Our 2013 audience survey on motion components revealed that 36% of respondents now employ high-efficiency motors and 30% use premium-efficiency motors.
Among the motion challenges the group noted, in order of importance, were the integration of electronic and mechanical components, more precision/less drift, faster updates/better synchronization, integration of digital safety with motion, migration to more electronic components and away from mechanical, combining electronics with pneumatics and/or hydraulics, and migration to more electronic components and away from pneumatic and hydraulics.
"Mirroring trends in consumer electronic products, compact ac drives now pack more performance-enhancing features in smaller, user-focused designs," says Jimmy Koh, marketing manager at Rockwell Automation. "Machine builders who restrict their selection criteria to simply sizing a drive can miss out on features that can help them be more competitive. While drives control technology — volts per hertz control, sensorless vector control, etc. — remained relatively unchanged over the last decade, drives engineers have made dramatic advances with features that ease communications, minimize programming, configuration and commissioning time, improve safety, speed installation, and ultimately lower costs to design, develop and deliver machines."
Machinery OEMs need versatile products, and these new drives have versatility in abundance, without needing to add hardware or choose configuration options, adds Michael Mikolajczak, product line manager for motion control at ABB. "Built-in, multi-protocol, Ethernet capability and local intelligence mean that the application's potential is truly broad," he says. "And the processing performance is spectacular — offering some 20 times the speed of one of our popular existing generations of smart drives — making it ideal for performance intensive applications such as high-speed labeling."
E700 series inverter is available with a safe torque off input eliminating need for a redundant contactor in installations that must comply with EN954-1 Cat.3 and IEC60204-1 Stop Category 0. The safe torque off version is denoted by the characters SC after the ampere rating in the model number. The new model is 6 mm deeper than the existing version across the power range, and is compatible with both connectivity and I/O option cards when using kits created for the safe torque off model.
Mitsubishi Electric Automation
Lexium MDrive integrated motor products are available with EtherNet/IP, ModbusTCP, and CANopen protocols. Models with internal encoder include hMTechnology to close the feedback loop for stepper systems and servo motor applications. They're available in NEMA 23 and 34 motor sizes, with operating power range 12-70 Vdc.
Schneider Electric Motion USA
Slide In Functions
CMMP-AS-M3 servo drive has optional slide-in network cards for all supported networks, and an optional slide card with Safe Torque Off (STO) functionality. Drive configuration and diagnostics are handled via integrated Ethernet interface (TCP/IP) for both direct- and remote-drive access (single or multiple drive systems). An SD memory card for storing and loading parameter settings can be used to duplicate settings for high volume production of machines and restoring drive configurations.
WSS stainless-steel ac motors have windings doubled-dipped and cured in polyester insulating varnish, anti-rust coated rotor, and double-lip seals plus V-ring shaft slingers. The three-phase industrial-grade washdown duty motors come in sizes 1/3-2 hp.
IronHorse general-purpose ac motor line includes stainless-steel, three-phase motors in horsepower ranges 0.33-2 hp, speeds of 1800 and 3600 rpm, and are electrically reversible. The 56C-frame TEFC motors are IP56-rated, equipped with a large junction box with fluorinated, silicone, rubber gasket and stainless-steel cable gland. NEMA design B motors come with or without mounting feet, and can be mounted in any orientation as long as the drain plugs are installed in the lower locations.
Flat Curve Output
Brushless dc servomotor Series 0824 and 1028 are 8 and 10 mm, have high continuous torque, 1.1 and 2.1 mNm respectively, and a flat slope of the n/M motor curve. The motors can be used with a wide variety of Faulhaber encoders, gearheads and speed and motion controllers.
All in One
0.72° PKA Series combines motor with a built-in microstepping driver and stored-data controller for noise and vibration reduction, so there's no wiring needed between the controller, driver and motor, and no need for a pulse generator. A positioning function is built in, and they come in 42-mm and 60-mm frame sizes.
One Cable Handles It
AM8000 series operates without an additional feedback cable, so encoder data, rotor position, multi-turn information and the status of the thermal conditions in the motor are transmitted in one standard motor cable via a digital interface. There are six motor sizes, each with two or three optional overall lengths, and users can select a motor suitable for universal use from a stall torque range of 0.9 to 65 Nm.
All in One
Movigear combines a gear unit, motor and drive electronics in one hygienically designed unit. It's available in three sizes with torque ranges of 200 Nm and 400 Nm, and with hollow shaft and keyway or with a hollow shaft-mounting system. Voltage ranges from 380 Vac to 500 Vac. It has LED display for operating and fault states, and integrated STO safety function.
PowerFlex 525 ac drive with a modular design in power ranges 0.5-30 hp at 100-600 V input includes embedded EtherNet/IP, safety, USB programming, energy savings and other motor control options. Users configure the drive through its human interface module (HIM), Connected Components Workbench software or Studio 5000 Logix Designer. With a standard USB connection, machine builders can download completed configurations and share with multiple drives.
AKD PDMM combines a multi-axis motion controller, complete IEC61131-3 soft PLC, EtherCAT master, and AKD servo drive in one compact package. AKD Basic incorporates a programmable, single-axis motion controller into the existing AKD drive footprint, and registration correction, camming, s-curve and free-form motion profile capabilities of the integrated controller combine with the simplicity of Basic programming language and a built-in program editor with debugging tools.
Custom Direct Drives
Custom, direct-drive motor assemblies with ULT, UTH, UTS and UTO brushless frameless motor kits inside include precision bearings, special encoders, special mounting features and cabling to provide a low-profile, direct-drive solution. Sizes range 10-500 mm diameter, with pancake profiles as low as 10 mm.
Works Well With Ethernet
MicroFlex e150 Ethernet servo drives with output up to 9 A are compatible with many industrial Ethernet protocols, and have a universal encoder interfacing capability and local motion control programming. They have embedded programming capability compatible with Mint motion control language. The drives support Safe Torque Off (STO) functional safety in accordance with IEC 61800-5-2, and are designed to meet SIL 3 and performance level e (PLe) standards.
Two- and five-phase stepping motors/drivers, and motion controllers come in 24, 42, 60 and 85 mm frame sizes, with rated currents of 0.75, 1.4 and 2.8 A/phase, and communicate via RS-232C, RS-485 or USB ports.
One for One
Single-axis Sinamics V20 drive comes in four frame sizes across 1/6–20 hp, and can be connected directly in-line and mounted as a push-through installation in addition to the conventional wall-mounting method. Integrated basic operator panel (BOP) enables on-site commissioning and operation. Universal serial interfaces connect to Simatic PLC controllers, and a Modbus interface is included. Pre-built connection and application macros are used for application-specific settings.
SWM24 fuses a motion controller to a high-torque NEMA24 step motor and is engineered to IP65 standards. All connectors are sealed, M12 style. Units provide 340 oz-in. holding torque, are available with Ethernet or RS-232 communication, and include a 4,000 count/rev optical encoder housed inside.
Applied Motion Products
D-Frame VLT drives in 125–450 hp range require less panel or wall space and use back-channel cooling to remove 90% of the heat generated. With IP20, IP21 (NEMA 1) or IP54 (NEMA 12) enclosure ratings, they can be factory-fitted with optional semiconductor fuses, mains disconnect, contactor and circuit breaker.
Danfoss VLT Drives
Get the Combo
DMC-30016 combines a single-axis motion controller with a 1.4-A per phase, 30-V stepper amplifier that drives a two-phase, bipolar stepper motor in full-, half-, 1/4- or 1/16-step. It is configurable at 0.5–1.4 A per phase in 10 mA increments at 12–30 Vdc. Servo loop update is 125 ms, encoder frequency is 15 MHz, and stepper pulse output is 3 MHz.
Galil Motion Control
P532 series disc magnet step motor with encoder has rated torque of 0.2 Nm for acceleration to 400K rad/sec2. Multipolar design requires no additional iron to the rotor, giving the motor very low inertia (12E-7kgm2). With encoder, it's capable of accelerations that, with a speed to 6,000 rpm, make the motor suitable for fast incremental motion.
Acoposmulti65m motor-integrated servo drives with IP65 rating unites motor, encoder, gearbox and servo drive into a compact unit. Three sizes provide a 1.8–10.5 Nm torque range and a 500-W to 2-kW power range. An optional fan assembly can be retrofitted for a performance boost of 100%.
B&R Industrial Automation
For Pumps and Fans
P1000 drive controls variable-torque loads through 500 hp, and has a multi-language LCD with real-time clock, parameter storage, and fan and pump application presets. DriveWizard software enables configuration, monitoring and trending via standard USB port. Communication standards include DeviceNet, EtherNet/IP, Modbus TCP/IP, Profibus-DP, Profinet, BACnet and LonWorks.
Gen2.0 PremiumPlus+ electronically commutated permanent magnet motors, driven by variable-frequency drives, have motor-only rated point efficiencies of 93% and 92% for 3 and 5 hp versions. With flux-focusing stator and rotor hub geometry, the motor has an all-ferrite magnet design.
SK 200E distributed frequency inverters enable safe shutdown in high-risk applications that comply with Category 4 or PLe per EN 13849-1. SK 21xE and SK 23xE models have certified safe pulse blocking as well as digital inputs for disable-voltage and quick-stop functions.
Nord Drive Systems
+49 45 32/2 89-0
Motor + Gearbox
150-W brushless dc motor with three-stage planetary gearbox provides output torque to 120 Nm, and handles high side loads with 1000 N radial and 200 N axial. The standard motor package is IP20-rated and can be upgraded to IP54. It operates on 6-75 Vdc, and uses Hall sensors and an industry-standard, eight-wire connection scheme.
Model 100 multipurpose ac drive has a graphical multilingual display and extended block programming for drive customization, safe torque off (STO), and EtherNet/IP, Profinet IO and Modbus TCP. It has ATEX-certified motor over-temperature protection. Model 100 X and 20 X decentralized ac drives have IP66/Type 4X enclosures.
On the Carrier
UDMpc line of EtherCAT universal single- and dual-axis drives for ac servo/dc brushless, dc brush, two-phase and five-phase step motors mounts on a carrier board. It operates as an EtherCAT slave under any SPiiPlus EtherCAT master controller, including PC-based SPiiPlusSC soft controller. Optional safe torque off (STO) module cuts the power to the motor without removal of the power source to comply with SIL-3 and PLE safety levels.
Go With the Flow
3G3MX2 ac drives with compact frequency inverters have built-in PLC functionality with flowchart programming for simple, single-axis positioning. Users create programs with up to 1,000 lines of code, running five tasks in parallel. It functions as a drive and position controller with speed synchronization with no additional programming.
Omron Automation and Safety
CAT and CAN
Compact brushless dc servo motors offer EtherCAT interface on BG45, BG65, BG65S and BG75 base models. Motors range 50-500 W of power in 45-mm to 75-mm square frame sizes, and have EtherCAT compatibility to CANopen's standardized DS402 motion profile. Modular system offers planetary and worm gearboxes, integral or connected absolute encoders, and brake options.
Open and Closed Cases
iPOS4808 BX-CAT drives come in open-frame, plug-in modules with vertical or horizontal mounting on user's main board, or as closed-frame boxes equipped with retractable connectors. They have an EtherCAT interface and current capability of 8 A continuous, 20 A peak for control of rotary or linear brushless, dc brush and step motors to 400 W and 50 V. Configuration, tuning and local programming of the drive uses Technosoft's graphical platform EasyMotion Studio.
41(0)32 732 55 01
XD Series Indexer servo drive has expanded I/O capability to include a second analog input, and an analog output and motion control modes for tension control, tachometer feedback and generator mode. MotionSet software with built-in motor wizard simplifies motor configuration and commissioning of most third-party motors.
Motion Card Plus Amp
Prodigy CME motion cards combine a full-featured, four axis motion card with on-card Atlas digital amplifiers, and are available in 1, 2, 3, and 4-axis configurations; support dc brush, brushless dc and step motors; have fault detection including over and undervoltage, motor short and overtemp; and up to 1 kW peak output power per axis.
Performance Motion Devices
Single-stage GP 32 AR and GP 32 CR gearheads position both bearings of the output stage as far apart as possible, and compensate for radial forces of up to 140 N. The gearheads have 6 mm and 8 mm diameter output shafts, and can be combined with various brushed, brushless or flat motors.
Adjust When Moving
Option for Uhing RG linear drives enables fine adjustment to the linear pitch of the drive unit while the drive is moving and without changing the motor speed or gear reduction. The standard linear pitch adjustment control is a lever that is manually moved to a notched setting on a scale. Each notch increases or decreases pitch by 0.01 increments. There are 100 discrete notched settings on the scale that enable a 10:1 turndown of the linear pitch of the drive unit.