Motor controller

PROMETHEUS

The two-axis controller Prometheus is designed for the control of two brushless synchronous motors or BLDC motors. Both motors can be controlled independently or synchronised. An optimised control concept guarantees ideal concentricity and very high positioning accuracy over the entire speed range. Especially at standstill or during “creep mode”, the running speed is optimally controlled up to zero speed.

1

Characteristics Application / area of application

- Driverless Transport System

(AGV) - Shuttle systems logistics

centres

- Rail-bound vehicles - Lifting applications - Pallet conveying technology - General industrial applications

Highlights

- Optimised for battery operation, voltage up to 75VDC - Independent control of two synchronous motors - Speed control, torque control, position control - Synchronisation of the two axes for synchronisation and cornering - Communication via CAN or I/Os - Several encoder interfaces available - Option: Communication via ProfiNET or EtherCAT - Option: STO function for each individual drive

Benefits

- Reduction of programming effort in the controller - Reduction of cabling effort - Minimum space requirement - Smooth positioning especially at lowest speeds - Flexible for a wide range of applications thanks to comprehensive

communication and encoder interfaces

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Performance characteristics

- Regulation of two synchronous motors (dual axis controller). - Synchronisation of both drives to each other (torque synchronous) - Voltage range up to a maximum of 75V (battery driven vehicles) - Continuous current 20A, peak current 100A per motor - Speed control, torque control, position control

Synchronisation control - I/Os per motor outlet:

- 10 x digital inputs per motor outlet - 1 x digital input per motor outlet - Option: 1 x analogue input 0-10V

- Brake chopper output per motor output - CAN interface onboard - SSI interface for an external additional displacement encoder - Encoder interface for magnetic encoders per motor - Encoder interface for sin/cos encoders per motor - Parameterisable master frequency input and output for the

synchronisation of several two-axis controllers with each other - Option STO function - Option: ProfiNET and EtherCAT

Model / Variants

Product variants Version

Prometheus Basic Basic version

Prometheus Advanced STO Version with STO option

Prometheus Advanced IE Version with Industrial Ethernet option (ProfiNET, EtherCAT)

Prometheus Premium Version with both STO and Industrial Ethernet options

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Technical data Controller

Technical data PROMETHEUS

Supply voltage power unit VDC 48 (nominal voltage)

75 (maximum voltage)

Supply voltage control part VDC 24

Nominal current A 20

Maximum current A 100A (2s)

Operating temperature °C 0 to 40

Control speed, torque, position Encoder, reverberation sensors

Digital inputs VDC 24 (number 10 per motor)

Digital outputs Ready M1, M2 VDC 24 (number 10 per motor)

Digital outputs Brakes M1, M2 VDC 24 (number 1 per motor, 1A)

Analogue input VDC 0 to 10 (option)

Bus system CAN, Option ProfiNET, EtherCAT

Brake chopper 1 x chopper per motor

Safety Torque Off 1x STO per motor (option)

Temperature monitoring PTC, PT1000, I²t

4

Pin and terminal assignment control part

The following illustrations show the connections of the control board: Pin 1 is on the outside left at each terminal.

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Supply control board X21

Terminal X21 supplies the control unit with the supply voltage 24VDC.

Terminal/pin Signal Function

X21.1 GND Power supply GND

X21.2 24V Supply 24 V

Digital inputs X10 and X11

The terminal X10 is provided for the connection of the digital I/Os of motor M1, the terminal X11 for motor M2. Both terminal strips are 10-pin.

Motor 1 Motor 2

Terminal/pin Signal Function Terminal/pin Signal Function

X10.1 24V X11.1 24V

X10.2 DI 1 CW M1 X11.2 DI 9 CW M2

X10.3 DI 2 CCW M1 X11.3 CCW M2

X10.4 DI 3 RFG X11.4 DI 11 RFG

X10.5 DI 4 G1 M1 X11.5 DI 12 G1 M2

X10.6 DI 5 G2 M1 X11.6 DI 13 G2 M2

X10.7 DI 6 G3 M1 X11.7 DI 14 G3 M2

X10.8 DI 7 Free X11.8 DI 15 Free

X10.9 DI 8 Free X11.9 DI 16 Free

X10.10 GND X11.10 GND

Digital outputs X20

Digital outputs are designed as follows.

Terminal/pin Signal Function

X20.1 DO 1

X20.2 GND

X20.3 DO 2

X20.4 GND

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CAN – Bus connection X24

The CAN bus is onboard on terminal X24.

Terminal/pin Signal Function

X24.1 High CAN High

X24.2 Low CAN Low

X24.3 GND CAN GND

Temperature monitoring motor and braking resistor X12 and X25

The terminal X12 (motor 1) and terminal X25 (motor 2) are provided for the connection of the temperature monitoring of both motors and if installed in the application, the temperature monitoring of the braking resistors. The connection of one brake also takes place via these two connection terminals. The terminal strips are 6-pin.

Motor 1 Motor 2

Terminal/pin Signal Function Terminal/pin Signal Function

X12.1 TK_Ch1 + Thermo-contact chopper motor 1 +

X25.1 TK_Ch2 + Thermo-contact chopper motor 2 +

X12.2 TK_Ch1 - Thermo-contact chopper motor 1 -

X25.2 TK_Ch2 - Thermo-contact chopper motor 2 -

X12.3 24V Brake motor 1 X25.3 24V Brake motor 2

X12.4 Brake M1 Brake motor 1 X25.4 Brake M2 Brake motor 2

X12.5 Temp. M1 + Temperature motor 1

+ X25.5 Temp. M2 + Temperature motor 2

+

X12.6 Temp. M1 - Temperature motor 1

- X25.6 Temp. M2 - Temperature motor 2

-

Connection for external SSI interface terminal X17

For an external reference measuring system, an additional SSI interface can be used.

Terminal/pin Signal Function

X17.1 5V Power supply

X17.2 GND GND

X17.3 A Bus Input

X17.4 B Bus Input

X17.5 n.c. -------

X17.6 n.c. -------

X17.7 Z Bus Output

X17.8 Y Bus Output

X17.9 n.c. --------

X17.10 GND GND

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Encoder feedback / encoder connector X3 and X5

At the terminals X3 (for motor 1) and X5 (for motor 2) the signals of the motor encoder or, in the case of the reverberation feedback version, the reverberation sensors are connected. The connector for the respective encoder/reverberation sensor is 10-pin.

Motor 1 Motor 2

Terminal/pin Signal Function Terminal/pin Signal Function

X3.1 ENC_GND ENC_GND X5.1 ENC_GND ENC_GND

X3.2 5V 5V Out X5.2 5V 5V Out

X3.3 ENC_I_N Track I Negative X5.3 ENC_I_N Track I Negative

X3.4 ENC_I_P Track I positive

/ Hall 3 X5.4 ENC_I_P Track I

positive

X3.5 ENC_B_N Track B Negative X5.5 ENC_B_N Track B

Negative

X3.6 ENC_B_P Track B positive

/ Hall 2 X5.6 ENC_B_P Track B positive

X3.7 ENC_A_N Track A Negative X5.7 ENC_A_N Track A Negative

X3.8 ENC_A_P Track A positive / Hall 1

X5.8 ENC_A_P Track A positive

X3.9 ENC_PWM_N Track PWM Negative

X5.9 ENC_PWM_N Track PWM Negative

X3.10 ENC_PWM_P Track PWM positive X5.10 ENC_PWM_P Track PWM

positive

Encoder feedback Sin/Cos encoder terminal X13 and X19

As an alternative to the magnetic encoder with ABI track, encoder feedback with sin/cos track is available. On customer request, this interface can be used as input for an external distance measurement signal.

Motor 1 Motor 2

Terminal/pin Signal Function Terminal/pin Signal Function

X13.1 Power supply X19.1 Power supply

X13.2 ENC_Sin_μCS1 Encoder Sinus X19.2 ENC_Sin_μCS2 Encoder Sinus

X13.3 -------------- X19.3 --------------

X13.4 ENC_Cos_μCS1 Encoder Cosinus X19.4 ENC_Cos_μCS2 Encoder Cosinus

X13.5 -------------- X19.5 --------------

X13.6 GND Iso 1 X19.6 GND Iso 2

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Master frequency input-output terminal X16

For synchronisation tasks distributed from a two-axis controller to several two-axis controllers, a parameterisable digital frequency input-output is available. The master frequency connection of the master is parameterised to output and the master frequency connection of the slaves to the input.

Terminal/pin Signal Function

X16.1 5V Power supply

X16.2 Ext_Enc_A Encoder A Track

X16.3 Ext_Enc_B Encoder B Track

X16.4 Ext_Enc_I Encoder I Track

X16.5 Ext_Enc_GPIO Encoder General Purpose Input Output

X16.6 n.c. n.c.

X16.7 n.c. n.c.

X16.8 GND GND

Options

Optionally, the following functions can be extended via additional boards. - Functional Safety STO per motor - ProfiNET - EtherCAT

Option Functional Safety Safe Torque Off (STO) X22 and X23

The safety function Safe Torque Off (STO) is available for each motor independently. The certification of the STO function takes place at Performance Level e.

Motor 1 Motor 2

Terminal/pin Signal Function Terminal/pin Signal Function

X22.1 STO A In Channel A X23.1 STO A In Channel A

X22.2 STO B In Channel B X23.2 STO B In Channel B

X22.3 STO Error Reset Error Input X23.3 STO Error Reset Error Input

X22.4 STO Error Out Error output X23.4 STO Error Out Error output

X22.5 STO 12 V Monitoring X23.5 STO 12 V Monitoring

X22.6 GND Iso 1 X23.6 GND Iso 2

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Terminals and pin assignment power board The following illustrations show the connections of the power board:

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PE connection and motor neutral point XM13 and XM23

The two terminals XM13 (motor 1) and XM23 (motor 2) are provided for the connection of the motor PE and the motor winding neutral point.

Motor 1 Motor 2

Terminal/pin Signal Function Terminal/pin Signal Function

X13.1 PE Grounding motor 1 !!Jumper position!! X23.1 PE

Grounding motor 2 !!jumper position!!

X13.2 NP Neutral point

Motor 1 X23.2 NP Neutral point

Motor 2

Power supply XM 14 and XM 24

The power supply for the power components is connected to the screw connections XM14 (motor 1) and XM24 (motor 2) using M5 ring terminals.

Motor 1 Motor 2

Terminal/pin Signal Function Terminal/pin Signal Function

XM14.1 48V + Supply M1 48V+ XM24.1 48V + Supply M2 48V+

XM14.2 48V + Supply M1 48V+ XM24.2 48V + Supply M2 48V+

XM14.3 GND Supply M1 GND XM24.3 GND Supply M2 GND

XM14.4 GND Supply M1 GND XM24.4 GND Supply M2 GND

Motor connections XM 12 and XM 22

The motor phases U,V,W are connected to the screw connections XM12 (motor 1) and XM22 (motor 2) using M4 ring cable lugs.

Motor 1 Motor 2

Terminal/pin Signal Function Terminal/pin Signal Function

XM12.1 U Phase U Motor 1 XM22.1 U Phase U Motor 2

XM12.2 V Phase V Motor 1 XM22.2 V Phase V Motor 2

XM12.3 W Phase W Motor 1 XM22.3 W Phase W Motor 2

Brake chopper XM 11 and XM 2 The two terminals XM11 (motor 1) and XM21 (motor 2) are brake chopper outlets. A brake resistor can be connected to these terminals.

Motor 1 Motor 2

Terminal/pin Signal Function Terminal/pin Signal Function

XM11.1 CH1 - GND Chopper Motor 1

XM21.1 CH1 - GND Chopper Motor 2

XM11.2 CH1 + 48V Chopper Motor 1

XM21.2 CH1 + 48V Chopper Motor 2

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Dimensions without option ProfiNET / EtherCAT

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Dimensions with option ProfiNET / EtherCAT

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Accessories Mating connector control part

Function Terminal Number of pins Number of rows Manufacturer number Manufacturer

Digital input X10, X11 10 1

FK-MC 0.5/10-ST-2.5 Phönix

Contact

Power supply X21 2 1 691 304 100 002 Würth

CAN X24 3 1 691 381 000 003 Würth

Encoder X3, X5 10 2 PUDP-10V-S JST

Temperature monitor

Motor and brake resistor,

brake connection

X12, X25 6 1 691 381 000 006 Würth

Digital outputs X20 4 1 691 381 000 004 Würth

STO X22, X23 6 1 691 381 000 006 Würth

SSI Encoder X17 10 2 PUDP-10V-S JST

Master frequency X16 8 2 PUDP-08V-S JST

Sin-Cos encoder X13, X19 6 1 PAP-06V-S JST

Crimp contacts to mating connector control part

Manufacturer number Connector housing Manufacturer

Manufacturer number Crimp contact

0,55 JST SPUD-002T-P0

PUDP-08V-S JST SPUD-002T-P0

PAP-06V-S JST SPHD-001T-P0