Kollomorgen- Direct Drive Embedded Motion For Robotic & Mechatronic Applications

Kollmorgen
Direct Drive Embedded Motion for Robotic & Mechatronic
Applications

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ELECTROMATE
Toll Free Phone (877) SERVO98
Toll Free Fax (877) SERV099
www.electromate.com 1
sales@electromate.com

What is Direct Drive Rotary?

Direct coupling of the load to the motor

For DDR (Direct Drive Rotary)

Timing belt/pulley

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Direct Drive vs. Gearbox

A typical application for DDR Technology
Gearbox DDR

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Why Customers Love Direct Drive

To gain Benefits of Eliminating Mechanical Transmissions
• 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 Sold & Serviced By:

ELECTROMATE
• Quiet performance…up to 20db reduction

DDR Product Formats
As the leader in DDR product technology, Kollmorgen provides 3 DDR solutions to
match best with your machine
DDR Product Format Best Application Fit

Significant design integration,
Frameless DDR
best mechanical package fit
parts set - KBM
Apply for maximum torque in
minimum volume

Easy to integrate,
Fully housed package size fixed
GOLDLine DDR® Apply for indexing or where
load needs to be supported

Easy to integrate,
package size fixed
Cartridge DDR™
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Apply where bearings already
ELECTROMATE
Toll Free Phone (877) SERVO98 exist in machine

Discover KBM – Embedded Motion

The Kollmorgen KBM family is built on a foundation of exceptional
quality construction, including:

• Fully encapsulated stator windings
• 155 degree C internal winding temperature continuous capability
• PTC thermistor (avalanche-type) overload protection
• Rare-earth neodymium-iron-boron magnets
• Fail-safe bands over rotor magnets
• RoHS compliant
• Latching digital hall effect sensors (KBMS Series)
• Choice of insulation system (S or H - <240Vac or 240 - 480 Vac systems)
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Product Overview

The Benefits of KBM Frameless Motor
• Industry-Leading Frameless Motor Performance
• Advanced electromagnetic designs deliver maximum torque density which minimizes required motor space envelope
• Extremely smooth rotation with minimal cogging and low total harmonic distortion (THD)
• Broad operating speed range and rapid acceleration

• Quality Construction Ensures Reliability and Safe Operation
• Redundant magnet attachment to rotor on high-speed models –• adhesive bonding and Kevlar® branding
• 155°C motor winding temperature rating with integral thermistor
• allows continuous safe operation for demanding applications
• Designed with UL-recommended insulation systems to simplify system regulatory approval
• RoHS compliant material selection

• Highly Configurable Design Minimizes Time to Solution
• 14 frame sizes with multiple stack lengths
• Standard sensor feedback using Hall effect sensors
• Standard high and low voltage insulation
• Multiple standard windings with custom windings available upon request
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• Mechanical interface changes easily accommodated

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KBM Options

No Fee Options

• Sensor Feedback (KBMS models)
• Latching digital Hall effect sensors are pre-aligned and factory installed
on the lead end of the stator. Wiring instructions and electrical timing
diagrams are included in this selection guide. KBMS models include
added axial rotor length to achieve proper sensor triggering.

• Choice of Insulation System
• S (standard) – acceptable for applications up to 240 Vac drive amplifier supply.
• H (high voltage) – required for applications >240 Vac and up to 480 Vac drive amplifier supply.

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KBM Options

Allowed Modifications – Fees may apply
• Various Windings
Motor windings may be optimized to provide desired speed and torque
performance according to the unique voltage and current requirements
of a customer’s application. Kollmorgen engineers must confirm
electrical feasibility and manufacturability of each special winding
arrangement prior to quotation.
• Rotor Hub Dimensions
Rotor hubs may be provided with different customer-designated hole
patterns, mounting features or smaller inner bore diameters. Standard
KBM(S) models shown within this selection guide include the largest
available inner rotor bore diameter.

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KBM Options

Allowed Modifications – Fees may apply
• Rotor Hub Material
Standard configuration KBM(S) rotor hubs are constructed from nonplated
cold rolled steel. If plating, coating, cleaning or alternate material
is desired, Kollmorgen engineers must confirm feasibility and pricing
adjustment prior to quotation.
• Stator Sleeve Material
Standard configuration KBM(S)-10, 14, 17, 25, 35, 45, 163 and 260
size stators are designed with uncoated aluminum sleeves around the
stator lamination stack. If coating or plating is desired for the aluminum
stator sleeve, Kollmorgen engineers must confirm feasibility and pricing
adjustment prior to quotation.

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Product Ranges

Torque and Speed
• Torque Ranges From .5 to 3500 NM
• Speed ranges from 42 to 20000 RPM
• Diameters form 2.36 to 33.46 inches

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Customer Considerations …

Mechanical Mounting Considerations

• Customer’s own bearings
• Customer’s shafting / drivetrain
• Bearing precision here dependent more on customer machine requirements than frameless
motor requirements
• Run-out more dependent on customer requirements
• Air gap of 0.38 mm – 1.90 mm (.015 to .030 each side) needed for frameless motor
•Well below total TIR on most bearings (.004)
• Mounting; Bonding, Clamping, and Shrink fit options discussed in some detail in back of
KBM Selection Guide

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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 13
• Customer ultimately responsible for proper design of:
• Housing dimensions accounting for thermal effects
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• Proper surface preparation and application of adhesive

Bonding

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Clamping

• Recommended for:
• Lower torque applications
• Applications requiring frequent disassembly
• Not recommended for:
• High shock and vibration applications
• Extreme temperature applications
• Design Recommendations
• Similar to bonding with some exceptions
• Slip fit with housing of 0.05-0.10 mm over stator OD max
• Separate clamp ring needed:
• At all tolerance conditions, 3-6 mm gap to housing recommended
• Secure with 4-12 fasteners equally spaced if possible
• Please note that:
• Customer ultimately responsible for proper design of:
• Housing and clamping ring 15

• Fastener selection to ensure adequate clamping force
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Clamping

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Customer 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 the Harowe Size 31 or 55 thru-bore resolver will easily adapt to the mechanical
system.
• Maximum ID of 30 mm or 92 mm

• Resolvers rated to a standard 200 degree C level.

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Repeatability

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

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Application Examples

• Reduce Weight
• Reduce Cogging
• Higher Bandwidth
• Improved Stiffness
• Increased Load
Capacity

Typical Markets
• Robotics
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• Machine Tool
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• Woodworking ELECTROMATE
Machinery Toll Free Fax (877) SERV099
www.electromate.com
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Application Awareness …

• MAKO Surgical Robot

– Four Frameless Motor Sizes
– Smooth, Precise Motion
– Torque Feedback for Doctor
Guided Surgical Tool
Movement
– Operating Room
Environment
– Potential: Ongoing
production and two new
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Robot Developments
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Application Awareness …

• Why did we win?

– High torque density
vs. footprint
– Smooth torque
– Higher reliability
– Catalog standard
product for their
design team
– Excellent technical
support
21

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MAKO wins 2010 Medical Design Excellence Gold Award

Customer Needs …

• Extreme Temperature
• Extreme Pressure
• Pressure compensated to
10K psi – Fluid Filled
• Temperatures to 280C
• Reduced Space and Weight
• No Hydraulics
Typical Markets
• Oil & Gas Downhole
• Deep Water ROVs
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• Hydraulic Actuator
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Replacement ELECTROMATE

Certification

KBM – CE Certification

• Declaration of Conformity
• EN-60034-1 2004
• Rotating Electrical Machinery
• 2006 – 95 - EC
• Low Voltage Directive

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Catalogs

KBM – Kollmorgen Frameless Selection Guide

• Rev B, now 80 pages
• Larger, readable detail drawings
• Updated, expanded Mounting &
Installation Guidelines
• Application Profile Questions
• Available KBM Modifications
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Additional Resources

www.Kollmorgen.com / Kollmorgen Youtube

• 3D Drawings
• Install Manuals
• White Papers
• Product Demo Videos
• Product Training/ Help Videos

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Kollomorgen- Direct Drive Embedded Motion For Robotic & Mechatronic Applications

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