Kollmorgen benefits of direct drive technology

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Benefits of Direct Drive Technology

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Toll Free Fax (877) SERV099www.electromate.com

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Putting the Best Solution Together

Operator Interface &

Machine Control

MotorAmpTorqueVelocityPositionPath Gen

PLC-Based

PC-Based

1-Axis Standalone

Multi-Axis Standalone

ArchitectureSpeed Torque

Matching

Rotary To Linear

Conversion

Con

nect

ing

the

Load

Feed

back

Motors

Gea

rbox

es

Screws

Bea

rings

Cou

plin

gs

Motion Control



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Why Direct Drive Technology?

• Direct coupling of the load to the motor

• No compliance between motor and load

• Inertia mismatch is irrelevant (theoretically)

• 1000:1 inertia mismatch applications in place (standard servo is 10:1)



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DDR Direct Drive Rotary Formats

DDR Product Formats Ease of Use

Frameless DDR (Parts set)

Significant integration, best package fit

Easy to integrate, package size fixedCartridge DDR™

Easy to integrate, package size fixed

Fully housed DDR



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Frameless -

Brushed

• Permanent magnet stator (stationary)• Wound armature/rotor (rotating)• Self-commutating

• Limited peak power due to mechanical switching that results in excessive sparking in DC motors.

• Least torque ripple of any motor design



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Frameless -

Brushless

• Wound stator (stationary)

• Permanent magnet armature/rotor (rotating - reduced inertia)

• Commutation is done based on rotor position such that synchronism is always maintained. This is referred to as self- synchronism. The motor maintains the ability to deliver torque regardless of the velocity error.

• High commutation frequencies = high speeds

• Good heat dissipation because the windings are on the outside• The ability to deliver current based on demand is a key feature of

servos. If the motor is at rest and there is no load, no current is consumed, and the motor can cool.

• High bus voltage to force current into the windings is available; mitigates the electrical time constant of the winding



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DDR: Direct Drive Rotary



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GOLDLINE DDR Features

• Housed motor with bearings and integrated feedback

• Resolver or sine encoder feedback

• Single or double bearing version

• Large thru bore

Typical application: • Rotary indexing table

• To replace any mechanical transmission that is high maintenance or has short life.



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To gain Benefits of Eliminating Mechanical Transmissions

The Benefits of DDR Technology

• Zero maintenance– No Belts or gears

• Reliability – Reduce down time – No transmission parts to

break• Improved performance

– Increase accuracy up to 50 times

– Eliminate resonance and oscillation problems

• Clean mechanical assembly– Lower parts count– Reduce assembly

time

• Smooth and quiet

• Hollow shaft option– Run process thru the

motorELECTROMATE

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Belt/gearboxmaintenance

Belt/gearboxreplacements

Unscheduled Downtime

Lower Throughput

Purchase PricePurchase Price

(all components)

Mechanical Transmission DDR

Unscheduled Downtime

Lifetime Cost –

DDR vs. Mechanical



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Cartridge DDR



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Cartridge DDR Product Line

• Best features of a frameless DDR and a fully housed DDR

• Direct drive servo performance & zero maintenance, in an easy to integrate package

• It has no bearings…but it has everything else

• Feedback is pre-mounted and pre- alignedat the factory

• Single part number ready to mount

• Eliminates significant engineering design through advanced mechanical design



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Cartridge DDR: Section

RINGFEDER



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Small Frame Cartridge DDR



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Small Frame vs

Large Frame



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CDDR Application Considerations

• Machine has existing bearings?• Through-bore required?• Fast, accurate motion is required?• Reliability and zero motor maintenance is a must?• Fast machine maintenance a requirement?

• Consider ...– Axial shaft movement– Shaft dimensions and TIR– Perpendicularity of mounting surface– Thermal capacity of machine structure



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Cartridge DDR Applications

• Any application where the machine has its own set of bearings, but still can benefit from the DDR performance advantages

• Converting:– Rollers, Coaters, Feeders, Die Cutters

• Other application examples– Injection molding: IM machine mold indexing– Press feed: Incremental motion



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DDR Videos



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GOLDLine DDR IndexerCustomer Load Wheel

4 Feet Diameter250 Pounds

DH143M Goldline DDR250 Lb-ft Continuous989 Lb-ft Peak

96 Steel pegs3.75 degrees per pegTotal Inertia 15 lb-ft-s2

S620 Drive Amplifier240 or 480 Vac20 A Continuous, 40 Peak



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Single Peg Index Velocity Profile

3.75 Degree Move)

Velocity Profile

Total Move Time 97 ms

Settling Time 13 ms



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Indexing a Single Peg

If the Video does not play:

• Right click inside Windows Media Player screen above and choose Properties

• Choose “SinglePeg WindowsMediaPlayer” from pull down and “Alphabetic” tab

• Click on button at the end of “(Custom)” row and “Browse” to file on CD-ROM

• File name is “DDR One Peg Index.wmv”, click Slide Show icon to viewELECTROMATE


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One Revolution Index


• Right click inside Windows Media Player screen and choose Properties

• Choose “FullRevolution WindowsMediaPlayer” from pull down and “Alphabetic” tab

• Click on button at the end of “(Custom)” row and Browse to file location on CD-ROM

• File name is “DDR One Revolution Index.wmv”, click Slide Show icon to view ELECTROMATEToll Free Phone (877) SERVO98


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Bar Clamped to Table

Indicator1 Thousandth Inch / Number1 Ten Thousandth Inch / division0.8 Arc Seconds / division

26 inch radius from center

Repeatability Test



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Repeatability Test Video


• Right click inside Windows Media Player screen above and choose Properties

• Choose “Repeatability WindowsMediaPlayer” from pull down and “Alphabetic” tab

• Click on button at the end of “(Custom)” row and “Browse” to file on CD-ROM

• File name is “DDR Repeatability Test.wmv”, click Slide Show icon to viewELECTROMATE


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DDR vs. Mechanical IndexerCustomer identified these advantages of the DDR over the mechanical indexer they used previously

– Improved Repeatability

– DDR Accuracy and Repeatability do not degrade over time as with the mechanical indexer

– Can immediately stop DDR motion if there is a process error

– Greatly reduced audible noise

– Easily change DDR index angle, speed, and dwell

– DDR provides better overall valueELECTROMATE


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Direct Drive Linear



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Linear vs. Standard Rotary Motors

Linear motor - rotary motor rolled out flat!

moving coil

magnetic way

air gap

Rotating rotor

windings

stator

N

S

magnetsELECTROMATE


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Mechanical Transmission Advantages Disadvantages

Timing Belt Speed Compliance, AccuracyWear, ContaminationMaintenance

Rack and Pinion Speed Backlash, WearLong Travel AudibleContamination

Ball Screw High Force Limited SpeedSettling TimeWear, Maintenance

Comparative Technologies



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Indicators for a Linear Motor Solution

• High Speeds - 200 in/sec (10 m/sec)• High Acceleration - 3-5 g's are typical• Fast Move and Settle• High Resolution • Long travel distances - 20 feet or more possible• Smoothness (zero cogging)• No maintenance (non-contact)• Zero backlash

• High dynamic stiffness, no compliance



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Comparison of DDL Motors

Ironless– zero cogging– zero attractive force– ultra-high acceleration– very smooth motion– Up to 1600 N peak force

Iron Core– high peak force– patented anti-cogging design– high force density– Up to 15000 N peak force



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Date post:	24-Dec-2014
Category:	Technology
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