notes •  Videos •  Sovware Downloads •  Manuals and Quick Setup Guides
  52. 52. #DWwebinar Resources White Paper: www.applied-mo'on.com DIRECT LINK: www.applied-mo1on.com/stepservo-white-paper
  53. 53. #DWwebinar Resources Contact www.applied-mo'on.com DIRECT LINK: www.applied-mo1on.com/contact 1-800-525-1609
  54. 54. #DWwebinar Monthly e-Newsle_er Sign Up Here: www.applied-mo'on.com/newsleKer DIRECT LINK: www.applied-mo1on.com/newsle_er • 1 Email per month • New product releases • Technical 1ps & tricks • More…
  55. 55. #DWwebinar Thank you!
  56. 56. #DWwebinar Miles Budimir Senior Editor Design World mbudimir@wtwhmedia.com @DW_Motion Eric Rice Marketing Director Applied Motion Products, Inc. erice@applied-motion.com @ampmotion Questions? StepSERVO Technology: Bridging the gap between Cost Effective and High Performance Motion Control
  57. 57. #DWwebinar Thank You q  This webinar will be available at designworldonline.com & email q  Tweet with hashtag #DWwebinar q  Connect with Design World q  Discuss this on EngineeringExchange.com

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