Theory, application & operation of frameless motor technology webinar 02 23-2016

February 23, 2016
Theory, Application & Operation
of Frameless Motor Technology
Tom S. Wood
Motor Product Specialist
Kollmorgen ELECTROMATE
Toll Free Phone (877) SERVO98
Toll Free Fax (877) SERV099
www.electromate.com
sales@electromate.com
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Speakers
Texas Instruments & Ethernet POWERLINK Standardization Group
Tom S. Wood
Kollmorgen
Meet The Presenter
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Thank You To Our Exclusive Sponsors
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4
Why Direct Drive Frameless ?
Direct Drive Frameless Story
This could be a Belt/Pulley,
Planetary Gearhead, Rotating
Nut or Driven Ballscrew
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5
Why Direct Drive Frameless ?
Direct Drive Frameless Story
This could be a Belt/Pulley,
Planetary Gearhead, Rotating
Nut or Driven Ballscrew
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Why Direct Drive ?
• 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
– Through-bore for process air or tooling
• Quiet performance…up to 20db noise reduction
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Housed Direct Drive Motor
Housed Direct Drive Motor
250 Lb-ft Continuous
989 Lb-ft Peak
Customer Load Wheel
4 Feet Diameter
250 Pounds
96 Steel pegs
3.75 degrees per peg
Total Inertia 15 lb-ft-s2
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Single Peg Index Velocity Profile
Single Peg Index
(3.75 Degree Move)
Velocity Profile
Total Move Time 97 ms
Settling Time 13 ms
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Bar Clamped to Table
Indicator
1 Thousandth Inch / Number
1 Ten Thousandth Inch / division
0.8 Arc Seconds / division
26 inch radius from
center
Repeatability Test
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Repeatability Test
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11
Embedding Frameless Motors
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12
Applications
• Applications
• Collaborative Robots
• Surgical Robots
• Semi Wafer-handling Machines
• Manufacturing Automation
• Machine Tools
• Unmanned Autonomous Vehicles
• Trends
• Machines need to be smaller
 smaller solutions
 explore Direct Drive
• Electric motors replacing hydraulics
 Reduces weight (operating costs)
 Reduces maintenance cost
 in environmentally sensitivity
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13
Applications
• Applications
• Surgical Robots
• Machine Tools
• Trends
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14
Applications
• Applications
• Surgical Robots
• Machine Tools
• Trends
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15
Robotics: NREC Robot
• DARPA Robotics Challenge is a competition to create
robots capable of assisting humans in a disaster
• Benefits provided by frameless motor integration:
• Small, compact integrated motor and gearing
actuate the robot’s 50 degrees of freedom
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16
Frameless Motor Mounting Video
Frameless Motor Mounting Video – Customer Application
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17
Frameless Motor Mounting Video
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18
Classic ‘Torquer’ Motor Shape KBM 10-35 ‘Servo’
Motor Shape
Stationary wound
armature
Rotating permanent
magnet field
Stationary wound
armature
Rotating
permanent
magnet field
Frameless Motor Form Factor
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19
Frameless Motor Form Factor
D2L Rule
Continuous Torque
Capacity is Directly
Proportional to
Length:
2 x Length = 2 x TC
But …
Doubling the Diameter
(Moment Arm) Squares
the Continuous Torque
Capacity
2 x Diameter = (TC)2
From
From
To
To
2x
2x
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20
Frameless Motor Optimization
Data to Consider
Torque / Speed Load
Point(s)
Duty Cycle / Temp Details
Drive Amplifier Details
• Current & Voltage
• Sine vs. 6 Step
Mechanical Envelope
• Max Available Diameter
• Max Available Length
• Through Bore data
• Mounting concept
Design Elements
Choose Largest Practical Diameter
• Low speed / higher torque suggests a larger
diameter - D2L rule
Stack Length Change
• Wattage increases with stack length
• Tc / Tpk will vary proportional to stack length
Optimize Winding Parameters
• Increase system efficiency
• Bus voltage will drive the winding choices based
on max speed needed
Water Jacket Cooling
• Channel features on stator sleeve
• Tubing integrated into back-iron design
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21
Position Feedback 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 a Size 31 or 55 thru-bore resolver will easily adapt
to the mechanical system.
• Resolvers rated to a standard 200 degree C level
• Rated for high shock and vibration applications ELECTROMATE
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22
System Design Feedback
Options
Harowe large
through-bore
Resolver
Up to 140mm
OD with
93mm max
Bore
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23
System Design Feedback
Options
Typical large
through-bore
Encoder
Up to 390mm
Bore
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24
Mounting Considerations …
Embedded Motion Technology -
Frameless Mounting Considerations
• The benefits of Improved System Performance, Reduced
Maintenance, Smaller Mechanical Footprint, Higher
System Efficiency are understood
• Customer still has a key question in mind …
I like the frameless design concept but how do I mount
the motor components into my machine?
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25
Mechanical Mounting Considerations
• Customer’s own bearings
• Customer’s shafting / drivetrain
• Bearing precision and machining tolerances are dependent
more on customer machine requirements than frameless
motor mounting requirements
• Run-out more dependent on customer requirements
• Air gap of 0.015” – 0.075” (0.38 mm – 1.9 mm) each side
of rotor needed for frameless motor
• Mounting; Bonding, Clamping, and Bolting options are
discussed in some detail in the KBM Selection Guide
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26
Radial Running Clearance –
“AirGap”
Source: KBM Selection Guide p.89 – KM_SG_00073_RevE_EN
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27
Customer
Through-bore type
Encoder
Customer
Duplex
Bearing
Customer
Machine Shaft
Customer Housing
KBM-43X03 Stator
KBM-43X03 Rotor
KBM-43X03 Mounting Example
Bonding
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28
Customer Housing with
Stator embedded
Customer Shaft with Rotor
Bonding
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Customer Housing
Customer Shaft
KBM Rotor
KBM Stator
Bonding
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Customer Housing
KBM Stator
Housing / Stator Exploded View
Bonding
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31
3D to 2D
Housing / Stator Assembly
See Detail A
Bonding
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32
Insert Stator
2 mm min.
end turn to
housing
clearance
0.10/0.05 mm
gap per side,
“slip fit”
0.26/0.13 mm
additional
adhesive
groove, 50+%
of surface
Depth
stop
shoulder
feature
Recommended Structural Epoxy
3M Scotchweld 2214
Hysol EA934NA
Detail A – Stator / Housing
KBM-43X03 Mounting Example Bonding
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• 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
• Customer ultimately responsible for proper design of:
• Housing dimensions accounting for thermal effects
• Proper surface preparation and application of adhesive
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34
Customer Shaft
Rotor
Rotor / Shaft Exploded View
Bonding
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35
3D to 2D
Rotor / Shaft Assembly
See detail B
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36
Detail B – Rotor / Shaft Assembly
0.05/0.025 mm
gap per side,
“precise location
slip fit”
No adhesive grooves with
Retainer Compound
mounting configuration
Recommended Retaining
Compound: Loc-Tite 640
Bolt-on Mounting
also practical for
removable rotor
Fit depth to shoulder
Rotor
Shaft
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37
Bonding with Structural Adhesives
• Structural adhesives represent a cost-effective, industry
proven, and mechanically sound approach to frameless
motor mounting
• Several mounting options; Bonding, Clamping, and Bolting
options are discussed in some detail in the KBM Selection
Guide ELECTROMATE
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38
Clamping & Bolting
Customer Through-
bore type Encoder
Customer
Duplex Bearing
Customer
Machine Shaft
Customer Housing
KBM-43X03 Stator
KBM-43X03 Rotor
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39
Customer Housing
Rotor Bolt Flange
KBM Rotor
KBM Stator
Customer Shaft
Stator Clamp Ring
Clamping & Bolting
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40
Customer Housing
KBM Stator
Stator Clamp Ring
Clamping & Bolting
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41
Customer Housing
KBM Stator
Stator Clamp Ring w/ 12
evenly spaced bolts
Actual number may vary with
motor and load conditions
Clamping & Bolting
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42
KBM-43X03 Mounting Example Clamping
& Bolting
3D to 2D
Housing / Stator / Clamp Ring Assembly
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43
Insert Stator
2 mm min.
end turn to
housing
clearance
0.05/0.025 mm
gap per side,
“precise location
slip fit”
Clamp ring needs to
have gap behind to
allow compression of
stator shoulder
Depth
stop
shoulder
feature
Detail A – Stator / Housing
Clamp ring with bolts,
must engage at least
half of stator shoulder,
with 2mm gap to
endturn encapsulation
KBM-43X03 Stator Clamping Example
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44
Clamping
• Recommended for KBM Frame size 118XX and smaller
• Designed for easy removal or maintenance access
• 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
• Precise Location Slip Fit with housing of 0.10-0.05 mm over stator OD typical
• Maintain gap behind clamp ring to allow for compression on stator
• Engage at least half of the stator shoulder with the clamping ring
• Please Note that:
• Engineering Best Practices should be followed for determining the number and size of
clamping ring bolts as required for the torque capacity of motor
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45
Customer Shaft
Rotor
Rotor / Shaft Exploded View
Clamping & Bolting
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46
3D to 2D
Rotor / Shaft Assembly
See Detail B
Clamping & Bolting
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47
KBM-43X03 Rotor Bolting Example
Detail B – Rotor / Shaft Assembly
0.05/0.025 mm
gap per side,
“precise location
slip fit”
Bolt-on Mounting
practical for easily
removable rotor
Fit depth to shoulder
Rotor
Customer Shaft
Bolt-on
Mounting from
either side of
rotor
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48
Clamping & Bolting :
• Clamping and bolting represent a cost-effective, easily
removable, and mechanically sound approach to frameless
motor mounting
• Several mounting options; Bonding, Clamping, and Bolting
options are discussed in some detail in the KBM Selection
Guide
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49
What do you do when the frameless motor
application needs are outside the range of the
standard catalog motor offering?
Frameless Motor Sizing
Considerations
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50
Frameless Motor Sizing
Considerations
What do you do when the frameless motor
application needs are outside the range of the
standard catalog motor offering?
What do we do when the application requires a
motor rating [derating] at a specific ambient
temperature or amplifier capability?
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51
• Winding
Changes
• Amplifier
Variations
• Ambient
Temp
Variation
KBM/TBM Performance Curve Generator (Coming Soon)
Frameless Motor Sizing Considerations
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52
Motioneering Online Motor Sizing Tool
Frameless Motor Sizing Considerations
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Questions?
Joanna Keel
Marketing & Membership Manager
Motion Control & Motor Association
jkeel@motioncontrolonline.org
+1-734-994-6088
Thank you to our exclusive sponsors:
Tom S. Wood
Kollmorgen
tom.s.wood@kollmorgen.com
+1-540-250-0399
Electromate Contact
1-877-737-8698
www.electromate.com
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Theory, application &amp; operation of frameless motor technology webinar 02 23-2016

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Theory, application &amp; operation of frameless motor technology webinar 02 23-2016

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Theory, application & operation of frameless motor technology webinar 02 23-2016