Phase - Artisan Technology Group
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1. NOTE As for motors different from the ULTRACT series see figure 6 a Phase Motion Control S r l Genova Italy 14 1 96 AXM1 2 AX Drive Application manual TABLE 2 4 C POWER CONNECTIONS MORS ON CARD PHOENIX PC4 10 ST 7 62 10 CONTACTS REMOVABLE FEMALE CONN TO THE ULTRACT MOTOR MS MIL C 5015 TYPE CVB 06A 22 228 Terminal Description ULTRACT Pin Wire color in the connector ULTRACT motor O o m Supply phase S Resistance connection for external Resistance connection for external braking Resistance connection for external braking Positive DC bus UT Ti foc negaivencs DC bus Phase Motion Control S r l Genova Italy 15 1 96 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual 5 EC norms and interference protection Brushless drives of the AX 4 series are components for PDS Power Drive System designed in accordance with the EMC 89 336 EEC and LVD 93 68 EEC norms and in particular with the EMC IEC 22G 21 CDV norm They are specified for the application Fields 2 3 As Components the AX 4 drives comply with the IEC 1000 4 2 IEC 801 2 and IEC 1000 4 4 IEC 801 4 without any accessory or protection The above mentioned IEC 22G norm specifies an electromagnetic interference limit for the active system and not for the component it would not be possible in any case As for applications similar to the refe2. servo series are foreseen to be coupled directly to the motor with keying device without a key machine The Harmonic Drive reducer is another reducer designed for the positioning It has no overall dimensions high ratios and low difference The angular stiffness is not very good and the obtainable passing belt is about 10 Hz Because of its limited energetic efficency it should be used only for positioning Another cathegory is presented by the tangent screw reducers Such reducers are not suitable for the application with speed changing motors The screw reducers in fact have a gain which decreases with the speed and the strong friction of the first leaving with the result that the systems are ineffective with a low speed while there is the development of a high reducer consuption As for the linear conversion the sphere screws offer a good solution till about 1 m s allowing to avoid any other reduction For very long movements it is necessary to control the flexion and torsional stiffness of the screw which may represent the limit to the system belt Longer movements are carried out with racks which have always a significative difference and limit the belt to a few Hz The classical systems for the recovery of the difference are not much effective inside the control systems and sometimes they are harmful too Fast and accurate movements can be obtained with metallic bands This technique which is not much spread and therefore not sta
3. A rtisan Artisan Technology Group is your source for quality Technology Group new and certified used pre owned equipment FAST SHIPPING AND SERVICE CENTER REPAIRS WE BUY USED EQUIPMENT DELIVERY Experienced engineers and technicians on staff Sell your excess underutilized and idle used equipment TENS OF THOUSANDS OF at our full service in house repair center We also offer credit for buy backs and trade ins IN STOCK ITEMS www artisantg com WeBuyEquipment EQUIPMENT DEMOS HUNDREDS OF Instra 4 REMOTE INSPECTION LOOKING FOR MORE INFORMATION MANUFACTURERS Remotely inspect equipment before purchasing with Visit us on the web at www artisantg com 7 for more our interactive website at www instraview com 7 information on price quotations drivers technical LEASING MONTHLY specifications manuals and documentation RENTALS ITAR CERTIFIED SELE BAD LE Contact us 888 88 SOURCE sales artisantg com www artisantg com AX Drive Application manual PHASE MOTION CONTROL Ultrasonic IGBT PM Brushless motor drive series AX AX5 7 11 2 APPLICATION MANUAL AX12 16 2 AX04 08 3 AX8 5 14 3 AX17 35 3 Phase Motion control S r l Genova Italy 1 1 96 AXM1 2 rtisan Technology Group a tal Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual 1 Contents L CONTEN Noe O IA 2 2 IN GENERAL e 3 DL TECHNICAL DA is 4 2 3 ELE
4. In the following figures it is possible to see the connection schemes of the speed reference in the following cases figure 4 b internal reference voltage 10 V and bidirectional functioning figure 4 c external reference signal and bidirectional functioning figure 4 d external reference voltage and bidirectional functioning As for the choice of the drive protection fuses see the below selection table No protection against overload is foreseen on the motor side as an input for the contact of the motor thermal protection is already present on the Motor Sensor Connector The tables 5 1 5 2 5 3 illustrate the functionality of each pin of the signal connectors and of each power terminal present on the drive Phase Motion Control S r l Genova Italy 8 1 96 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Phase Motion Control S r l Genova Italy LED DI SEGNALAZIONE TRIMMER DI TARATURA UMPER DI ESCLUSIONE ADAGNO IN NSERZION O DI MESSA IN FASE AXPALE REMOVABLE PERSONALITY BD LED JUMPER RAMPUP A RAMP DOWN AA DER GAIN A MAX SPEED A OFFSET LIMIT AN PROP GAIN gt INT GAIN A SE SET MOTOR CONNECTOR Hook az WARNING BEFORE CONNECTING EXTERNAL BRAKE DISCONNECT IN
5. mann ms pass varz Dimensions L x P x H 85 x 225 x 341 182x225x 341 Protection degree mr Vibration resistance Osgimaldieci s shock resistance 1osginandieston 0 34 2 4 Environmental data Operational temperature 0 40 20 70 EN 0 95 RH n c Storage temperature Humidity Height 1 1000 1 with nominal performances Derate current by 5 every 100 m higher than 1000 m Phase Motion Control S r l Genova Italy 5 1 906 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual 3 Mechanical installation The device is suitable for a wall assembly inside an electric cabinet and in non dangerous environments The dimensions of the drive and the hole positions for fastening are indicated in figure number 4 1 The installation place has to be dry without vibrations and protected from the presence of conductive powder and steam The maximum operational temperature is 40 C For operation at lower temperatures refer to the derating curve in Fig 6 The drive must be installed vertically It is also important to respect the minimum distances between each drive and the cubicle walls and the ones among different drives as in figure 3 b figure 3 A Mechanical obstructions and position of the fixing holes Dimensions mm a fe e ja M 2 AX17 35 3 Phase Motion Control S r l Gen
6. always used when it is necessary to control a power winders unwinders textile machines and machines for the band processing etc The torque control is generally steady the steadiness does not depend on the load and fast passing belt gt 300 Hz but not much accurate 10 In the multi axes applications with very fast and modern CN with an adaptive control or with variable parameters it is necessary to set the drive in torque control and to assign the closing of the other loops to CN As for the torque control the drive regulates the motor current the motor therefore is also a transducer No external sensors are necessary The sensor on the motor can be semplified only to the Hall system for the motor commutation The speed control is the most traditional It usually uses an integrative term so that the speed error is limited to the system offsets In the digital drives the speed loop is obtained by the space loop see The position or space control is carried out only by digital drives AX V In this operative way the speed error is limited to a few calculations of the sensor that is in the case of an encoder with 4096 pulse revolutions 1 16 000 of a revolution In this operative way it is also possible to synchronize several axes electrical axis 8 6 Control of the electronics and motor dimensioning After choosing the motor and the transmission it is necessary to control the application in an analytic way Such control is immedia
7. auxiliary supply The TORQUE Led is not lit Check the presence of the enabling command on the Command Connector One of the ENC A ENC B ENC C Leds does not light up while the motor is rotating or it remains always lit Deenergize the power section rotate by hand the motor shaft controlling the presence of the signals of the encoder channels on the Motor Sensor Connector and their commutations The UV Led is lit There has been a voltage decrease on the DC bus Check the value of the line voltage The Led lightning does not block permanently the drive but the message is stored In order to reset the alarm it is necessary to stop and start again the auxiliary voltage In case the undervoltage situation lasts for a too long time there is a breakdown of the capacitors on the bus with the possibility of a motor stopping In this case it is necessary when the right main voltage has been reset to disable and enable the drive to start it again In undervoltage conditions lasting more than 2 ms there is the commutation of the alarm relay The OV Led is lit There has been a voltage increase on the DC bus Check the value of the clamp resistance The Led lightning does not block permanently the drive but the message is stored In order to reset the alarm it is necessary to stop and start again the auxiliary voltage In overvoltage conditions lasting more than 2 ms there is the commutation of the alarm relay The HALL CODE Led is
8. electronics supplies the current and the motor starts to rotate loading the system elasticity and avoiding to move the load inertia 2 if the electronics is fast it is able already in this phase to detect that the motor has reached a speed higher than the one foreseen and it decreases the torque 3 at the same time the belt stretches and slows the motor reducing its speed 4 the combined effect of the torque reduction and of the load acceleration via the belt makes the belt tension decrease 5 the electronics notices the speed reduction and increases the motor torque starting a new cycle We are therefore in presence of a swinging phenomenon where the motor and the load increase and decrease their speed continuously It is possible to notice a vibration and a high noise A superficial observer would ascribe this phenomenon to a noisy motor such idea could be supported by the fact that sometimes the noise can be eliminated changing the motor with another of lower quality that is with a slower answeloop capacity On the contrary analyzing what stated above it is clear that 1 the phenomenon has to be ascribed to the disagreement between the system elasticity and the electronic regulation practically the motor reacts with a speed equal to the reaction time or to the load setting time of the mechanics 2 the possible solutions are e decreasing the system elasticity and therefore accelerate the load setting time of the mechanics for e
9. is possible to find the best solution only in a few particular cases precisely e with a direct outlet Phase Motion Control S r l Genova Italy 29 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual e with the maximum obtainable ratio with just one reduction torque e with the maximum obtainable ratio with two reduction torques etc The economic optimization in this case is carried out checking these points and adding the obtained costs of the motors to the ones of the reducers On the contrary as for the applications with a high dynamic axes the situation is completely different If the torque required in the drive cycle is dominated by the inertial torque both of the motor and of the load it is clear that increasing the reduction ratio there is a decrease of the importance of the load inertia and an increase of the motor one It is possible to state therefore that for an application where the torque given is exclusively inertial the reduction ratio able to make the load inertia compared to the motor axis equal to the motor inertia inertial coupling is the one the minimum torque given corresponds to as a consequence the motor is smaller For this reason the inertial coupling has been considered for a long time the only correct coupling system Such rule on the contrary is only a useful indication In fact the minimum dimensi
10. lit The card has detected an error on the sequence of the Hall commutation signals Stop supplying the power section then rotating by hand the motor shaft control the presence of the duct signals on the Motor Sensor Connector The Led lightning does not block the drive permanently but the message is stored In order to reset the alarm it is necessary to stop and start again the auxiliary voltage The ENC FAIL Led is lit Phase Motion Control S r l Genova Italy 23 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual The card detects the lack of the encoder signal see the note Check the presence of all direct and denied encoder signals on the Motor Sensor Connector If all the signals are correct check the ground connections The SH C Led is lit Short circuit signal in the wiring or motor ground fault on motor side Apart from the short circuit it can be activated by 1 wrong encoder phasing 2 poor connection of the motor ground to the drive ground 3 radio interferences in the supply or in the cabinet 4 too long wiring with an excessive capacity In the last case adding an inductance on the output cables generally solves the problem NOTE In order to use motors without encoder channel only in current loop close jumper S7 TABLE 7 2 A SIGNALING LEDS LED Color Normal Alarm Meaning condition ENC B Yellow Bl
11. that this situation will require a higher current 8 6 2 Electronic limitations The selection of the electronic size is carried out according to the torque which has to be supplied to the load and according to the chosen motor and winding which determine the necessary current It has to be underlined that contrary to the motor the thermal time constant of the electronics lasts a few seconds Therefore the definition of the electronic overload or peak has a quite different meaning each current supply lasting more than 2 3 seconds has to be considered as a continuative current When the motor has been chosen and when the value of its K is known the peak and avarage currents required by the drive are expressed in this way Es E ave I max K I media K The electric drive should be able to supply continuative and peak currents higher than values resulting from these formulas taking into consideration that the drive max current has to be compared to Imax only if Temax lt 5 minutes In all other cases it is necessary to use a drive whose nominal current is higher than Imax The amplifier supply main is not necessarily loaded with the same motor current the amplifier in fact operates with an electronic transformer In order to evaluate the max power required by the power supply you have to consider the power required by the load and divide it by motor and electronic output about 95 It can happen that a drive supplying 50 A to a mot
12. 0 V supply voltage Additionally all AX drives are able to supply the rated peak current for 5 minutes or indefinitely with duty cycle up to 50 The drives embody an innovative input stage characterized by limited inrush current instantaneous drive availability and a low content of harmonics in line with the future IEC 555 3 norm for this reason the input power factor of the drives is unusually high and nears unity AX is supplied with the ULTRACT brushless motor series which use the last generation of FeNdB permanent magnets for high temperature allowing operation up to 155 C The motor is controlled with six step technology with a double control loop current inside and speed outside the current modulation is carried out at 16 kHz in order to obtain a noiseless functioning and a low current ripple and a 4 kHz current loop bandwidth The motors with a sinusoidal f e m are equipped with a built in optical encoder which apart from the standard channels used for speed control is supplied with 3 commutation channels at 120 electrical degrees with a cycle number equal to the motor polarity The encoder signals A and B and the index C are available to the user transparently on the control connector for the coordination of the space and positioning loops AX drive also supplies the stabilized power supply for the encoder on the motor and checks the motor thermal protection PTC The series is completed by the parallel AX S drive mo
13. 5 3 25 15 25 55 5 3 kW Aeff Aeff kg 96 AXM1 2 35 1 rtisan Technology Group Cuan Instruiedialion Guaranteed 888 88 SOURCE www artisantg com A rtisan Artisan Technology Group is your source for quality Technology Group new and certified used pre owned equipment FAST SHIPPING AND SERVICE CENTER REPAIRS WE BUY USED EQUIPMENT DELIVERY Experienced engineers and technicians on staff Sell your excess underutilized and idle used equipment TENS OF THOUSANDS OF at our full service in house repair center We also offer credit for buy backs and trade ins IN STOCK ITEMS www artisantg com WeBuyEquipment EQUIPMENT DEMOS HUNDREDS OF Instra 4 REMOTE INSPECTION LOOKING FOR MORE INFORMATION MANUFACTURERS Remotely inspect equipment before purchasing with Visit us on the web at www artisantg com 7 for more our interactive website at www instraview com 7 information on price quotations drivers technical LEASING MONTHLY specifications manuals and documentation RENTALS ITAR CERTIFIED SELE BAD LE Contact us 888 88 SOURCE sales artisantg com www artisantg com
14. CTRIC DATA EET 5 2 4 THERMAL DATA cs cecececececececesecevevecececesesusevesesecececesevecesesececoesusscesssecscesssesscsesecscesssusscesetecscesssessrscessssesessessrecesecscesssessess 5 2 5 MECHANICAL FEATURES ccccccccssessssscecececeeseaueceeececsessaaesecececeesenseseeecececseausaeseeeceesesusaeeecececeeseaueceescecsesaaeeeeeeecesseaesaeeeeesns 5 2 6 ENVIRONMENTAL DATA ii 5 3 MECHANICAL INS TAL LATION cssssssscecussceccceceusessassececssseue aiins ASSISEN SEEEN EE E rE ATE asais 6 4 CONNEC TIONS E E L A E E E E E E E E ANE A EA 8 5 EC NORMS AND INTERFERENCE PROTECT ION cccccsssssssccssssssessscccccssssseseccescssssceccccsesessesseccccesscssescess 16 6 COMMUISSTONING em M 18 6 1 ENCODER PHASE aa 18 MANNI CR RR ARE 21 Te ESenIaNIH Ile O 23 7 1 LEDS AND DIAGNOSTIC SIGNALING 5 eeaeee aE RARI eai eei ve a letus Ee Eee HER ee Ee Eno Re RE Ee SE Ea eS ERE PE e a ved 23 Ta ALARM HANDLING 23 8 APPLICATION GUIDE e U 26 8 1 INTRODUCTION L ie 26 8 2 CHOICE OF THE TRANSMISSION AND OF THE OPTIMAL DRIVE ACCORDING TO THE APPLICATION 26 8 3 BRUSHLESS SYSTEM OPERATIVE PRINCIPLES DETAILS AND LIMITS ci 27 8 4 CH
15. OICE OF THE TRANSMISSION METHOD OF THE TRANSMISSION RATIO OF THE TYPE OF CONVERSION OF THE KEYINGS AND THE COUPLINGS ccee erre rire ee eee 28 8 5 CHOICE OF THE FEEDBACK METHOD 30 8 6 CONTROL OF THE ELECTRONICS AND MOTOR DIMENSIONING 0 eh ehen enin enin e ene inen enne enin ene e enin ee nene 31 OLMOS MUS aii eta 31 6 6 2 Electronic limitations iia esee tete tee ERES E EFE BR SEN HEU Ve ae Ye E ove avo ava e e eR Rete E even a 32 8 6 3 Considerations about the electric supply eese eene tre nre 32 8 7 RECURRING APPLICATION PROBLEMS cccccceessssseeseeececsessssececececeenssaececececeessauscecececcesesaeeeeseseseasaeseeseeesesaeeeeeeseseneea 34 Phase Motion Control S r l Genova Italy 2 1 906 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual 2 General Data The AX drive is an electronic converter suitable for driving with high dynamic performance permanent magnet brushless servo motors with low inertia with and with any polarity up to a speed of 100 000 rpm The converter is supplied by the three phase mains with or without an available neutral at 220 240 and 380 440 V 5 20 50 60 Hz AX drive is supplied in three models for the 230 V supply voltage with a nominal rms current of 5 7 12 and in tree models with a nominal rms current of 4 8 5 and 17 A for 380 44
16. TE 1 SOLA VOLTA PER CIRO 360 MECCANICO figure 6 B Encoder signal sequence Hall sensors 96 AXM1 2 Phase Motion Control S r l Genova Italy 20 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual 6 2 Tuning The following tuning trimmers are available on the drive They are located on a removable personality card NAME DESCRIPTION RANGE FACTORY STANDARD SCALING RAMP UP Acceleration ramp time for a clockwise rotation 0 30 s Os Deceleration ramp time for an anti clockwise rotation i i i 0s RAMP DOWN Deceleration ramp time for a clockwise rotation 0 30 s Acceleration ramp time for an anti clockwise rotation DER GAIN Derivative feedback gain speed loop set for the standard motor foreseen for the size of drive 1 MAX SPEED Speed range set 0 100 0 OFFSET Offset speed 0 I MOTOR Current limit 0 100 set for the value of the size max current PROP GAIN Proportional gain speed loop set for the standard motor foreseen for the size of drive 1 set for the standard motor foreseen for the size of drive 1 INT GAIN Integration gain speed loop 1 The factory setting of the feedback loop provide moderate loop quality for load inertia ranging 0 to 5 times the motor inertia but they are not optimized for a fast response time which requires a good knowledge of the mechanical system The integrator can be enabled or disabled w
17. TERNAL BR DC RESISTOR LIVE CONTACTS DIRECT CONNECTION WITH MOTOR GND GND REQUIRED FOR MINIMUM E M 1 figure 4 A Front view of the device Application manual 1 96 AXM1 2 9 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual Common mode inductance filter Phase 11A4X 1 MOTOR CURRENT 1 2 ENCODER A 2 Jd o va o n 3 ENC C amp PROXY 3 a 4 TACHO 4 O 5 ENABLE 5 6 SPEED REF 6 o 7 SIGNAL GND 7 3 AUX 5V TS Pu T9 e sme c 9 READY l o SPEDREF 40 LL i 2 i oOo o dyi os 252 10V REFERENCE i CURRENT LIMIT mE so O AUX 24V E E lt q AUX24V NC ni i PROXIMITY BYPASS RAMP toi Poop und ii ALARM NC 18 ALARM NO DO NH i RAN RR ile AUX 0V lt q AUX 0V 8 ALARM COM MAR E CURRENT SEL SIGNAL GND ENCODER B NC i NC CURRENT SEL Connection table OFF current ON speed pag 14 15 1 1 3 2Moto r Sensor Use shielded cable only with shield coverage gt 85 Power cables longer than 20 meter may generate overvoltages on the motor and damage to the drives Insert series inductance LINE FILTER j E ni E i Suggested circuit ME A Vichi E i for motor brake RS S IR i
18. a constant speed is needed the electronics increases gradually the torque supplied by the motor till the sensor does not detect a speed equal to one required If the load increases suddenly the speed decreases the sensor detects such decrease and the electronics increases the torque supplied so that it is possible to bloop the motor back to the speed set at the beginning As a consequence 1 the speed accuracy is almost independent of the load and completely independent of the motor but it depends only on the sensor quality and on the electronic regulations 2 the time used to react to the load variations depends critically on the speed for the acquisition of the sensor signal and on the electronic regulation The modern brushless systems may reach reaction times of milliseconds and therefore they offer high quality performances such performances anyway are often limited by the mechanical answeloop times of the system in order to use the new available performances it is necessary an evolution of the mechanical project of the conventional applications For instance consider a drive with a constant speed like the one mentioned in the above example If the motor is coupled to the load with a timing belt there is a certain degree of elasticity between the motor and the load axis If as assumption the load has a significative inertia and if the first moments of the motion are analyzed it is possible to state the following sequence 1 the
19. ained from the formula Im Ipk 9V Output impedance 10 kOhm Channel A encoder reversed Signal open collector 24V 20mA See note 2 ENC C Digital Encoder index logic Signal open collector 24V 20mA PROXY output AND between the See note 1 and 2 Proximity input and zero encoder The output signal refers to the Pin 7 The speed can be obtained from the ratio 850mV 1000rpm Output impedance 10 kOhm TACHO Analog Indication of motor speed output ENABLE Digital input Drive enable SPEED REF Analog input SIGNAL OV analog GND signals AUX 5V Auxiliary supply output The drive is enabled for voltages from 14 to 30V compared to the Pin 7 Input impedance 1 kOhm Disabling the drive the motor is free at any speed Negative of reference 10V input If it is not used connect to the Pin 7 A positive voltage value corresponds to the clockwise rotation of the shaft seen from the torque side Input impedance 10 kOhm Max current 100mA Regulation 0 200 mV READY Digital output SPEED REF Analog Positive of reference input 10V input 10V ref Analog Reference voltage output CURRENT Analog LIMIT input AUX 24V Auxiliary supply NOR of protection logic output Dynamic limitation of current torque Aux supply for regulation circuits Phase Motion Control S r l Genova Italy 12 1 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www a
20. anual e tangent screw reducer or Gleason Rotation rectilinear motion conversion timing belts sphere screw pinion rack metallic band For any transmission system the load parameters are compared to the motor axis as follows If n transmission ratio ratio between the motor and the load speed in the case of a conversion from rectilinear motion rad m you will have Motor torque Torque push to the load n Motor speed Load speed x n Load inertia brought to the motor axis inertia or mass load n Among all the listed transmissions the first ones which are the less expensive are the slowest and they allow only medium low passing belts lower than 10 Hz always using a belt with a low stretching degree for the same reason it is important to avoid the ratios which make the load inertia brought to the motor axis too much higher than the motor one The belt transmissions can not be applied for positioning applications with cycles lower than one second The gear reducers represent a perfect solution only when their difference is a value lower than the accuracy required by the system the best reducer the most expensive too is always epicycloid there are special series of cycloid and epicycloid reducers designed on purpose for servo controls where the difference at the output axis is contained in 10 15 arc minutes Such reducers are the only one that can be used in applications with passing belts higher than 10 Hz The reducers
21. control connector In particular the critical alarm drives a relay which can be used to cut off the power supply The drive is supplied with a braking module and a dissipative element for full torque braking with a limited energy for a braking cycle with considerable power an external resistor can be added Phase Motion Control S r l Genova Italy 3 1 96 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual 2 1 Electrical Specifications Pf ans nean axes Supply voltage 198 254 350 460 Input current aac 6 2 4 o 17 Supply frequency 40 100 Output rms current Output peak current Aeff 11 16 5 14 35 5 min or lt 50 duty cycle PWM frequency Max output frequency kHz 2 5 standard scaling 200 Hz Efficency at nominal 97 6 96 5 96 5 power output Form power factor LI 0 85 Max braking torque 100 of the nominal torque Effective braking power with internal resistance Phase Motion Control S r l Genova Italy 4 1 906 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual 2 2 Thermal data awsome axons m 1 1 Thermal capacity ol tgp Thermal resistance K W junctions environment 7 Thermal time constant EN 1540 518 476 Cooling natural forced ventilation convection 2 3 Mechanical data i
22. ctor Note 2 Open Collector Signal he drive is not provided with an internal pull up resistance If it is necessary use an external one connected to a potential not higher than 30 V Phase Motion Control S r l Genova Italy 13 1 96 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual TABLE 2 4 B MOTOR SENSOR CONNECTOR FUNCTIONALITY AND SIGNAL DESCRIPTION CONN ON CARD 15 PIN D Type CANNON REMOVABLE MALE CONN TO THE ULTRACT MOTOR TYPE IPT 06A 12 14S MIL C 26482 Terminal Function Signal Block description Q o E 5 GND PTC ov HALL 1N Digital input Hall sensor phase 1 Square wave 0 denied 5V HALL 1 Digital input Hall sensor phase 1 Square wave 0 5V Digital input Hall sensor phase 2 Square wave 0 5V zk Digital input Hall sensor phase 3 Square 0 5V AUX 5V Auxiliary supply Digital input Channel A encoder Digital input Motor thermal protection Digital input Denied encoder index Square 5V HALL 2N Digital input Hall sensor phase 2 Square denied 5V HALL 3N Digital input Hall sensor phase 3 Square denied 5V ENC A Digital input Channel A denied Square encoder 5V N Digital input Channel B denied Square encoder 5V Digital input Encoder index Square 5V oa Digital input Channel B encoder Square 5V E MEME NN pp pp Lr a EA PA Gn UN LN Pp C
23. ducers load cells thermocouples etc keep the maximum distance between the instrumentation ground and the power one As the high voltage caused by the drive is partially coupled on the ground conductor it is normal that a weak current with a high voltage crosses the conductor itself because of this it could be impossible to use high sensitivity differential switches For the same reason the ground cable may represent a duct carrying the electromagnetic interference to the other parts of the plant as a consequence it is useful to remove the small signal cables from the ground cable even in the upper part of the drive NOTE as specified in the EMC IEC 22G 21 CDV norm the AX drives are not destined to be used in a domestic environment and they may cause some interferences to the radio and television receptions Phase Motion Control S r l Genova Italy 16 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual figure 5 A Ground connection diagram Phase Motion Control S r l Genova Italy 17 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual 6 Commissioning 6 1 Encoder phasing IMPORTANT The Ultract motors supplied for the use with AX drives are factory set and therefore the phasing has not to be carried out except after a possib
24. dule which allows to use several parallel axes sharing the energy flow among the axes The AX S module moreover incorporates a RFI filter which allows compliance of the system PDS with one or more axes to the EMC IEC EN 55011 norms Class B equivalent to the more stringent VDE 871 norms without individual drive filters The control section for speed current and all the other protections of the AX card are completely isolated from the power stage In order to simplify the interface of the card with the electronics controlling the system this section is supplied by the external control system with any voltage between 20 and 30 Vdc Such a configuration allows to control the drive with any electronic card without the need of optocouplers The innovative control logic used in the drive allowed to eliminate the power electrolytic capacitors and the preload cycle at start up the card is immediately available with the presence of the power supply The personalization of the feedback loops is carried out via scaling trimmers placed on a removable card which can be accessed from the front side of the drive AX drive is supplied in a closed IP20 version with an internal fan and a thermal protection The drive is protected from thermal overloads blocked axis overvoltage low power supply lack of phase and short circuit such situations are signalled by LEDs The alarm conditions are gathered in normal and critical alarm and are indicated on the
25. e mechanics possible cycle but it is noisy steadiness differences in the transmission reduce the derivative term of the feedback loop The motor is noisy in the The system is not able to use a Improve the torsional steadiness application where the higher dynamic of the load if it is impossible others are not reduce the drive passing belt decrease the proportional gain The motor answers Insufficient gain in the electronics Increase the proportional and slowly and does not derivative terms follow the required cycle The motor does not too high Ke Change the motor with another reach the required one with a higher speed it speed while the requires much more current electronics is not at the current limit It is not possible to Stiffness mechanics mechanical Improve the mechanics obtain the required resonances eliminate the joints the belts accuracy and speed reduce the differences increase without causing the shaft diameters if possible unsteadiness operate in top gear Phase Motion Control S r l Genova Italy 34 1 96 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive ERRATA CORRIGE Application manual Ax17 23 2 Ax17 23 3 drives are replaced by Ax4 8 3 and Ax17 35 3 with features Input Current Nominal Power Output rms Current Output peak Current Mass Phase Motion Control S r l Genova Ital Ax4 8 3 4 2 6 3 5 Ax17 3
26. e motor itself The choices made by the designer of the brushless motor system are made both on a mechanical and electronic basis in order to choose the best solutions it is necessary to know the operative principles and the capacities offered by the modern brushless drives In particular the basic choices present in every system are e mechanically Choice of the transmission method of the transmission ratio of the type of motion conversion of the fits and the couplings e electronically Choice of the feedback strategy of the sensor type and number of their disposition of the control and synchronizing devices of the method for the command transmission In the following paragraphs it is possible to find a list of some criteria used to direct these choices according to the application Phase Motion Control S r l Genova Italy 26 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual 8 3 Brushless system operative principles details and limits Each brushless drive is made up of an electronic amplifier a motor and at least a feedback sensor The motor acts only as a power generator the effect produced by such power is measured by the sensor the electronics makes a comparison between the effect and the desired result and changes the power generated by the motor in order to reach the desired result For example in an application where
27. gnetizing current increases with a temperature lower than the max one which is indicated in the catalogues Control of the thermal dimensioning First of all it is necessary to control that the point Cer wer is included in the continuously functioning area of the chosen motor More precisely the temperature increase of the motor can be foreseen approximately via the following formula 65 Coy Um AT not E T el zn eLo n n C where L represents the nominal losses of the motor with an overheating of 65 C If the foreseen temperature is higher than the motor max one or at least higher than the required one it is necessary to use a bigger motor Attention the excessive temperature is the only possible reason for the choice of a bigger motor 2 Control of the electric dimensioning It is necessary to control that at the max speed the voltage required by the motor to supply the max useful torque is lower or equal to the one supplied by the electronics for the minimum main supply which can be foreseen usually for a main equal to 9096 of the voltage of the nominal main If Emin is the voltage value which can be supplied by the electronic power supply at the minimum supply voltage it is necessary to control that a R C Y C P y Van V3 Ae n 2 ra ra Oa lt E rin t I If this condition is not verified it is necessary to choose a motor with a winding suitable for a higher speed taking into consideration
28. igh as short is the time used by the drive feedback loop to stabilize itself on the desired value This parameter depends critically on the mechanics because in order to realize a steady system it is not possible to stabilize the electronics before a period equal to 2 3 times the period needed to damp the swingings of the mechanics of the activated system For example you want to realize the axis of a gnawing machine with 10 strokes per second in positions which are continuously updated by a fast numeric control If the transmission system between the motor and the piece joint screw holder etc has a frequency of mechanical resonance equal to 50 Hz and it swings in a period of 20 msec it will not be possible to stabilize the system in less than 3 x 20 msec that is 60 msec At this point there are only 40 msec left in the total cycle for the stroke and the whole motion The application is quite impossible independently of the motor used On the contrary if there is an improvement of the mechanics with stiffer joints with bigger screws etc till reaching a frequency of mechanical resonace of 100 Hz it is possible to have a drive stabilizing period of 30 msec Leaving 70 msec for the stroke and the motion In this case the application starts to be realizable 8 4 Choice of the transmission method of the transmission ratio of the type of conversion of the keyings and the couplings The dimensions of a brushless motor like all the others a
29. inking Channel B encoder OK ENC A Green Blinking Channel A encoder OK HALL Yellow Out Lit Wrong Hall sensor X CODE code ENC FAIL Out Lit Failure on the X encoder TH DRIVE Out Lit Thermal protection X drive TH MOTOR Out Lit Thermal protection X motor with a rotating motor Phase Motion Control S r l Genova Italy 24 1 96 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual with enabling command ON Phase Motion Control S r l Genova Italy 25 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual 8 APPLICATION GUIDE 8 1 Introduction The drives based on brushless motors with rare earths permanent magnets are considered to be the motors with the highest dynamic performance and with the highest specific torque and power available on the market The progressive replacement of the traditional DC inverter or hydraulic drives with brushless motors on the automatic machines allows to improve the obtainable performances above all as far as the cycle time the tracking and actuation precision the dynamic and the operating system are concerned This changing in the motorization anyway requires the knowledge and the correct use in the system or in the activated machine of the capacities of the new drives the simple change of the o
30. ith the INT GAIN ON OFF jumper In a new application adjust the feedback loop parameters with the following trial and error procedure 1 Disable the integrator by removing the INT GAIN jumper 2 Enable the drive with zero reference or better with an adjustable asquare wave generator set at 1Hz 3 Increase progressively the proportional gain until the system starts becoming unstable 4 Enable the integrator and increase it until the the overshoot becomes unacceptable 5 Increase the derivative gain until the overshoot disappears NOTE Transplanting the personality card to a new drive allows transplanting all the settings for maintenance purposes Phase Motion Control S r l Genova Italy 21 1 96 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual Phase Motion Control S r l Genova Italy 22 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual 7 Diagnostic 7 1 LEDs and diagnostic signalings On the front side of the drive there are 14 signaling leds The meaning of each LED is indicated in the TABLE 8 2 1 7 2 Alarm handling Here you can find a description of the measures to be taken in case an alarm signal appears The SUPPLY Led is not lit Check if the power circuit is supplied The AUX 0K Led is not lit Check the presence of the
31. ld motorization with new brushless motors can cause big problems on those machines which are not designed for the available dynamic and sometimes it can also decrease the quality of the system instead of improving it The guide has been designed in order to supply an operative instrument for the first commissioning of the application on the side of users who are not familiar with these motors and their performances in order to determine immediately the practicability of each new task In order to optimize completely the important applications it is advisable anyway to refer directly to the supplier 8 2 Choice of the transmission and of the optimal drive according to the application At the basis of every application there is a right choice of the system parameters which have to be definied so that it can be possible to use in an excellent way the remarkable features of the modern brushless drives which sometimes are not fully understood The range of choices derives from the fact that a brushless drive is not a simple motor but on the contrary a complex drive system with a high feedback degree therefore it is much more flexible and sofisticated Conceptually speaking the brushless motor in fact is much more similar to the membrane of a loudspeaker than to a conventional motor it is able to answer in a very short time to any electric command but as for the loudspeakers the quality of the result depends much more on the control system than on th
32. le replacement of the encoder The following procedure has therefore to be used only in such a case or with the use of motors not belonging to the ULTRACT series In order to allow a correct functioning of the drive it is necessary that the Hall effect encoder sensors group mounted on the motor is located in a precise position consideloop the windings of the motor phases Normally the encoder positioning or phasing is carried out with the motor construction and therefore no intervention is required to the user Anyway should this operation be necessary act as follows 1 Disengage the axis letting the motor free to rotate 2 Open the rear motor cap and loosen the screws of the encoder stator 3 Supply the drive both for power and signal and enable the drive without reference with a current control 4 Press the PHASE SET button and keep it pressed the motor takes a direction and blocks itself In this condition if the encoder position is a wrong one the two LD3 LD4 leds light up simultaneously 5 Rotate by hand the encoder body observing the LD3 LD4 leds till they change their condition simultaneously 6 Block the encoder screwing the screws with a 0 2 0 5 Nm clamping torque and depress the PHASE SET button 7 Close the rear cap screwing the screws with a 5 Nm torque We suggest to carry out the encoder phasing with the highest possible care The max accepted error is 1 degree equal to 0 5 mm on the encoder perimeter NOTE 1 Sh
33. ndardized is able to reach excellent performances in the control of small masses some kilos The use of linear motors is the best solution to obtain the best performances with a rectilinear motion To select the most suitable method and transmission ratio for a specific application it is necessary to distinguish between two application types 1 Power applications the motor supplies power to a process mandrels traction windings etc where the dynamic performances are marginal the transmitted power is significative the motor cost is an important fraction of the system cost 2 Positioning applications or rapid cycle applications electronic cams the majority of the energy is used to accelerate to brake and to position the objects in short times and with a more or less high accuracy Traditionally the two above mentioned categories are referred to respectively as mandrels and axes In the first case the dynamic is often not important therefore it is possible to use cheap reducers and as the powers used are often relevant a mechanical transmission with a reduction phase is normally useful In order to choose the best transmission ratio we have to consider that the dimension and the cost of the motor till the speed is lower than 4000 RPM decrease in a linear way with the transmission ratio On the contrary the cost of the transmission increases step by step according to the number of gear torques or pulleys economically speaking it
34. nificative in the case of motors longer than any other size The series of brushless motors are superimposed so that the same torque can be obtained with a long and narrow motor or with a short and stocky one For this reason e long motors have a minimum moment of inertia and they have to be used for high accelerations with low inertia loads e stocky motors have a maximum torsional stiffness and they have to be used with loads whose inertia is sometimes higher than the motor one Here is the formula expressing the torsional stiffness of a shaft whose diameter is D and whose length is L the shaft is made of steel 4 ag sn 32 L m while the first sequence of torsional resonance of a load with inertia JI connected to an axis with torsional stiffness Sm is given by the following formula 1 S F e m 2 e x Jl If you decide to use an application with short times and with a high load inertia it is necessary to set a proof of the first mechanical resonance of the system 8 5 Choice of the feedback method The drive system can be set in three different operative ways e torque control the speed depends on the load e speed control the torque depends on the load e position control Phase Motion Control S r l Genova Italy 30 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual The first operative way is the easiest and can be
35. old the phasing be impossible that is the motor does not rotate uniformly in the current loop control the sequence of the motor phases and of the Hall ducts as in figure 7 1 NOTE 2 If after the phasing the motor operates regularly in the current loop but it presents a runaway effect in the speed loop control the sequence of the encoder signals A B and C as in figure 7 2 Phase Motion Control S r l Genova Italy 18 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual Li E p uy Pd PA L 9 F figure 6 A Motor phase sequence Hall probes Phase Motion Control S r l Genova Italy 19 1 96 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual FASATURA ENCODER SEGNALI HALL GRAN ELETTRICI 000000 n e i PIN 7 lil TII enc cB PN 15 ENC C Eno ch Z AN 14 A ______ SEGNALI SUL HALL 1 SENSOR CONNECTOR t Enc enw PIN 3 HAZ Enc ch PIN 4 NE HA E IRE IER ds aa 705 1122 120 1275 35 DIREZIONE DI ROTAZIONE ALBERO ANTI ORARIO CCW VISTA DAL LATO ALBERO VEDI FIGURA SCHEDA SONDE DI HALL SE PRESENTE MONTATA CON LATO COMPONENTI VERSO LO STATORE VEDI FIGURA VALIDO PER ENCODER TAMAGAWA CON LATO MONTAGGIO VERSO LO STATORE A 1024 IMPULSI GIRO E MOTORE AD 8 POLI NOTA BENE L INDICE C SI RIPE
36. oning of the motor consideloop that the cost of a reducer is usually the double of the motor one does not correspond to the cheapest application dimensioning If we consider also that the application dynamic depends on the elasticity and on the differences of the transmission it is not logic to optimize the ratio taking into consideration only the motor In general it is possible to state that e any transmission ratio higher than the inertial ratio is not correct e the best ratio is always lower or equal to the inertial one and it is obtained consideloop the motor and reducer costs e high ratios present always a passing belt and a lower degree of accuracy with a higher energetic consumption than what can be obtained with lower ratios These considerations explain the today attempt to eliminate the reducers in order to operate in a direct way When the load inertia is higher than the motor one it is necessary to be particularly careful because the motor inertia is no more able to carry out a stabilizing action on the possible mechanical resonances of the system As a consequence the mechanical system in these applications has to be of high quality stiff and without differences and the coupling without machine key that is with keying device Operating with a direct traction it is necessary to check the torsional stiffness of the system In particular you have to consider also the torsional elasticity of the motor shaft which is sig
37. ontacts CURRENT Digital input Regulation selection of High speed regulation SEL current speed Low current regulation High signal for voltages from 14 to 30 V in comparison to the Pin 7 Input impedance 10 kOhm 22 SIGNAL GND 23 ENC B Digital Channel B denied encoder Signal open collector 24V 20mA tput Mild See note 2 ee O E MN s qe o oo o Note 1 Using the circuit for the suppression of the encoder zeros When there is the presence of a simple mechanical transmission system where the transmission ratio between the motor shaft and the activated axis is an integer the signal of the motor encoder can be converted into a position signal of the activated axis If R is the transmission ratio between the motor and the axis in order to have the inidcation of the shaft position it is necessary to eliminate the R 1 zeros of the encoder signal To this purpose it is sufficient to use a sensor with a low resolution for example a proximity which is able to supply a signal differnt from zero only in connection with the zero angular position of the activated axis This function is enabled when the jumper S10 is taken away from the card The proximity signal is taken by the Pin 15 of the Command Connector and the zero suppression circuit carries out a logic AND between the proximity signal and the encoder zeros The operation result equal to 1 in connection with the useful zero is available on the Pin 3 of the Command Conne
38. or with a very low speed and with 5 A at the max speed is never able to load the main with more than 5 A 8 6 3 Considerations about the electric supply The amplifier supply for the motor driving is converted in CC by the input stage of the amplifier which is made up of a rectifier and a capacitor battery The particular input stage of the amplifiers belonging to the series AX avoids the negative form factor typical of the conventional input stages and supplies a wave of the input current which has a square form and which is practically in phase with the voltage Therefore you will find a capacitive power factor with a 0 98 phase and a 0 9 form factor It is necessary therefore to overdimension the connections and the possible magnetothermal limiters both for the peak loads and for such values When the electronics is switched on it absorbes a current equal to 200 of the nominal one for about 0 01s in order to charge the internal capacitors As for the use of differential limiters all the RFI filters absorb a significative current on the ground connection of the drive it is therefore necessary to take into consideration the use of differentials with a high intervention threshold gt 20 mA still better if it is adjustable With multi axes applications with high wiloop capacities it can be impossible to use a sole differential unless there is the presence of a supply transformer Phase Motion Control S r l Genova Italy 32 1 900 AXM1 2 Ar
39. ova Italy 6 1 96 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com Application manual AX Drive SRR TTT a E WNH SS SS SS ANNA ANN NNN ANNA ANNA SS SS SS SS SS SS SS SS ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN ANN SS ANN ANNA ANNA NANNA ANNA NANNA ANNA ANNA ANNA ANNA NNNNA NANNA NANNA ANNA ANNA NNNNA NANNA SS ANNA ANN ANN ANN ANNA ANNA ANNA ANNA ANN ANNA ANNA SS SS RW figure 3 B Criteria for the placement of the devices AXM1 2 1 96 7 Ital Artisan Technology Group Cuan Insbuiediallen Guaranteed 888 88 SOURCE www artisantg com l Genova Phase Motion Control S r AX Drive Application manual 4 Connections The exchange of the command and reference signals but also that of the feedback signals coming from the encoder is carried out via the two connectors placed on the front side of the device Command Connector and Motor Sensor connector On the front side ar and of the scaling trimmers see figure 5 1 together with the power terminal board with an extractable connector Figure 5 2 illustrates the basic scheme for the connection of the AX drive with an unidirectional speed reference and with an internal reference voltage 10 V
40. re based on the supplied torque and not on the given power In all applications therefore a low motor speed corresponds to a low specific power and to a low gain It has to be underlined that the brushless motor has no minimun speed the speed depends only on the sensor used there are applications whose axis speed is 1 revolution year as a consequence it is logic to act on the transmission to allow a high rotation speed of the motor only when it is important to minimize the motor dimension e g with electric traction or to maximize the gain on the contrary it is not a logic solution for the costs and the dynamic performances of the system Anyway all applications where the motor acts directly on the load are characterized by the highest passing control belt because there is the maximum transmission stiffness and because these applications are able to offer the best position or following accuracy in shorter times Before starting with the selection of the right drive for a specific system it is necessary to know the type of mechanical transmission which can be used The most common transmissions are the following Rotation rotation conversion timing belt reducer with helical wheels and parallel axes cycloid and epicycloid reducer Harmonic Drive Phase Motion Control S r l Genova Italy 28 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application m
41. relay DC and BR is needed to activate Note For model 17 353 jumper Zener50V 5W as 1 1 3 7GROUND J BAR 1 96 AXM1 Phase Motion Control S r l Artisan Technology Guaranteed 888 88 SOURCE www artisantg com AX Drive WARNING BEFORE CONNECTING EXTERNAL BRAKE DISCONNECT INTERNAL RESISTOR LIVE CONTACTS Application manual figure 4 B Connection scheme for the speed reference with internal reference voltage and bidirectional functioning The input selection relay has to be mounted as near as possible to the drive Ta OV 10 BO 160 170 180 02 03 O4 O5 Speed ref e 190 O6 200 210 220 O7 o8 09 230 240 250 EE O10 of 012 figure 4 C Connection scheme for the speed reference with external reference signal 10V f s figure 4 D Connection scheme for the speed reference with external reference voltage and Phase Motion Control S r l Genova Ital 11 1 Artisan Technology Group Cuan Instruiedialion Guaranteed 888 88 SOURCE www artisantg com bidirectional operation 96 AXM1 2 AX Drive Application manual TABLE 2 4 A COMMAND CONNECTOR FUNCTIONALITY AND SIGNAL DESCRIPTION CONN ON CARD 25 PIN D Type CANNON REMOVABLE FEMALE MOTOR CURRENT 1 2 ENC A Digital output 3 Instant indication of the motor current The output signal refers to the Pin 7 The current can be obt
42. rence one the single or multi axes coupling with the AX S filtrated supply module that is with the filter SHAFFNER FN351 25 33 or something equivalent with up to 100 meters of shielded conductor cable between the drive and the motor allows the active system PDS to satisfy the requirements of the IEC EN 55011 norm Class B equivalent to the more urgent VDE 871 norms If required type test certificates are available With these limits the EC marking even though it is not necessary has been present on the AX series starting from 1 1 1996 Operative advice In order to minimize the electromagnetic interference the signal cables have always to be shielded the use of a shielded cable is suggested also for the power connections As for the shields and ground connection see the figure 6 1 In order to reduce the interferences caused by the motor cable and the induced noises in the encoder connection cable such cables have not to be longer than 20 meters Such length is necessary also for the protection of the drive itself It is important that the power wiloop is inserted in wireways different from the signal and supply one and that any cross between the power and signal cables is carried out at right angle It is necessary to have always a mass cable between the motor and the drive with a layout similar to the one belonging to the power cables If the plant foresees the use of sensitive instruments for example analog non preamplified trans
43. rmances of the brushless motors often let the dynamic limit of the system to be determined by the mechanics which is activated Therefore in this case it is much more important to understand and control the system mechanics in order to realize efficient applications From the above mentioned example it is possible to draw some observations e the accuracy does not depend on the motor but on the sensor e the answeloop speed and therefore the ability to follow the reference with accuracy depends critically on the stiffness of the transmission e the noise problem which sometimes is underlined by the system does not depend either on the motor or on the electronics but on a primordial mechanics as compared to the system performances the same mechanics in fact would not have caused any problem using a slower motor with a less modern technology e the motor noise is caused by the continuous accelerations and brakings in such conditions it is possible that the motor overheats not ascribing the cause to its insufficient dimensions As the system dynamic is a basic feature for the dimensions of the motors it is important to define it more precisely The dynamic is made up of two elements e the ability to accelerate the load at different levels which depends exclusively on the ratio torque moment of inertia of the motor such feature is sometimes defined as passing belt with big signals e the passing control belt which is so much h
44. rtisantg com Signal open collector 24V 20mA See note 2 If it is not used connect to the Pin 7 A positive voltage value corresponds to the anti clockwise rotation of the shaft seen from the torque side Input impedance 10 kOhm Stabilized voltage output Max current SmA Regulation 1 It allows the variation of the current torque limit via an analog input Range 0 10V 0 100 If it is not connected the limit is 100 The internal pull up is 15V 10 kOhm Voltage 24 30 V referred to Pin 19 Supply current 600mA 96 AXM1 2 AX Drive Application manual TABLE 5 1 COMMAND CONNECTOR FUCTIONALITY AND SIGNAL DESCRIPTION CONN ON CARD 25 PIN FLOAT CHAMBER CANNON EXTRACTABLE FEMALE 15 PROXIMITY Digital input Input for suppression of High signal for voltages from 14 to 30 V in the encoder zeros comparison to the Pin 7 iin If it is not connected it is recalled to 0 internally See note 1 Ramp clear If enabled voltages from 14 to 30 V in comparison RAMP to the Pin 7 it clears the ramp Input impedance 22 kOhm 17 ALARM NC Alarm relay Normally closed contact Contact isolated from power and signal Max current 1A Max voltage 250V 18 ALARM NO Alarm relay Normally opened contact Contact isolated from power and signal Max current 1A Max voltage 250V 19 AUX 0V OV auxiliary Internally connected to the Pin 7 suppl pey To be used only for the auxiliary supply ALARM COM Alarm relay Common on relay c
45. te for applications with a speed and load which are quite steady or which may vary on the long term of the time constant of the motor or of the electronics In this case it is necessary to control only that the maximum load is within the capacity specified for the motor and the electronics For the applications where the load varies according to a fast cycle it is necessary to act as follows 1 Trace the speed time diagram of the cycle taking into consideration that the reaching of a precise position or speed requires apart from the time stated by the limit accelerations of the system also a period of settlement equal to 2 3 times the opposite of the system passing belt see applications 1 and 2 2 Bloop back the inertia and the loads of the system to the motor shaft 3 Calculate the cycle of the accelerations and the inertial torques accelerationx motor inertia load inertia brought back to the motor shaft without forgetting the inertia of the joints keying devices and intermediate transmission devices 4 Adding the load on the motor axis to the inertial torque it is possible to obtain a torque time diagram in the cycle 5 Calculate from the torque time diagram the avarage square value of the torque dividing the cycle into segments t t2 tn if the torques given in each segment of the cycle are respectively C4 C2 Cn the avarage square or effective torque in the cycle is 6 Ceff 7 Calculate the avarage square or effec
46. tisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual Phase Motion Control S r l Genova Italy 33 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual 8 7 Recurring application problems It often happens to be impossible to dimension the application in a good way either because the system is not well known or because the mechanics or the system are already in place This section is destined to the diagnosis of the recurring applicative problems of the most common errors and of the fastest and most suitable solutions The motor torque is not The motor is NOT Increase the current limit or the sufficient to start the load underdimensioned the electronics size electronics supplies insufficient current increase the motor size The motor makes noises The motor is NOT Study the steadiness change the and overheats underdimensioned the parameters decrease in electronics is not steady proportion The motor is unsteady Wrong reaction parameters Study the steadiness change the parameters decrease in proportion The motor does not Wrong wiloop loss of hall duct Control the proportion of the rotate or rotates phase power and signal cables execute irregularly and ina idle again the phasing way The motor follows the System with a marginal Improve th
47. tive speed in the cycle we with the same formula 8 Calculate the avarage torque in the cycle Cave 9 Calculate the maximum duration time of the maximum torque in the cycle temax 10 Calculate the required torque at the maximum speed Cwmax 11 Calculate the maximum torque Cy The obtained data will be compared with the motor and electronic limits 8 6 1 Motor limits The brushless motors are very good torque transducers able to supply peak torques which sometimes are higher than the nominal ones As a consequence the obtainable peak torque is usually determined only by the choice of the electronic drive The correct dimensioning of the motor is thermal and electric the motor dimensioned in the right way is the one which stabilizes itself at the foreseen temperature usually 40 50 C above the room temperature The complete control of the dimensioning of the motor is carried out going through three different steps 1 Control of the peak or smagnetizing torque 2 Thermal dimensioning 3 Electrical dimensioning 1 Control of the smagnetizing current It is carried out with a comparison with the max value of the peak current obtained via the following formula Phase Motion Control S r l Genova Italy 31 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual Cor e K v2 and with the motor smagnetizing current knowing that the motor sma
48. xample replacing the belt with gears e slowing down the answeloop time of the motor electronics system renouncing to a part of the possible performances The second solution degrades the machine quality because it increases the time used to reach the position or the speed desired that is it decreases the motor possibility to react to sudden loads and interferences It is important to underline that the motors of lower technology that is bigger and slower ones meet the lack of speed with a considerable inertia the brushless motor on the contrary having a reduced inertia must be activated in some cases with a sufficient speed in order to avoid a high performance degradation On the basis of the mentioned example it is easy to understand the behaviour of a brushless system with mechanical instruments for example a machine key for this reason the best quality brushless motors are designed with a smooth shaft and they have to be coupled at interference via a keying device The only flexible joints suitable to the dynamic are those with a metallic bellow All these considerations rvation Phase Motion Control S r l Genova Italy 27 1 900 AXM1 2 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com AX Drive Application manual while the traditional motorizations motors CC and PM were with their inertia the limit to the dynamic performances of the activated system the higher perfo
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