Maxon Motor Webinar. DC Motor Types and Usage in Typical Applications

1/19/2016 1
DC Motor Types and
Usage in Typical
Applications
February 3, 2015
Presented by: Dr. Urs Kafader
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Introducing your Moderator
Carrie Hitchner
Marketing Manager,
Motion Control Association
chitchner@a3automate.org
734.994.6088
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Introducing your Presenter
Dr. Urs Kafader
Technical Training Manager,
Maxon Motor
Urs.kafader@maxonmotor.com
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Thanks to Our Sponsors
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Climate control system
© maxon motor group
Brushed – brushless ?
Flat – long ?
Slotted – slotless
winding ?
Torque – speed ?
Size and weight
restrictions ?
Ambient?
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What are we talking about?
 DC motors with permanent magnets
 Small size: below 1 horse power or approx. 700 Watts
 1. Motor designs
 2. Brushed or brushless?
 3. Slotted or slotless?
 4. Motor selection
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1. Motor designs for high speed or
high torque?
 … and the role of gears
and mechanics
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Speed
Torque0.3 Nm 3 Nm
1000 min-1
10000 min-1
0.03 Nm
100 min-1
High speed designs
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Grinders and drills.
Brushless
Slotless
Long, autoclavable
Source: driven 2/14
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Respiratory therapy
© iStock Photo
Brushless
Slotless
Long
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0.3 Nm 3 Nm
10000 min-1
0.03 Nm
1000 min-1
100 min-1
Medium speed and
torque
Speed
Torque
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Air Cushion
System
© 2012 Lantal
Brushless
Slotted
Flat
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Pocket-sized Delta
robots
© Asyril
Brushless
Slotted
Multi-pole direct drive
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0.3 Nm 3 Nm
10000 min-1
0.03 Nm
1000 min-1
100 min-1
Where do typical
stepper motors fit into
this diagram?
Speed
Torque
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0.3 Nm 3 Nm
10000 min-1
High torque
low speed applications
0.03 Nm
1000 min-1
100 min-1
High torque designSpeed
Torque
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0.3 Nm 3 Nm
10000 min-1
0.03 Nm
1000 min-1
100 min-1
Gearhead for high
torque
Speed
Torque
Use of mechanics
(gears)
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Autonomous robots at
logistics companies
© YLOG GmbH
Brushless
Slotless
Long + gear
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Example: Bionics
Source:driven3/13
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0.3 Nm 3 Nm
10000 min-1
0.03 Nm
1000 min-1
100 min-1
Where do typical
stepper motors fit into
this diagram?
Speed
Torque
hybrid
stepper motor
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2. Brushed or brushless?
 Selection criteria for going
brushed or brushless
Brushed DC
maxon DC
Brushless DC
BLDC
maxon EC
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Service life
100 1000 10 000
Service life [hours]
rate of failure
Standard
expectations
Worst
case Optimum
100 1000 10 000
Service life [hours]
rate of failure
Standard ball
bearing life
Higher life
More predictable
current
speed
cw-ccw
vibrations
Brushed DC
Life limited by brushes
EC, brushless DC
Longer life limited by bearings
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Motorized caddy for
the green
© YuCAD
Brushed
Slotless
Long + gear
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Snake arm robot
© OC Robotics
Brushed
Slotless
Long
+ ceramic gear
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Speed and torque
torque M
speed n
100 000
50 000
25 000
10 000
75 000
torque M
speed n
100 000
50 000
25 000
10 000
75 000
2-pole
4-pole
multi-pole2-pole
Brushed DC EC, brushless DC
high speed application
brushed motor operated
at high speeds
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Grinders, drills
Brushless
Slotless
Long
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Hull cleaning robot
© Sea Robotics
Brushless
Slotted
Flat + gear
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Speed and torque
torque M
speed n
100 000
50 000
25 000
10 000
75 000
torque M
speed n
100 000
50 000
25 000
10 000
75 000
2-pole
4-pole
multi-pole2-pole
Brushed DC EC, brushless DC
high speed application
reduced life
more vibrations and
brush fire
more audible noise
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Special Ambient Conditions
Brushed DC
Complications
EC, brushless DC
Easier to adapt for special ambient
Brushfire
 electromagnetic noise
 explosive environments
Graphite brushes
 clean room applications
 use in optical systems
 high and ultra-high vacuum
Lubricant of metal brushes
 high and ultra-high vacuum
Sterilizable (autoclavable) motors
Vacuum, clean room
 low outgassing level
 high temperature
 no graphite dust
Down-hole drilling:
Heavy duty motors
 high temperature
 high pressure
 high vibration / shocks
Mercury 167°C
Venus 464°C
Earth 15°C
Mars -63°C
Jupiter -108°C
Saturn -138°C
Uranus -197°C
Neptun -200°C
Pluto -229°C
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Heavy Duty motors in
down hole drilling
Brushless
Slotless
Long + gear
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Heavy Duty motors in
particle accelerator
© Diamond Light Source (DLS)
Brushless
Slotless
Long
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Implantable
pump system
© iStock Photo
Brushless
Slotless
Long
Sterilizable
Bio compatible
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Operation and control
Brushed DC
Simple operation
EC, brushless DC
Needs electronics
 additional cost for electronics
 more cables
+ +
or
or
…
+
DC or EC
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Automatic wind
deflector
© Mercedes Benz AG
Brushed
Slotless
Long + gear
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3. Windings with and without iron core
 Slotted and slottless
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Brushed: Slotted vs. coreless
conventional, slotted
e.g. Dunkermotor
coreless
e.g. maxon
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Brushless: Slotted vs. slotless
slotted
e.g. maxon EC flat
slotless
e.g. maxon EC motor
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What makes coreless motors special?
 no cogging
 smooth motor running even at low speed
 less vibrations and audible noise
 smooth position control behavior
DC motors - overview
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Surgical robot
© 2010 Intuitive Surgical Inc
Metal brushed
Slotless
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Hobby-Eberly-
Telescope (Texas)
© 2012 HET
Brushless
Slotless
Long
+ encoder + brakes
+controller
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 no iron losses => high efficiency
Why is high
efficiency
important for
hand-held tools?
Bild Handgerät
driven 2/14
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Battery driven drive
systems for surgery.
Brushless
Slotless
Long, autoclavable
Source: driven 2/14
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Dosing
systems
8mm brushed
Slotless
Long + gear + encoder
6mm brushless
Slotless
Long + gear
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driven 2/14
 no iron losses => high efficiency
Why is high
efficiency
important for
hand-held tools?
Bild Handgerät
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 stronger magnets possible
 high torque and power density
 small rotor mass inertia
 high dynamics
Coreless maxon RE 30
 Ø 30 x 68mm
 85 mNm
 33.7 gcm2
 260g
 3 ms
Conventional, with iron core
 Ø 45 x 70mm
 38 mNm
 71 gcm2
 390g
 12 ms
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Kenshiro: Robot with
160 muscles and 93
maxon motors
Brushless
Slotless
Long
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4. The perfect maxon motor
 Selection of “motor size”
based on load torque and
speed
 Winding selection
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Application: Load operating points
torque M
e.g. continuous operation at constant
speed and friction torque
e.g. high torque needed for
short-term acceleration
e.g. maintaining a
position against gravity
speed n
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Application: Load key values
torque M
Extreme operation point:
max. load speed and load
torque (limited time)
Key load data
speed n
RMS average load
torque (continuous)
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Motor torque and speed limit
torque M
RMS average load
torque (continuous)
Nominal torque MN
nmax
Continuous
operation
Short term
operation
speed n
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Overload MN 2 MN 3 MN
Short term operation
torque M
RMS average load
torque (continuous)
Nominal torque MN
nmax
Continuous
operation
Short term
operation
speed n
Duration approx. 5 τW 0.3 τW
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Winding series of a motor type
resistance increases from left to right
low
resistance
winding
high
resistance
winding
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The perfect speed constant
torque M
speed n
current I
Mmot
nmot
𝑘𝑘𝑛𝑛 > 𝑘𝑘𝑛𝑛,𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 =
𝑛𝑛𝑚𝑚𝑚𝑚𝑚𝑚 +
∆𝑛𝑛
∆𝑀𝑀
∙ 𝑀𝑀𝑚𝑚𝑚𝑚𝑚𝑚
𝑈𝑈𝑚𝑚𝑚𝑚𝑚𝑚
=
8000 + 110 ∙ 50
24
= 563
𝑟𝑟𝑟𝑟𝑟𝑟
𝑉𝑉
8‘000 rpm
50 mNm
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Summary
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Brushed DC
EC
brushless DC
Multipole
Service life
Special
conditions
Operation and
Control
Approx.
< 3000 hrs
Approx.
> 10’000 hrs
< 10 000 rpm
< 100 000 rpm
haptic
Speed / Torque
with gear with gear
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Climate control system
Reliable, long service life => brushless
Varying ambient conditions (temperature, humidity, pressure)
=> brushless
Valves: Rather low speed but higher torque
=> multipole, slotted
Size and weight restrictions => flat, low weight gear
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Thank you!
Visit also
 www.maxonmotor.com/academy
 www.maxonmotorusa.com/academy
 www.electromate.com
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Questions?
Contact: Urs Kafader
maxon motor ag
6072 Sachseln (Switzerland)
Phone +41 41 666 16 74
Email urs.Kafader@maxonmotor.com
Thank you!
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Maxon Motor Webinar. DC Motor Types and Usage in Typical Applications

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Maxon Motor Webinar. DC Motor Types and Usage in Typical Applications