Industrial Devices Corporation 707-789-1000 • 800-747-0064 • E-mail: [email protected]Brushless Servo Systems Servo Systems H-2 Brushless Servo Products IDC has a wide range of brushless servo products to meet your motion control needs. These products are: • B8001 digital, brushless servo drive • B8961, B8962 programmable brushless servo Smart Drives • 961, 962 stand-alone programmable motion controllers • 12 brushless motors ranging from 17 frame to 42 frame size • Brushless gearmotors Overview Digital Brushless Servo Drives If your application requires high performance brushless servo drives, consider IDC’s B8001. This DSP-based, high bandwidth servo uses an innovative vector control motor commutation scheme that delivers exceptional shaft power and performance. For more information on this technology, see page H-11. B8001 Operates from 120/240 VAC 5A/10A cont/peak current Internal power supply See page H-20 Automated Force Control Applications such as drilling, spot welding, pressing, clamping, automated fastening and shuttling each have unique requirements for control of torque not addressed by traditional servo products. These applications require velocity, position and torque control (or force control when used with a linear system), all at the same time. Until IDC Smart Drives were introduced, solutions were often complicated and difficult to integrate. At IDC, our experience in solving torque control applications has led to an integrated, easy-to-program solution. See application examples on pages H-31 through H-35 for details. OK Mis-Feed Missing Servo Products
If your application requires high performance brushlessservo drives, consider IDC’s B8001. This DSP-based, highbandwidth servo uses an innovative vector controlmotor commutation scheme that delivers exceptionalshaft power and performance. For more information onthis technology, see page H-11.
B8001
Operates from 120/240 VAC5A/10A cont/peak currentInternal power supplySee page H-20
Automated Force Control
Applications such as drilling, spot welding, pressing,clamping, automated fastening and shuttling each haveunique requirements for control of torque not addressedby traditional servo products.
These applications require velocity, position and torquecontrol (or force control when used with a linearsystem), all at the same time. Until IDC Smart Driveswere introduced, solutions were often complicated anddifficult to integrate.
At IDC, our experience in solving torque controlapplications has led to an integrated, easy-to-programsolution. See application examples on pages H-31through H-35 for details.
OK Mis-Feed Missing
ServoProducts
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Stand-alone Programmable MotionControllers
For applications that require a stand-alone motioncontroller, consider the 961 one axis and 962 two axisindexers.
• Integrated Motion Controller/Power Supply/OperatorInterface/and I/O rack provides the user with anindustrial motion control solution
• 30 I/O, 8 OPTO I/O slots
• Uses IDC’s IDeal™ programming language
• See page H-44 for more information
Overview
Brushless Motors and Gearmotors• Wide range of motor Torque/Speed curves for
system optimization
• Both inline and right angle brushless gearmotorsavailable
• IDC brushless gearmotors come in gear ratiosfrom 3:1 to 700:1
• 12 motors from size 17 to 42 frame
• High Speed, Low Torque windings, or HighTorque, Low Speed windings
• New BN series motors provide smooth operationand true NEMA dimensions including the shaftdiameter
• MS connectors, and 12 ft quick disconnect cablesstandard on B series motors
• 12 ft. jacketed cables standard on BN seriesmotors
• Optional 24 VDC failsafe integral motor brake onB series motors
• 25, 50, 100 ft cables optional on B series motors
• See page H-47 for more information
Programmable Brushless ServoSmart Drives
IDC’s B8961 (single axis) and B8962 (two axis)programmable brushless servo Smart Drives weredesigned for ease of use, and to minimize system set-upand programming time. When using a B8961/2 you canliterally have your system up and running in a matter ofminutes! See page H-24 for more information.
Product Description Maximum Speedrev/sec (rev/min)
Rotary Tables Accuracy to 3 arc minutes 30 [1800] inputRatios to 180:1 0.66 [40] output
Low Static TorqueRunout to 0.001”
Gearmotors High Value/Low Cost 108 [6500] inputRight Angle & Inline High Input Speeds 28 [1650] output
Ratio to 700:1
Note 1: Electric Cylinders are designed primarily for thrust applications where loads are supported externally.See engineering section for more details.
Note 2: Thrust ratings are based on mechanical limits rather than motor limits unless indicated.
Note 3: Maximum Speed and Thrust ratings are not necessarily achievable simultaneously.
Product Description Maximum Speedin/sec [mm/sec] [Note 3]
Electric Cylinder Highest Force (Thrust) 52.5Rod Type Clean, Hydraulic Replacement [1300]
Compact Cross SectionExtends into Work Area
Rodless Screw Drive High Force (Thrust) 40High Repeatability [1000]
Long TravelLoad Carrying Capability
Rodless Belt Drive Very High Speed 120Quiet Operation [3000]
Long TravelLoad Carrying Capability
Linear Servo Module Highest Speeds 196Highest Accelerations [5000]
High RepeatabilityLow Maintenance, Long Life
High Moment Loads
Cartesian Systems Fully Engineered Multi-Axis Systems 120Complete 2 & 3 Axis Large Work Area — 60 x 108 inches [3000]Assemblies Multiple & Custom Configurations
0.2 arc minutes to 214 to 108 6 to 12 inches E-1[952] [480] [152 to 304.8 mm]
7 to 25 arc minutes to 1260 to 1260 Frame Size I-1[5605] [5605] 17, 23, 34, 42
Note 4: Repeatability is dependent on encoder resolution, load, friction, settling time and gain settings in the servo control.Note 5: Repeatability is uni-directional unless otherwise specified.Note 6: Cartesian systems can be configured using a combination of IDC technologies. Repeatability and Max. Thrust are
The following steps describe the process of selecting a linear motor which matches your application
requirements.
1) Complete the Product Selection Worksheet(pages H-8 through H-10)
3) Peak Torque Requirement (see Engineering Section)Determine the peak torque requirement for your motor to complete the desired motion profile.Adjust your peak torque requirement by 20% to include a safety factor.
330 oz-in x 1.2 = 396 oz-in (required for selection of brushless servo motor)
2) Peak Speed Requirement (see Engineering Section)In order to calculate the peak speed of the motor, your mechanical system must be known, or youmust make an assumption as to which mechanical system will meet your application’s requirements.Calculate the peak speed required for your motor to complete the desired motion profile. Severalmotion profiles are covered in the Engineering Section. One commonly chosen motion profile is thetriangular profile.
Formula: Triangular Move Profile (peak speed = average speed x 2).
Sample Calculation:
Desired Motion: Move 5 revolutions in 0.2 secondsPeak Speed Requirement: (5 revolutions ÷ 0.2 seconds) x 2 = 50 revolutions/second
Graph your most demanding cycle, include accel/decel, velocity and dwell times. You may also want to indicate load variations and I/O changes during the cycle. Label axes with proper scale and units.
Servo
Motor Type Preferred
Other
Stepper
Other
Servo
System
s
ServoSystems
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Motor Selection Data
Radius (R):
L
R
Direct Drive System
in
Inner Radius (R1) in
Outer Radius (R2) in
Density of Material oz /in3
Weight of Cylinder oz
Length (L) in
LR2
R1
R2
R1
Type of Material
Will a gearbox be used? Yes / No / Not Sure
Distance from Cylinder CL to Motor Face in
Tangential Drive System
Radius (R) in
Weight of loadplus belt or chain (W) lbf
Efficiency of belt or chain
Weight of Pulleys lbf Friction (F) lbf
R
W F
Will a gearbox be used? Yes / No / Not Sure
Belt Tension
Will pulleys be supported by external bearings? Yes / No
lbf
Environment
Operating Temperature
Normal 32-140°F [0-60°C]High Temp.Low Temp.
°F / °C°F / °C
Conditions
Washdown Outdoor
Vacuum Cleanroom
Contaminants (Check all that apply)
non-abrasiveabrasive
coarse chipsfine dust
Solid:
drippingmist / spray
splashinghigh pressure
non-corrosivecorrosive
Liquid:
Move Requirements
revs of motorMove Distance inches
secsMove Time
rev/sRequired Motor Peak Speed
secsRequired Accel Time
secsRequired Decel Time
rev/sMinimum Motor Speed
arcminutes, degrees, or inchesAccuracy
arcminutes, degrees, or inchesRepeatability
Time in MotionDuty Cycle (%)
Cycle Time
secsMaximum Continuous Time in Motion
secsTotal Cycle Time
Cabling Requirements
ftLength of Motor / Encoder Cable Required
Will cable be moving in application? Yes / No
lbf
Gearhead / Geartrain
Gear Ratio
Gearhead Inertia (reflected to pinion)
Efficiency %
oz-in-sec2
Radius of Pinion in Radius of Driven Gear in
Weight of Pinion oz Weight of Driven Gear oz
Radial load on output shaft lbf
Distance of radial load from gearhead face in
Axial load on output shaft
LD
W
Leadscrew System
Orientation
Horiz
Efficiency of Screw
Pitch of Screw
Length of Screw (L) in
Diameter of Screw (D) in
Weight of Load (W) lbf
Running Friction Coefficient (Load/Surface)
Breakaway Force
Will a gearbox be used? Yes / No / Not Sure
Vertical Incline:
Ball Screw Acme Screw Other
lbf
revs /in
Orientation
Horiz Vertical Incline:
4) RMS Torque Requirement (see Engineering Section)Calculate your application’s RMS Torque requirement using the formulas in the EngineeringSection. Be sure to adjust your RMS Torque requirement by 20% to include a safety factor.
Sample Calculation:RMS Torque = 120 oz-in
120 oz-in x 1.2 = 144 oz-in (required for selection of brushless servo motor)
SelectionChecklist
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Brushless Se
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ServoSystems
6) Decide which IDC servo control system is most appropriate for your application.IDC offers brushless servo drives, programmable brushless servo indexer/drive systems, andmotion controllers.
8) Proceed to Motor and Control How-to-Order PagesYou have now selected the IDC servo motor and control system most appropriate for yourapplication. Proceed to the Motor How-to-Order page (H-48) and the How-to-Order page for the IDCcontrol system you selected.
5) Select Speed-Thrust CurveSearch through the motor performance curves on pages H-49 through H-60 to find a brushless servo motorwhich meets your application’s torque and speed requirements.
7) Decide if a gearmotor is appropriate.A gearmotor may be more appropriate for your application than simply a motor-only solution. Theinformation needed to make this determination can be found by reviewing:
Graph your most demanding cycle, include accel/decel, velocity and dwell times. You may also want to indicate load variations and I/O changes during the cycle. Label axes with proper scale and units.
Servo
Motor Type Preferred
Other
Stepper
Other
SelectionWorksheet
ServoSystems
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In 1995, IDC introduced its B8000 Series of brushlessservo products. They came in several configurations andoffered many unique and desirable features, at aremarkably low price. Originally attracted by featuresand pricing, customers have discovered somethingelse—that IDC’s B8000 Series products deliverunprecedented servo performance. In fact, it has beenthose customers most interested in getting the highestpossible throughput from their equipment who havebecome IDC’s strongest advocates. Several havecommented, “never before have we been able to get thiskind of performance out of our machine.”
This is the “Inside Story” of IDC’s unique, DSP driven,sinewave/vector commutated, positioning servos. This iswhy our B Series performs far superior to hall effectcommutated six step drives, and meaningfully superiorto the sinusoidal servos which until now have beenconsidered the “state-of-the-art.” We acknowledge thatthe answer is a little complicated and that ourexplanation may err on the side of oversimplification.But, hopefully, the following pages will provide someuseful insights into the improvements our customers areexperiencing.
The information provided here applies to all of ourB8000 Series brushless servo controls. The B8000 seriesuses the same digital control architecture, advancedservo algorithms and power amplifier design—theB8001 digital servo drive, the B8501 analog positioncontroller, and the B8961 (single axis) and B8962 (twoaxis) programmable smart drives.
IDC’s unique servo architecture is a framework fortightly synchronizing the calculated commands withtheir subsequent execution. Any delay or timinguncertainty within any part of the total servo cycle –from reading the feedback to outputting the correcttorque for that moment in time – wreaks havok on servoperformance. The sum of these delays and uncertaintiesis called Total Servo Phase Delay.
As mentioned before, one DSP is dedicated to everymotor. Via digital step and direction inputs, it controlsall the servo loops, including position. This architectureenables precise loop synchronization thus minimizingtiming uncertainties. Furthermore, the most criticalservo loop – the torque loop – is continually auto-calibrated and completely digital, thus virtuallyeliminating control defects caused by sensor drift, andanalog phase delay. With this attention towardminimizing cycle delays and uncertainties, we haveachieved a total servo phase delay of less than 100microseconds!
The following pages show you how this fusion ofinnovative ideas and technology within IDC’s servos giveyou benefits, and performance unmatched by servostwice the price.
OperationThe two functions most critical to any servo’sperformance are the servo algorithm calculations andthe execution of these calculations, through dynamiccontrol of the motor’s torque. The foundation of IDC’scompetitive advantage is a proprietary DSP ASIC thatcontrols these drive functions.
Advanced Servo Algorithms
To calculate servo control parameters, the B8000 DSPuses a “Proportional-Integral-Embedded Velocity (PIV)”servo compensator algorithm with acceleration, andvelocity feedforward. This PIV algorithm iscomputationally intensive, but it is superior to otheralgorithms (such as PID), both in performance and easeof tuning. Its use is made practical by dedicating thehorsepower of one DSP to every motor. IDC Servosattain further performance advantages through the useof fuzzy logic technology within its proprietaryintegrator, and Anti-hunt™ routines.
Vector Torque Control
The DSP’s other main function, critical to effective servoperformance, is dynamic control of motor torque. TheIDC Servos continuously determine the amplitude andangle of the magnetic field necessary within the motorto produce the calculated instantaneous torque. The 3-phase voltage needed to produce this magnetic fieldvector is also calculated, phase adjusted for motor speedand load, and synchronously applied to the motorwindings. This allows nearly perfect execution of theservo algorithm’s commands, and results in tight servocontrol, and maximum motor efficiency.
configurationdata
PWM-T
PWM-R
PWM-SState Space
PIV Compensator
VoltageRotator
PM 3ø Motor
E
Velocity or Torque Command
Hall Commutation Sensors(Optional, for start-up only)
Current de-rotator
HW fault
Thermal fault
diagnostic"scope" port
DiagnosticStimulus
Generator
velocityvel. errorpos. errortorque
Vector TorqueController
I vector amplitude
voltage
phase
DSP ASIC
I vector phase
torquecommand Power
Switching Stage
A/D Subsystem
+
-
Encoder Prescaler
Step InputPrescaler
D/A
E2ROM
Step Inputstep
dir
+ limit
- limit
enable
velocity/ torque
fault
power /statusindicator
RS-232configuration
Analog InputOption
ir
is
10V+-
B8000 Series Digital Drive
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Brushless Se
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OperationThe Most Important PerformanceSpecification
It may be interesting to hear about advanced algorithmsand torque control techniques, but these things are onlyimportant to you to the extent that they give youbottom-line performance advantages. Much of servoadvertising is focused on the individual elements thatcontribute to performance—raw processor speeds, DACbits, and update rates—but these elements are only partsof a bigger picture; they mean little by themselves.
Servo bandwidth—the range of input frequencies aservo can follow (within a specified degree of error)—isthe fundamental performance specification. Mostelements of servo performance are directly related toservo bandwidth:
• Move time—acceleration and velocity for a giventracking accuracy
• Settling time
• Disturbance rejection (“stiffness”)
• Smoothness of motion (rejection of velocitydisturbances)
The Weak Links
Everyone knows that a chain is only as strong as itsweakest link. This is as true with servos as with anythingelse. We carefully analyzed the factors that limit servobandwidth, and found that in most servos the strongestlinks have been given all the attention, while the weak
links have been neglected. The raw processor speed,number of DAC bits and update rate are not typicallythe weak links in any competitive system.
We discovered two major weak links related to systembandwidth—specifications that nobody talks about.One is the speed with which the correct torque can beproduced once the desired amount has been calculated,and commanded. This is called “torque response time.”The other is “total servo phase delay.”
All Torque is not Created Equal
Torque response time is similar to the more commonlyspecified current loop bandwidth except that itconsiders commutation effects that govern the actualtorque response at the motor shaft. Current loopbandwidth alone is an incomplete measurement. Anydelay in the response between the commanded torque,and its execution at the motor shaft, will result ingreatly compromised system performance.
The B8000’s torque response time is shown below incomparison to an above-average, competitive servo.While the B8000 has a noticeable advantage even atzero speed, you can see that its real superiority is itsnear-zero response time at rated speed. This is thecondition under which supplying the correctinstantaneous torque has the most impact onperformance—tracking accuracy, settling time,disturbance rejection, smoothness and efficiency.
Even a “high-tech” sinewave drive has difficulty producingtorque as quickly as necessary for optimal performance,especially when running at speed.
The B8000’s torque response is extremely fast and virtuallyconstant regardless of motor speed. The desired instantaneoustorque can be delivered immediately upon demand.
Torque response at rated speed
5mS/division
Torque produced with motor shaft locked
Torque response at 25% rated speed
0
Torq
ue
Torque response at rated speedNote:
5mS/division
Torque produced with motor shaft locked
Torque response at 25% rated speed
Torq
ue
0
In addition to being sluggish this driveis also unable to produce the fullcommanded torque at rated speed.
B8000 Series indirect torque vectorcontroller test
Competitive “digital” sine wave drive withanalog current loops
2. 3 phase sinewave lookup and multiply (100µS typical)
3. PWM sample uncertainty and analog current loop phase delay (100µS typical)
0. Encoder and step counter read
4. PWM voltage output to motor
0µS
300µS
Total Servo Phase Delay
You have seen how quickly andaccurately the B8000 producestorque after it calculates the requiredamount—this is the torque responsetime. Now let’s examine the totalservo phase delay—the total timefrom the moment the positionfeedback is read to the time thattorque begins to be updated.
Total Servo Phase Delay (TSPD) isnot only dependent upon the time ittakes for each individual step in theservo process to be completed, butit is also influenced by the degree ofsynchronization of these steps. Ifelements of the system operateasynchronously, as is the case withthe traditional servo architecture(where one or more servo loops areclosed by the controller, and theremainder by the amplifier), this lackof synchronization will causeuncertainties which, on average, willdrastically increase the TSPD.
We chose a step and direction inputarchitecture not only for noiseimmunity, or as a convenience forupgrading from stepper motorsystems, but because this allowed usto close all the servo loops with oneprocessor. This eliminated all of thedelays and uncertainties associatedwith the asynchronism of thetraditional architecture. This is a bigadvantage of any skillfullyimplemented step and directionservo.
We went several steps further toreduce TSPD. We dedicated a DSP toeach motor, designed a true digitaltorque controller, and developedproprietary algorithms optimizedspecifically for reducing TSPD. Theresult of these efforts can be seen inthe figures to the right. Low TSPD,combined with improved torqueresponse time, strengthens theweak links found in other servos andresults in state-of-the-art servobandwidth.
1. Servo controller processes other axes (100µS each, typical)
2. Servo controller calculates PID for axis of interest (100µS typical)
6. Amplifier 3 phase sinewave lookup and multiply (100µS typical)
7. PWM sample uncertainty and analog current loop phase delay (100µS typical)
0. Encoder(s) read by servo controller
4. Encoder read by amplifier
8. PWM voltage output to motor
The traditional servo architecture – position controller with separatevelocity/torque amplifier – has many delays and uncertainties becauseof asynchronism between controller and amp, and because oneprocessor controls multiple axes.
IDC Servos minimize total servo phase delay. Combined with rapid torqueresponse, this results in superior servo performance.
A well-designed step and direction sinewave drive eliminates many ofproblems associated with the traditional architecture, but still has delaysdue to sinewave lookup and current loop phase delay.
0µ 1. B8000 DSP ASIC calculates:
0. Encoder, step counter and current sensors read by B8000
2. PWM voltage vector output to motor
• State space PIV servo compensation• Feedforward compensation• Fuzzy augmentation• Current sensor drift compensation• Actual torque vector from current sensor readings• PWM voltage vector required
100µS
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Brushless Se
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OperationAn Illustrative Analogy
To more clearly illustrate how torque response time andtotal servo phase delay affect bottom-line performance,the following analogy may be helpful.
Imagine you’re being driven in a car where the frontwheels don’t turn until some extended time after thedriver starts turning the steering wheel. In our analogy,this time delay represents torque response time. You caneasily see that the worse this delay is, the harder itwould be to negotiate even the slightest curve in theroad. If the delay is significant, it wouldn’t matter howgood of a driver you had (i.e.: how good of a servo“algorithm” he has in his brain), he would not be able tostay on the road.
The difficulties presented to your driver by this slowresponse time would obviously become morepronounced as you asked your driver to drive faster. Tokeep our analogy accurate, however, driving fasterwould not only make the delay more treacherous, itwould also increase the amount of the delay, thuscompounding the problem. (See the torque responsetime curves on page H-13.)
Your driver’s reflexes, decisiveness and concentrationare analogous to the elements of total servo phase delay.If your driver is talking on the cellular phone, adjustingthe radio, and reading a map while he’s trying to drive(i.e.: he’s “controlling other axes”), you can bet he’dhave a problem under anything but the easiest drivingconditions.
On top of this, if the link between his brain and hismuscles has become somewhat unsynchronized becausehe’s had a few drinks, you’ll really have a mess.
Overall, the link between command and execution is notonly delayed, but also unsynchronized, and furtherimpaired by a controller that’s overburdened. All of thiscombines to greatly impede effective servo control. Tocomplete our driving analogy, the impedimentsdiscussed above would have many negativeconsequences: your tracking accuracy would be poor,your car would be swayed by outside disturbances(wind, potholes, etc.), you would have a tendency tooscillate all over the road, the ride would be far fromsmooth, and your driver would get very tired and needto rest often from being so inefficient.
If conditions are perfect, the road is perfectly smooth,and you’re not in a rush, your ride in this car may beacceptable. If, however, you tell the driver to rush youto the airport and you drive along a less than perfectroad with luggage strapped to the roof of your car,there’s a good chance that you’ll miss your plane.
Analogously, a motion application with a light inertialload, superior mechanics, slow accelerations and lowvelocities will be adequately controlled by mostrespectable servo systems. On the other hand, if youneed to make fast point-to-point moves, use coordinatedaxes, require above average accuracy or smoothness,want to use a smaller motor or have an inertial loadlarger than that of the motor, then you will greatlybenefit from a servo system with high bandwidth, fasttorque response, and low total servo phase delay.
This is an oscilloscope print of tracking error (positionerror) versus time with a B8000 System. The horizontalcenter line represents zero error and each division aboveand below center represents 30° of error. Thedownward vertical spike is a forced, instantaneousposition disturbance of 90°. The system completelycorrects this large, step-function error within 10milliseconds!
Earlier, we discussed torque response time, a keyspecification regarding motor torque that is notgenerally discussed by servo manufacturers. Now let’silluminate a well known torque specification – thetorque-speed curve – what it tells you and doesn’t tellyou.
The torque-speed curve in a servo’s specifications istypically only estimated by manufacturers. The torque ismeasured with the shaft locked (i.e.: at zero speed), andthen other end of the curve, the maximum no-loadspeed, is also measured. Using these two data points anda ruler, the torque-speed curve is constructed from atheoretical formula.
Unfortunately, the formula does not account for severallosses that occur in drives that use standard current looptechnology (analog or digital). These losses are causedby dynamic misalignments of the magnetic field withinthe motor’s stator with respect to the magnetic field ofthe rotor. This misalignment is a result of the limitationsinherent in the technology used to control the current inthe stator windings.
To understand these limitations, first realize that allcontrol of a brushless servo motor ultimately dependson two things: 1) properly rotating the magnetic field ofthe stator to cause rotation of the magnetic rotor, and2) controlling the strength of the magnetic field of thestator so as to regulate the torque generated by therotor. To precisely control all aspects of the stator’smagnetic field, the alternating currents flowing throughthe stator’s phases must be accurately controlled, bothin phase (with respect to the rotor) and in amplitude.
Sinusoidal (AC) Servos—State-of-the-Art?
With a traditional sinusoidal (AC) servo drive, thecurrent in each winding phase is actively servo-controlled. In other words, there is a current loop foreach phase that compares actual current to the desiredcurrent and makes corrections as needed. As the motorgoes faster (i.e.: the stator field spins faster), thealternating phase currents need to change more rapidly.There is an inherent problem, however. A finite timedelay exists in all traditional current loops which causesa phase error which, in turn, causes a magnetic fieldmisalignment. To make fast point-to-point moves, thephase currents need to change fast and the misalignmentbecomes a problem.
Some AC servo designs attempt to remedy this problemwith a phase advance scheme, but alas, the solution isnot so simple. The amount of phase advance is highlydependent upon speed, inertia, friction, and torquedirection relative to motor direction. The mostsophisticated phase advance scheme available cannothandle all these variables.
The effect of the misalignment is that the torquecalculated by the main servo algorithm as necessary toachieve the desired velocity, and position is notproduced. Under steady-state velocity and loadconditions, the result of this progressive misalignmentwith respect to speed is a large “droop” in the torque-speed curve, as shown below.
As everyone knows, energy can be neither created nordestroyed, so what happens to the current that goes intothe motor but doesn’t come out as torque?
Speed
Torq
ue
0
100
200
300
400
500
600
0 500 1000 1500 2000 2500 3000 3500 4000
Torque produced by the B8000 drive(max power is 31% higher)
Torque produced by the sine wave drive with analog current loops
Lost torque and power due to current loop delay inherent in a "direct" type sine wave drive.A portion of these actually heat the motor's windings reducing its continuous torque capacity.
Here, as in the torque response time curves, it can be seen thatbasic sinewave servo drives are no longer state-of-the-art.
B8000 indirect vector torque control vs acompetitive, sine wave drive with analog currentloops (direct phase current control)
Servo DriveTechnology
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Brushless Se
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OperationThe misdirected current that causes misalignment andreduces torque, converts to heat in the motor windings,thus reducing the motor’s continuous torque capability.
More important than the steady-state torquedisadvantages are the dynamic performanceimplications. Compounding the torque response delaydiscussed earlier, the magnetic field misalignmenteffectively lowers the main servo algorithm’s gains,further reducing the position/velocity bandwidth. Thisretards dynamic response and increases tracking errors.
New! Vector Torque Control
In contrast to simple current control, our proprietarytorque vector controller does not use a separate servoloop for each phase. Instead, it “de-rotates” themeasured phase currents – in other words, convertsthem into one vector value (amplitude and phase)—andcalculates the actual magnetic field vector. This vector,which is independent of motor speed and load, is thenservo-controlled to remain in precise alignment with themagnetic field of the rotor. Therefore, the true torquecan be accurately determined and accurately produced.Consequently, the torque command from the higher-level servo calculations is executed quickly andaccurately for excellent servo performance.
The exact control of the magnetic field also results in aflatter and broader torque-speed curve compared toother servos driving the same motor, and the measuredcurve looks very much like the theoretical curve. Peakpower and efficiency are greatly improved because thelosses within the motor are actively minimized.Furthermore, less wasted current means less heat, so youcan use a smaller motor for any given application—reducing costs, machine size and power requirements.
Additionally, what’s not evident from the torque-speedcurve, is that by accurately controlling the magnetic fieldof the stator, torque ripple is virtually eliminated, as is itsassociated vibration. This gives you ultra-smooth motorrotation.
How the Simple Hall-Commutated ServoCompares
Comparing IDC Servos with a 6-step (Hall-effect sensorcommutated) brushless drive is even more dramatic. In a6-step drive, the current in each phase is not monitored.Only the total bus current amplitude is measured. Thistotal is directed into the appropriate windings with acrude resolution of 60 electrical degrees by switchingthe phase voltages on and off as determined by the Hall-effect sensors that monitor the relative position of therotor. The drive does not know the phase relationshipbetween the individual winding currents – which iscritical for orienting the stator’s magnetic field – nor can
it accurately produce the desired phase currentscalculated by the servo algorithm because of its poorswitching resolution. These factors lead to inefficientand sub-optimal control. The magnetic field of the statorcan end up virtually anywhere, particularly at higherspeeds and with loads that have inertias larger than thatof the motor. Additionally, the steady-state torque droopof this common type of drive scheme is significantlyworse than the sinusoidal drive discussed earlier. Thiscan be seen in the torque-speed curve below.
Speed
0
100
200
300
400
500
600
0 500 1000 1500 2000 2500 3000 3500 4000
Torque produced by the B8000drive (max power is 70% higher)
Torque produced by the 6-step (Hall-commutated) amplifier
The Hall-commutated amplifier's torque ripple pulsations increase the average torque at low speed by about 10%, but the worst case torque over a full shaft rotation is no greater than the B8000's smooth, consistent torque output.
Lost torque and power due to various commutation defects inherent in a Hall-commutated amplifier. A portion of this actually heats the motor's windings reducing its continuous torque capacity.
Torq
ue
B8000 indirect vector torque control vs acompetitive, 6-step (Hall-commutated) amplifier
Notice that by simultaneously extending both torque andspeed, the B8000 produces a 70% advantage in peak power.
Superior Servo Performance PoweredBy Proprietary DSP ASIC Technology
Vector Torque ControlThe instantaneous magnetic field vector in a brushlessmotor stator is calculated based upon measurements ofcurrent from continually auto-calibrated sensors andcompared with the magnetic field necessary to producethe desired instantaneous torque. A voltage vector,adjusted in phase to compensate for motor speed andload, is calculated and output to a “voltage rotator” tosend PWM output to the motor.
Advanced Servo AlgorithmsPosition and velocity input, based on digital “step anddirection” signals, are compared to high-resolutionencoder feedback and fed into advanced controlalgorithms powered by one dedicated DSP per axis.
Servo compensator incorporates Proportional-Integralcontrol with an embedded Velocity loop (PIV), plusvelocity and acceleration feedforward, and proprietaryalgorithm enhancements based on fuzzy logictechnology.
Accurate Servo CalculationFast, precise calculation of instantaneous torquerequired to achieve desired position and velocity.
Fast Torque ResponseFast, precise and efficient execution ofcalculated instantaneous torque requirement.
Benefit: Superior Servo Performance• Fast moves—quick acceleration and high velocity
• Excellent tracking accuracy
• Rapid settling time
• Smooth and quiet movement, free from torque ripple
• High servo gain without jitter or “hunting”
• More continuous and peak power from the same size motor
• Higher stiffness and excellent disturbance rejection
• Consistently high performance over a wide range ofconditions
Tight Synchronization100 microseconds elapsed time for receipt offeedback and output of phase-adjusted, torque-producing voltage at the motor.
The B8001 Drive is a DSP-basedbrushless servo amplifier, designedto drive brushless or brushed DCservo motors. Both Step & Direction,and ±10V velocity or torquecommand signals are accepted,insuring wide compatibility withavailable motion controllers.
OverviewConfiguration/Tuning
B8001 Drive/Actuator Systems arepre-tuned to our motors andactuators. Where fine-tuning isrequired, our IDCMotion™ ServoTuner software includes a tuningutility to tune from your PC. Since
there are no DIP switches, jumpersor potentiometers to adjust, tuning isquick and efficient. To set up repeatsystems, simply download the datastored on disk from the previoustuning session.
• 10kHz sample rate Vector Control Smooth motion atall speeds
• 2kHz position servo sample rate Fast settling time• Removable screw terminals. Clean, easy wiring to and
Second connections for limits from driveand encoder to controller
• Built-in and externalregenetative energy capacity
Protects system, allows greaterinertial loads
Host Computeror
ProgrammableController
High LevelCommands
Analog Signalor Step Pulses
MotorCurrent
MotionController
ServoMotorDrive
,
ServoSystems
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IDCMotion™ Tuning Utility
Drive configuration and trouble shooting are facilitatedwith the tuning utility included in our IDCMotion™Servo Tuner software. This Windows based programprovides a clear, intuitive interface, with contextsensitive on-line help available every step of the way.
In many applications, tuning of the servo loop will notbe necessary, since the default tuning parameters areadequate. Repeat systems can be tuned to the samespecs by downloading the tuning data file from theprevious system. When manual tuning is desired, thesoftware greatly simplifies the procedure.
Things You Can Do:• Save a complete configuration to a file.
• Load entire configuration to a system.
• Define motor specs.
• Define drive specs.
• Define controller interface.
• Configure analog monitor output for actualvelocity, commanded velocity, velocity error,position error, analog torque command, actualtorque, or phase current.
IDC’s Programmable Smart DrivePositioning Controls offertremendous application flexibility.They provide exceptional value andperformance relative to similarcompetitive integrated controlsolutions.
A single compact package combinesa one- or two-axis motioncontroller, drive(s), OPTO modules,an AC input power supply plus anoptional, detachable front panel.Our Smart Drive Systems feature thesame outstanding dynamicperformance as our stepper andbrushless drives.
Our powerful and intuitive IDeal™programming language willdramatically reduce the time it takesto get your machine running. 6Kbytes user memory is available for upto 199 motion programs (30Koptional). Our IDCMotion™Application Development Software isincluded to program from your PC.
These controls are designed, built,tested and supported by IDC—acomplete motion control solutionfrom one reliable source.
Dedicated home andend–of–travel limit inputsfor each axis.
Programactivation viaBCD/binaryinputs or TM99thumbwheelmodule.
RS–232C communications programming,status reporting and program execution.Up to 99 units may be daisy chained.
Removablescrewterminals—easy wiring.
One or two axes ofbrushless servo motors(see chart)
8 bi–directional I/O plugs—compatible with OPTO–22 (and others)
G4 digital modules andGrayhill G5 analog
and temperature moduleseliminate wiring external signal
conditioning boards.
OverviewB8961/2Smart Drive
Motion Controller
y
t
One or Two Drives
RS-232C
Programming/Operator Panel
IDC Smart Drive
Encoder
1 or 2Brushless
Servo Motors
24Configurable
I/O
AxisSpecific
I/O
ACPowerSupply
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Motor Type Brushless ServoNumber of Axes 1 & 2Compatible Mechanics NV-BN, N2-B, EC2-B, EC3-B, EC4-B, EC5-B, R2A-BN, R3-B, R4-B, LD, LM, TablesShaft Power Continuous/Peak 100/1900 WattsAC Power 120/240 VACControl Method PIVF Feedforward ServoOther Features DSP-based, State Space Vector Control, High Bandwidth Digital Servo,
Sophisticated, Simultaneous Torque/Velocity/Position Control, Registration,Linear Interpolation, Go Immediate Mode, Optional Analog I/O
Simple panelmounting—drill and
punch only, suppliedwith 6 ft conductor
shielded cord.
Easy to read, 2–line,40–character, back litdisplay.
Standard panel sealed toIP65 (NEMA 4)—washdownenvironment.
User scaling of position,velocity and acceleration—tothe units you prefer.
Easy to hold. Alsoattaches directly tocontrol.
Large, scratch–proof keys haveexcellent audible and tactile feedback.
IDC Setup Wizard Makes Application Configuration Easy!
Select a Product☞
Pick a Motor☞
Select yourMechanics☞
Select your Units☞
What you can do:
ApplicationDeveloperSoftware
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OperationFor those who prefer RS-232C communications, IDCprovides Application Developer, a Windows-basedapplication development tool. It helps you quickly setupyour system, and create programs using your PC. UsingApplication Developer allows you to download afinished application, or retrieve an existing programfrom an IDC Smart Drive. It is also possible to tune yourB8961/2 via RS-232 using IDC’s Servo Tuner program.See page H-21 for more information on the tuning utility.
Motion CommandsAC AccelerationCL Current LimitCT Current Time OutDA Distance AbsoluteDC Distance to ChangeDE DecelerationDI Distance IncrementalGH Go HomeGI Go ImmediateGO Start MoveGP Go Point (Linear
Program Flow CommandsBR BreakEB End BlockEN End RoutineFK Function KeyGS Go to SubroutineGT Go to ProgramIF If ConditionalLP LoopLU Loop UntilLW Loop WhileST# Stop on CommandTD Time DelayWT Wait
I/O & Display Commands
IV Input VariableOT Outputs On/OffMS Message to Keypad“ ” Message out Serial Port
Misscellaneous Commands{} CommentsEA Enable AmplifierSP Set PositionSQ Square RootST Stop Move on Input
The B8961 and B8962 Servo SmartDrives are sophisticated, fullyfeatured controls, which are quicklyand easily programmed with theintuitive IDeal™ programminglanguage. Here is a partial list of theIDeal command language:
Serial Immediate CommandsCB Clear BufferK KillS StopIS Input StatusOS Output StatusPAC Tell Commanded PositionPAE Tell Encoder PositionRS ResetSA Axis StatusSD Drive StatusSS System StatusSW Firmware VersionUN Unit Number
Serial Supervisory CommandsAA Auto AddressDP Delete ProgramDR Download Programs to
RAMEC Enable Terminal EchoEP End ProgramEX End Load AllLA Load AllLS List ProgramsOC Original ConfigurationPR Define ProgramPW PasswordRN Run ProgramUA Upload AllUL Upload Programs
Servo Setup CommandsAH Anti HuntAM Maximum AccelerationAW Anti-Inertial Wind-upBV Break VelocityCU Current UnitsER Encoder ResolutionFA Feed Forward AccelFE Following ErrorFV Feed Forward VelocityIR In RangeKI Integral GainKP Position GainKV Velocity GainMV Max Velocity
ApplicationDeveloperSoftware
ServoSystems
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OperationProgramming Example, Go Immediate ModeIDC Solution: B8962
(VAR1)=10 {Intialize Variable}LP {Beginning of Loop Block}
DI55,10 {Define Two Axis Move}VE10,10AC.5,.5GI {Start Go Immediate Move Both Axes}MS1,“” {Clear Screen}MS1,(AI9) {Write Analog Input 9 to the Screen While Moving}WT,#2 {Wait for Axis 2 to Stop Moving}TD.5 {Time Delay of 0.5 seconds}DI,10 {Define Axis 2 Move of 10 units}GI {Start Axis 2 Go Immediate Move}IF8,1 {If Input 8 is on}
OT10,1 {Turn on Output 10}TD.1 {Time Delay of 0.1 seconds}OT10,0 {Turn off Output 10}
EB {End of If Block}WT,#2 {Wait for Axis 2 to Stop Moving}TD.5 {Time Delay of 0.5 seconds}DI,10GI {Start Axis 2 Go Immediate Move}(DIST)=(VAR1)*1000 {Do Variable Math while Moving}(TERM)=(DIST) {Send Value of DIST Variable out of Serial Port}WT#1,#2 {Wait for Axis 1 and 2 to Stop Moving}OT1,1 {Turn On Output 1}DA0,0GO {Move Both Axes Back to Starting Position}
EB {End of Loop Block, Restart Loop}EN {End Program}
A customer requires a very long move on axis 1, whilesimultaneously making 3 short moves on axis 2 withtime delays of 0.5 seconds between the moves. The timedelay of 0.5 seconds between axis 2 moves is importantto the overall machine process. Solving this applicationsuccessfully requires executing operations while bothaxes are moving such as: asserting outputs, checkingstatus of inputs, doing math, and sending ASCII text outof the RS-232 port.
This same programming exampleapplies to all of our IDeal™programmable controls.
Operation
A customer wants to use thecontrol’s analog I/O capabilities tocreate conditional branching basedon the input values. Note: Only the“analog inputs” may be configuredto read analog information (seeexample command statements withthe use of conditional statements,variables and math).
(TEMP)=(AI9) Reads temperature on analog input #9(TEMP)=(AI9)*1.2 Temperature is scaled by factor of 1.2IF(AI1Ø)<200 GO EB If analog input 10<200, execute the
move (Go)IF(TEMP)>50 OT1 EB If temperature variable>50 turn on
Output 1IF(PARTS)=25 GS20 EB If PARTS variable=25 Gosub to
Program 20WT(A1Ø)<200 GO Wait for analog input 2<200 before
moving
Example showing math, display, outputs and variables:(PIECES)=10 Assigns 10 to a variable called PIECES(SPEED)=(AI14)*(VEL SCALE) Speed = analog input #14 times a scalerMS21, “Enter Length:” IV32,(LENGTH) Prompts user to input feed lengthVE(SPEED) Sets velocity to the value in the variableMS1,(POS1) Displays current position on screen(TEMPERATURE)=(AI16) Reads temperature in from analog
input #16(AO13)=256 Sets the analog output to 6.25% of full
scale
A customer wishes to control the temperature in two test chambers using asingle 120 VAC filament and two thermocouples (T1 and T2) in each room.At “home” position the valves/gates are open (actuators at retractedposition).
[SHUTDOWN]
OT13,0 Turn off heating elementGH5,5 Open both valves (home)EN End program
T2
T1
T4
T3
Axis #1 Axis #2
HeatingElement
[CHAMBER] Name chamber program, CHAMBEROT13,1 Activate discrete output #13 on the
OPTO module (controls filament)AC.5,.5 Set acceleration on both axis @ .5 secVE10,10 Set velocity on both axis to 10GH5,5 Home both axisLP Start continuous loop(T1)=(AI9) Reads temperature on analog input #1(T2)=(AI10) Reads temperature on analog input #2(T3)=(AI11) Reads temperature on analog input #3(T4)=(AI12) Reads temperature on analog input #4IF(T1)<170 GT[CHAMBER] EB Re-start CHAMBER program(SUM1)=(T1)+(T2) SUM1 = the sum of T1 and T2 readings(AVE1)=(SUM1)/2 Average the temperature in chamber 1 (SUM2)=(T3)+(T4) SUM2 = the sum of T3 and T4 readings(AVE2)=(SUM2)/2 Average the temperature in chamber 2IF(AVE1)>180 Evaluates if average temperature is >180DA3.5 GO EB Move axis #1 to close valveIF(AVE1)<170 Evaluates if average temperature is <170DA0 GO EB Move axis #1 to absolute zero to open
valveIF(AVE2)>75 Evaluates if average temperature is >75DA,3.5 GO EB Move axis #2 to close valveIF(AVE2)<70 Evaluates if average temperature is <70DA,0 GO EB Move axis #2 to absolute zero to open
valveIF6,1 GT[SHUTDOWN] EB If input 6 is active go to SHUTDOWN
routineEB End loopEN End program
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AutomatedForce Control
One control, one actuator, is all you need.
Easy-to-Use ControlsThe ability to alter program flowbased on torque or force limitsopens the door to a world of newapplication solutions. IDC hasintegrated this feature with its Smartcontrol products without losingtheir easy-to-use reputation. Thefollowing pages clearly illustratesome of the many possibilities andbenefits of this capability.
B8961/2Smart Drive
Electric Cylinders,Rodless ActuatorsIDC electric cylinders and rodlessactuators provide quick and easymechanical solutions to force controlapplications.
We offer the widest variety of sizes,styles, lengths and mounting options.Our actuators control forces wellover a ton.
If we do not have exactly what youneed, we can customize a solution tofit your mechanical specifications.
Applications such as drilling, spotwelding, pressing, clamping,automated fastening and shuttlingeach have unique requirements forcontrol of torque not addressed bytraditional servo products.
These applications require velocity,position and torque control (orforce control when used with alinear system), all at the same time.Until IDC Smart Drives wereintroduced, solutions were oftencomplicated and difficult tointegrate.
At IDC, our experience solvingtorque control applications has ledto an integrated, easy-to-programsolution. The following pagesdescribe several of theseapplications and give examples.
– Ball bearings onto shafts– Sleeve bearings into housings
• Inserting pems
• Snapping together plastic parts
Specific Application Needs• Precise and repeatable force control.
• Detect if bearing is missing, pressed correctly, orcockeyed.
• Programmable force.
• Protect mechanics.
• Ability to press until an input is made, distance isreached, or time delay is achieved.
• Ability to fire an output to a PLC when the specifiedcurrent is reached.
IDC Solutions
Our B8961/2 Smart Drives provide consistent control ofpressing applications. Bearings are pressed withprecisely the force you desire.
By determining how a pressing move ends, our controlsimplifies your machine solution by detecting when abearing is not pressed correctly.
This error detection and handling allows you to programsolutions to these events, such as reloading a bearing if itwas missing or alerting an operator if the bearing goes incockeyed.
Force Control: Pressing
OK Mis-Feed Missing
Example Program
[Press] Name subroutine
(OK)=2 Define Variable(Missing)=0(Cockeyed)=1
AC.1 Accelerate in 0.1 sec
VE3 Approach at 3"/sec
CL30 Press at 30% of force
CT1 Press for 1 second
DI5 Stop if not pressed by 5"
GO Begin the pressing move
IF(CLSTAT1)=(OK) If the press was normal,GT[Press] EB press another.
IF(CLSTAT1)=(Missing) If we detect a missingGT[Reload] EB part, reload a bearing
IF(CLSTAT1)=(Cockeyed) If the bearing goes inGT[Alert] EB wrong, alert the operator
OperationB8961/2Smart Drive
ServoSystems
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B8961/2Smart Drive
Example Program
[Clamp] Name subroutine
AC.3 Accelerate in 0.3 sec
VE3 Set max speed to 3"/sec
ST6,1 Stop clamp if input 6 goes on. A PLCreads the At Current Limit outputfrom the B8961 and stops theclamping move after machiningoperation is complete
CL70 Clamp at 70% of force
DI4.7 Stop if not clamped by 4.7"
GO Begin the clamping move
Typical Applications• Holding part for machining or processing
• Flexible tooling or fixturing
• Shuttling part held with constant force
• Holding parts for cutting or sawing
Specific Application Needs• Precise and repeatable force control.
• Ability to clamp until a specific event occurs (input,built-in timer, distance is reached, etc.)
• Ability to indicate when object is held (fire an outputto a PLC).
• Safety parameters preventing “run-away” due tobroken or missing part.
• Ability to “Shuttle” a part while being held with aconstant force.
IDC Solutions
Our B8961/2 Smart Drives provide consistent forcecontrol in clamping applications.
Typical IDC clamping solutions involve only one axis.The object is usually held between a solid structure andan IDC actuator. When the specified clamping force isreached, an output from the IDC Smart Drive (AtCurrent Limit output) can signal the PLC that the partclamped. This allows the clamping operation to be easilysynchronized with other machine processes.
IDC also offers some extremely unique clampingsolutions using a special rodless actuator. A speciallythreaded, right hand/left hand lead screw in one of ourrodless actuators moves two carriages in and outtogether in exact mechanical synchronization to clampparts from both sides.
Specific Application Needs• Repeatable and precise torque.
• Non-drifting torque setting.
• Ability to tighten a nut onto a screw, or thread
a screw through a nut, until a specific torque isreached.
• Programmable torque setting.
• Eliminate re-calibrating torque wrenches.
• Increased productivity.
IDC Solutions
Nut-running and screw driving applications require fastmoves that stop and reverse direction as soon as aspecified torque is reached.
Our B8961/2 Smart Drives provide consistent control ofthese applications by monitoring the applied torque as amove is made. Programmable torque settings eliminatecostly changeover times between setup of differentparts.
Our Smart Drive’s digital electronics eliminate the needto re-calibrate torque-wrenches that drift over time.Repeatable and precise torque can be set easily.
B8961/2Smart Drive
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Typical Applications• Printed Circuit Boards
• Machining Metal
• Wood Working
Specific Application Needs• Precise speed control
• Indication of worn drill bits.
• Ability to detect “knots” in wood or other materials,preventing broken bits.
• Ability to drill through layered material withdifferent maximum forces and speeds allowed fordifferent layers.
• Rapid approaches to material with constant feedspeeds.
• Improved precision of drill holes throughpreventative maintenance.
IDC SolutionsOur B8961/2 Smart Drives provide consistent controlof feed speeds and maximum forces during drilling.
Worn drill bits or knots, if drilling wood, are detectedwhen the control sees the force necessary to feedyour drill bit rise above proper levels. When thisoccurs the control can stop the feed, and indicate tothe operator that the drill bit should be changed. Thefeed force and speed can even be changed at specificpositions during the move. This is useful whendrilling through different materials of differentthicknesses.
Example Program
[Drill] Name subroutine
(Worn)=2 Define variable
AC.1 Accelerate in 0.1 sec
VE5 Set initial speed at 5"/sec
DA1.35 Set drill distance
CL51 Set max force to 51%
CT.1 Stop drilling if max force isexceeded for 0.1 seconds,indicating tool wear or “knot”hit.
DC.7 At layer 2 (0.7 inches)
VE1 Slow down feed of drill bit to1"/sec
DC1 At layer 3 (1")
VE3 Speed up feed to 3"/sec
GO Begin the drilling operations
IF(CLSTAT)=(Worn) If the move ended due to aworn bit,
IDC’s B8961 (1–axis) and B8962 (2–axes) BrushlessServo Smart Drives are user friendly systems that offeryou many compelling features and benefits. Considerthese systems when your motion control applicationrequires:
• A well integrated motion controller, digital servodrive, operator interface, power supply, 30 I/O, andbuilt in Opto I/O rack
•
• A sophisticated servo controller capable of controllingposition, velocity, and force/torque simultaneously.This capability makes the B8961/2 an ideal solutionfor clamping, pressing, drilling, and automatedfastening applications
• A simple Machine Controller
• Interrupts
• Configurable I/O
• Linear Interpolation, and Registration
• Coordinated motion between two axis
• Go Immediate Mode. This mode of operation allowsthe controller to multitask between motion controland I/O operations. Immediate Mode also allows eachaxis to move completely independently of the otheraxis
• 1–99 axes of immediate control via host RS-232Ccommunication
• Optional analog I/O for:
– Reading an analog input proportional totemperature, distance, pressure, or force
– Setting an analog output to control position ofanother axis of motion (for use with a D2500,H3501/4501, or B8501 analog position controls)
Optional Keypad• Both a programming and a operator interface
• Menu-driven setup, tuning, Help Function, DiagnosticScreens, Trace Mode-easy set up, troubleshooting andprogram debugging
• Easy to read 40 character display
• Keypad is protected to Nema 4 (IP65) when panelmounted
Drive Performance• The B8961 and B8962 features the same outstanding
dynamic performance and reliability as our DSP basedB8001 digital brushless servo drive, described on pageH-11
Motion Control• 6K memory for up to 199 user programs (30K, 400
programs optional)
• User scaling of position, velocity, and acceleration
• Descriptive variables, math and conditional branching
• High Speed interrupt driven inputs–registration
• B8962–linear interpolated vector moves
• IDCMotion™ Windows Application Developersoftware included. See page H-26.
Opto Compatible I/O• Accepts OPTO–22 (G4) digital modules and Grayhill
(G5) analog and temperature modules
• 100% solid state, opto–isolation to 4000 volts
• 8 positions, all bidirectional
• Specify (intermix) Opto I/O modules: for AC, DC,analog, and temperature signals
RPACK-1, 115 VAC Operation External regenerative power dissipation module. See page H-40.RPACK-2, 230 VAC Operation External regenerative power dissipation module. See page H-40.FP220 Operator interface, front panel. See page H-41.TM99 Thumbwheel input module. See page H-42.
A DC/AC In, 10-32 VDC, 12-32 VACB DC In, TTLC DC In, 35-60 VDCD AC In, 90-140 VACE AC In, 180-240 VACF DC Out, 5-60 VDC, 3 AmpsG AC Out, 12-140 VAC, 3 AmpsH AC Out, 24-280 VAC, 3 AmpsI Input test switchJ Analog In, 0-10 VDCK Analog In, 4-20 mAL Analog Out, 0-10 VDCM Analog Out, 4-20 mAN J Thermocouple In, 0-700°CO K Thermocouple In, -100-924°CP RTD In, 100 OhmX Empty
-LMTR For operationwith an IDCLinear Motor
-FK1 Fan Kit, 115 VACSee page H-39.
-FK2 Fan Kit, 230 VACSee page H-39.
-30K 30K userprogram memory
B8961 1-axis unit, withFP220 front panel
B8962 2-axis unit, withFP220 front panel
B8961NP 1-axis unit, no frontpanel
B8962NP 2-axis unit, no frontpanel
1 2 3 4 5 6 7 8Position
Operation
To confirm your selection,review the checklist on page H-6.
B8961/2Smart Drive
Model Description Code I/O Module Description Option Description
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How To Order
IDC controls are designed forconvection cooling. The shape andsize of our heatsinks are the result ofthermal analysis andexperimentation.
All of our controls have built-intemperature protection. Thermalsensors inside the B8000 controlswill activate at a conservativeheatsink temperature of 55°C. Thus,IDC controls will not be damagedwhen overtemperature conditionsoccur.
A number of factors affect theinternal temperature of a controland whether or not it needsadditional cooling:
• Ambient temperature
• Air flow
• Duty cycle
• Power delivered (the RMS currentoutput)
• Number of axes per control
• Regenerative energy returnedfrom the load
• Bus voltage (B Series)
Adequate ventilation in theenclosure does a lot to cool ourcontrols. Most often, a single fan inyour enclosure or panel willcirculate enough air.
When is a Fan Kit Needed?
Here are a few general guidelines toindicate when a fan kit may benecessary for your high performanceapplication.
B Series Controls:
• With high regenerative loads thatdo not require an RPACK. Seepage H-40.
• Vertical, high friction, or clampingapplications
9.06[230.1]
10.50[266.7]
3.547 [90.1]
1.05 [26.6]
Fan
Kit
B80
01 o
r B
8501
Driv
e
Model A
B8961 3.73 [94.7]
B8962 6.79 [179.5]
10.08[256.0]
A1.76[44.7]
Fan
Kit
Front View (B8001, B8501)
Dimensions in [mm]
Side View (B8961, B8962)See page H-37 for complete mount-ing dimensions for the B8961/2
Fan KitOption Specifications
Model Description
FANKIT-1 120 VAC Fan Kit
FANKIT-2 230 VAC Fan Kit
The Fan Kit is available as an option on the controls listedabove by adding an -FK1 or -FK2 suffix to the control modelnumber.
If you are in doubt as to whether a fan kit will be needed foryour application, simply leave sufficient panel space for thecontrol with fan kit and test the control without a fan. Ifyour control requires forced air cooling, the fan kit can bepurchased separately and easily retrofitted in the field.
When a large inertial load isdecelerated or a vertical load islowered, the mechanical energy thatis not dissipated as heat in theactuator or drive is “regenerated” bythe motor and transferred back intothe drive’s power supply. Thiscauses the drive's power supplyvoltage to increase. Without circuitprotection, this voltage increase candamage a drive. Without a means ofdissapating this energy, suchapplications cannot be solved.
All IDC servo drives are fullyprotected against excessiveregenerative energy. First, they are
overvoltage and short circuitprotected. Second, they are capableof dissipating regenerative energyboth internally, and in extremecases, externally using our modelRPACK-1 or RPACK-2. Our drive’sLEDs will even indicate whenexcessive regenerative energy ispresent in your application.
An RPACK allows you to make moreaggressive moves in high inertia, lowfriction applications. Each RPACKprovides connections for hook-up toeither servo or stepper drives for atotal dissipation of 240W continuousand 1000W peak (for 3 seconds).
Front View
Regen Capacity(watts or joules) B8000 SeriesInternal without fan Total energy storage capacity (max)
Select motor modelScale acceleration, velocity, distance, coordinate system and gear ratio.Set up I/O and OPTO module functions.Set Jog acceleration, velocities, and allow Jog access from run menu.Set type of home switch and offset position.Select program to run on power up and how to scan program select inputs.Select open/closed loop mode, encoder resolution and following error Set RS-232C parameters.Set useful tools like display mode, stop-rate and faults and shutdown polarity.
SETUP:
All of IDC’s programmableSmart Drives and stand-alone motion controllers,which use the IDeal™programming language,can be programmed andoperated from the FP220removable front panel(keypad). The FP220makes a great operator-machine interface, as itprovides the user withmany features andbenefits. Some of thefeatures of the FP220 are:
Keypad Menus andFunctions
• Remote mountable
• Menu-driven set up and Help
• NEMA 4 (IP65) standard
• Scratch-proof, large keys
• Easy to read, backlit 2 line, 40character display
• Displays current position and I/Ostatus
• Great for machine diagnostics andtroubleshooting
IDC’s 961 (single axis) and 962 (two axis) indexersoutput step and direction or CW/CCW control signalsto one or more drives. The 961 and 962 use IDC’sIDeal™ command language, insuring a user-friendlyprogramming environment. These indexers can be usedwith any stepper drive or any digital servo drive thataccepts an industry standard step and direction controlsignal (either differential or single ended). Consider the961/2 for your motion control application when yourequire:
• A mix of servo and stepper drives. The 962 is an idealsolution when your application requires coordinatedmotion between two axis: one of which requires ahigh power brushless servo, and the other requires alow power stepper.
• Multiple drives to be run from one command signal.This is very useful when an application calls formultiple drive/motor systems to always do identicalmoves.
• The motion controller to be separate from the drivefor E–Stop reasons. Using a 961/2 with a separatedrive allows power to be cut from the drive withoutcutting power to the motion controller.
• A non-IDC drive/motor system, but would like toimplement a user friendly motion controller.
Drive Compatibility
The 961 and 962 easily interface to a wide variety ofstep motor, and digital servo, drives which acceptindustry standard step and direction control signals. The961/2 accept incremental encoder feedback, providingclosed loop, and stall detect features. The frequencyrange of the 961/2’s step output signal allows you tocontrol drives ranging from the simplest full–step stepmotor drive to high speed digital brushless servo drives.
Opto–Compatible I/O• Accepts Opto-22 (G4) digital modules and Grayhill
(G5) analog and temperature modules.
• 100% solid state, opto–isolation to 4000 volts
• 8 positions, all bidirectional
• Specify (intermix) factory installed AC, DC, and analogI/O modules
Optional Keypad• Both a programming and operator interface
• Menu–driven setup, help functions, diagnosticscreens, and trace mode to facilitate easy setup,programming and troubleshooting
• Easy to read, backlit 40 character display
• Commands listed on keys for easy reference
• Attaches to the control or mounts remotely
• Keypad is NEMA 4 (IP65) when panel mounted
Motion Control• 6k of memory for up to 199 user programs (30k, 400
programs optional)
• Up to 2 axis of incremental encoder feedback
• User scaling of position, velocity, and acceleration
• Variable math and conditional branching
• IDCMotion™ Windows Application Developersoftware included
• 50K resolution
961/2StandaloneMotion Controller
Host Computeror
ProgrammableController
High LevelCommands
StepPulses
MotorCurrent
Indexer DriveRotaryMotor
ServoSystems
Industrial Devices Corporation707-789-1000 • http://www.idcmotion.com • 24 hour info by fax 916-431-6548 H-45
Brushless Se
rvo Syste
ms
Input Power 120 VAC single phase, 50/60 Hz
2.0 Amps max.
Serial Interface RS-232C, 3 wire implementation (Tx, Rxand Gnd), 9600 Baud, 8 data bits, 1 stop bit,no parity.
Environmental
Ambient Temperature 0–50°C.
Humdity 0% to 90% non-condensing.
Drive Signals
Step, Direction & Shutdown Optically isolated. Low signal <0.8 VDC,
Outputs high signal >3.5 VDC, ±60 mA. Active high.Step pulse width is 0.8 to 10msec(depending on drive resolution setting).
8 Programmable Open collector, sink current 100 mA max
Programming IDeal™ programming language. Programfrom the front panel, or via your PC usingour Windows-compatible IDCMotion™Application Developer software (included).
A DC/AC In, 10-32 VDC, 12-32 VACB DC In, TTLC DC In, 35-60 VDCD AC In, 90-140 VACE AC In, 180-240 VACF DC Out, 5-60 VDC, 3 AmpsG AC Out, 12-140 VAC, 3 AmpsH AC Out, 24-280 VAC, 3 AmpsI Input test switchJ Analog In, 0-10 VDCK Analog In, 4-20 mAL Analog Out, 0-10 VDCM Analog Out, 4-20 mAN J Thermocouple In, 0-700°CO K Thermocouple In, -100-924°CP RTD In, 100 OhmX Empty
Model Description
961 1-axis unit, with frontpanel
962 2-axis unit, with frontpanel
961NP 1-axis unit, no frontpanel
962NP 2-axis unit, no frontpanel
1 2 3 4 5 6 7 8Position
To confirm your selection,review the checklist on page H-6.
B Series Features• 17, 23, 34 and 42 frame brushless servo motors• Optimized for use with IDC’s B8000 servo controls• High Torque-to-inertia ratio for quick acceleration• Rugged MS-style connectors, 12-ft quick-disconnect cables included
Brushless Motor Comparison
Continuous Stall Torque Peak Torque Max Speed @ 115 VAC Max Speed @ 230 VAC For Completeoz-in [N-m] oz-in [N-m] rps [rpm] rps [rpm] Motor Specs, see:
BN Series Features• 23 and 34 frame brushless servo motors• True NEMA dimensions (including motor shafts)• Smooth operation/low cogging• 12-ft jacketed cables included
Motor Models Description
To confirm your selection,review the checklist on page H-6.
-B 24 VDC motor brake
-C25 25-foot cable
-C50 50-foot cable
-C100 100-foot cable
B12 B12 motor w/ 12-ft quick-disconnect cable
B23 B23 motor w/ 12-ft quick-disconnect cable
B23H B23H motor w/ 12-ft quick-disconnect cable
B32 B32 motor w/ 12-ft quick-disconnect cable
B33 B33 motor w/ 12-ft quick-disconnect cable
B40 B40 motor w/ 12-ft quick-disconnect cable
B41 B41 motor w/ 12-ft quick-disconnect cable
B42 B42 motor w/ 12-ft quick-disconnect cable
BN21 BN21 motor with 12-foot jacketed cable
BN23 BN23 motor with 12-foot jacketed cable
BN31 BN31 motor with 12-foot jacketed cable
BN32 BN32 motor with 12-foot jacketed cable
Note: Currently, no options areavailable for the BN motors.
ServoSystems
Industrial Devices Corporation707-789-1000 • http://www.idcmotion.com • 24 hour info by fax 916-431-6548 H-53
Brushless Se
rvo Syste
ms
Performance• For operation over 6000 rpm,
consult IDC ApplicationsEngineering.
• Performance using B8000 Seriescontrols
• IDC recommends at least a 10%torque safety margin, and takingwinding tolerances into accountwhen applying servo motors.
• See How to Order on page H-48.
• Brake option adds 1.0 in [25 mm]to motor length.
Gear Ratio in [mm] L A x B3 to 10 8.05 [204.5] 2.79 x 10.39 [70.9 x 263.9]16 to 100 8.58 [217.9] 2.79 x 10.93 [70.9 x 277.6]160 to 700 9.19 [233.4] Above 100:1, not available
L
In-line Right-angle
Applying Gearmotors*• See page I-1 for IDC gearmotor
information
• See page I-1 for how to determinegearmotor performance
• The servo drive should be currentlimited if the continuous orintermittent torque of the motorexceeds the gearhead torqueratings.
2.3[58]Max
0.2500 [6.350]0.2495 [6.337]Ø
0.0015 [0.04] A
5.42[137.7]
Max
0.31[7.9]
1.575[40.00]
1.000 [25.40]0.998 [25.35]
1.02 [25.9]0.98 [24.9]
PT02E-16-23PMating Connector
PT06E-16-23S (SR)
#6-32UNC-280.250 [6.35] (4)Eq. Spaced asshown on Ø1.531[38.89] B.C.
Gear Ratio in [mm] L A x B3 to 10 6.01 [152.7] 3.61 x 9.74 [91.7 x 247.4]16 to 100 6.84 [173.7] 3.61 x 10.57 [91.7 x 268.5]160 to 700 7.63 [193.8] Above 100:1, not available
In-line Right-angleApplying Gearmotors*• See page I-1 for IDC gearmotor
information
• See page I-1 for how to determinegearmotor performance
• The servo drive should be currentlimited if the continuous orintermittent torque of the motorexceeds the gearhead torqueratings.
Gear Ratio in [mm] L A x B3 to 10 8.49 [215.7] 5.20 x 13.46 [132.1 x 341.9]16 to 100 9.61 [244.2] 5.20 x 14.59 [132.1 x 370.6]160 to 700 10.84 [275.3] Above 100:1, not available
In-line Right-angle
Applying Gearmotors*• See page I-1 for IDC gearmotor
information
• See page I-1 for how to determinegearmotor performance
• The servo drive should be currentlimited if the continuous orintermittent torque of the motorexceeds the gearhead torqueratings.
