Flat Linear Motor Hardware Manual
Contents
1. C 1 C 1 Current Changes Revision 2 00 00 C 1 C 2 rore pet edenda C 2 INDEX D 1 HEADEHS COMMENTS 2 25 acc uEaedcas ue dedS Eun dUEEU EU dUEU M E 1 VVV www aerotech com iii Table of Contents Flat Linear Motor Hardware Manual www aerotech com Flat Linear Motor Hardware Manual List of Figures LIST OF FIGURES Figure 1 1 Flat Linear Motors cerne Figure 1 2 BLMF Straightness and Flatness Tolerances Figure 1 3 SLACKING Tracks ecc b d c EC e Figure 1 4 Linear Motor with Tape Scale Encoder and Cable Managernent ec re e thee c ERE GE Peu e MERE e Figure 1 5 Wiring Overvlew 2 intere itn Figure 1 6 Typical Amplifier Wiring Figure 1 7 Thermal Sensor Resistance as a Function of Temperature Response Temperature Figure 1 8 Typical Thermistor Interface Figure 1 9 Linear Motor Figure 1 10 BLMF Model Figure 1 11 BLMFS5 Model Dimensions www aerotech com List of Figures vi Flat Linear Motor Har2. sss 1 2 Stacking Straightness Tolerances 1 5 T Thermal Protective Device 1 9 Thermistor Wiring eee 1 9 Tolerances rsono 1 5 BLEMES einen 1 5 BLMESS 1 5 Flatness Straightness iiis 1 5 Track Stacking sess 1 6 Wiring Guidelines 2222222 1 9 www aerotech com READER S COMMENTS Flat Linear Motor Hardware Manual P N EDA138 October 29 2007 Revision 2 00 00 Please answer the questions below and add any suggestions for improving this document AEROTECH Is the manual Yes No Adequate to the subject Well organized Clearly presented Well illustrated How do you use this document in your job Does it meet your needs What improvements if any would you like to see Please be specific or cite examples Name Title Company Name Address Mail your comments to Fax to AEROTECH INC Technical Writing Department 412 067 0870 101 Zeta Drive Email Pittsburgh PA 15238 U S A service aerotech com
3. MTF240 BLMF 81 309 BLMF 142 MTF360 BLMF 264 MTF480 BLMF 325 MTF540 BLMF 386 Dimensions Do Not Apply To BLMF 81 Consult Aerotech Inc Figure 1 10 BLMF Model Dimensions www aerotech com Flat Linear Motor Hardware Manual Introduction OPTION THERMISTOR CABLE 1 0m LONG 21 00 0 83 STD MOTOR THERMISTOR WIRES IN HALL CABLE 0 00 0 89 M5 x 0 8 x 13 0 DP MOTOR CABLE 7 WIRES 1 0 METER LG ME HIE CUSTOMER MTG HOLES PHASE BLACK BLUE PHASE RED BROWN 7 PHASE C WHITE YELLOW 50 00 1 97 GROUND GREEN YELLOW i 66 00 2 60 HALL CABLE 7 WIRES 1 0 METER LG M c 28 AWG GRAY HALL MODULE 31 00 1 22 m 50 00 1 97 oue RI E 2 66 00 2 60 MAX 2l 50 00 1 97 TYP Max 07 x i0 DP 36 99 1 46 HALL CABLE 40 00 1 57 24 00 0 94 13 00 0 51 14 00 0 55 s de d 4 20 0 17 3 80 0 15 3 4 24 50 0 96 12821049 7 1 12 20 0 48 36 36 1 43 36 1 43 1 Ro Pe 0 76 0 03 AIR GAP SHOWN WITH MAGNET TRACK SHOWN WITH MAGNET TR
4. Commutation Sinusoidal Coordinated Motion Critical Speed Flat Linear Motor Hardware Manual A support mechanism allowing relative motion between two surfaces loaded against each other This can be a rotary ball bearing linear slide bearing or air bearing zero friction See Repeatability technique used to perform nonlinear motion that is electronically similar to the motion achieved with mechanical cams A load not symmetrically mounted on a stage A broad term relating to any system where the output is measured and compared to the input Output is adjusted to reach the desired condition Computer Numerical Control A computer based motion control device programmable in numerical word address format Defined as the ratio of the force required to move a given load to the magnitude of that load Nonuniform angular linear velocity Cogging appears as a jerkiness especially at low speeds and is due to magnetic poles attracting to steel laminations The action of steering currents to the proper motor phases to produce optimum motor torque force In brush type motors commutation is done electromechanically via the brushes and commutator A brushless motor is electronically commutated using a position feedback device such as an encoder or Hall effect devices Stepping motors are electronically commutated without feedback in an open loop fashion Also referred to as trapezoidal commutation The process o
5. iet 1 5 1 3 2 Straightness and Flatness Requirements 1 5 1 3 3 Mechanical Arrangement of the Magnet Track 1 5 13 4 Track Stacking ri eee net 1 6 1 3 5 Position Transducer 1 6 1 3 6 Cable 1 6 1 4 Motor etus 1 7 1 4 1 Motor Power 1 8 1 4 2 Protective 1 8 1 4 3 Over Current Protection 1 8 1 4 4 Hall Effect Device and Thermistor Wiring 1 9 1 4 5 Wiring Guidelines sss 1 9 1 4 6 Thermal Protective 1 9 1 5 Hall Effect Operation and Motor Phasing 1 11 1 6 Motor Heating rette deis 1 12 1 7 ener Cree e Reden ek nh 1 13 1 8 Environmental 1 14 1 9 Motor Specifications 1 15 1 10 Brushless Motor 1 18 1 11 Part Number and Ordering Information 1 20 APPENDIX A GLOSSARY OF TERMS A 1 APPENDIX B WARRANTY AND FIELD SERVICE B 1 APPENDIX C TECHNICAL CHANGES
6. time to total cycle time used to determine a motor s rms current and torque force Time in a cycle at which no motion occurs Used in the calculation of rms power Ratio of input power vs output power Technique used to electrically simulate mechanical gearing Causes one closed loop axis to be slaved to another open or closed loop axis with a variable ratio Once per revolution signal provided by some incremental encoders to accurately specify a reference point within that revolution Also known as Zero Reference Signal or Index Pulse Measure of the smallest positional change which can be detected by the encoder A 1000 line encoder with a quadrature output will produce 4000 counts per revolution Position encoding device in which the output is a series of pulses relative to the amount of movement Signal that provides process or loop information such as speed torque and position back to the controller to produce a closed loop system Measure of the vertical deviation of a stage as it travels in a horizontal plane The value of force that a particular motor can produce in a continuous stall or running as calculated by the rms values condition The maximum value of force that a particular motor can produce When sizing for a specific application the peak force is usually that required during acceleration and deceleration of the move profile The peak force is used in conjunction with the continuous
7. B Optional winding V Vacuum prepared Flat Channel Magnet Tracks MTF series for BLMFI or BLMFS motors MTF240 240 mm 9 4 in length MTF360 360 mm 14 2 in length 480 480 mm 18 9 in length MTFx Custom lengths available consult the factory www aerotech com Introduction 1 21 Introduction 1 22 Flat Linear Motor Hardware Manual Table 1 8 BLMFS5 Motor Part Number and Ordering Example Ordering Example BLMFS5 142 A Where Forcer Coil Length Winding Options 142 Table 1 9 55 Motor Options Brushless Linear Servomotors BLMFS5 142 A Flat linear motor coil steel lamination design for higher force with HED and temperature switch BLMFS5 262 A Flat linear motor coil steel lamination design for higher force with HED and temperature switch BLMFS5 382 A Flat linear motor coil steel lamination design for higher force with HED and temperature switch Options LH Remove HED sensor from forcer coil B Optional winding V Vacuum prepared Flat Channel Magnet Tracks MTF5 series for BLMFS5 motors MTF5 240 240 mm 9 4 in length MTF5 420 420 mm 16 5 in length MTFx Custom lengths available consult the factory 1 Water cooling option available consult the factory for more information www aerotech com Flat Linear Motor Hardware Manual APPENDIX A GLOSSARY OF TE
8. neutral Wye Connection typical white Phase C Figure 1 6 Typical Amplifier Wiring 1 4 1 Motor Power Conductors The motor power conductors must be sized to handle the electrical current requirements of the motor The motor data sheets list the required values for the various motors The wire insulation voltage rating is chosen based on the maximum voltage that will be applied to the motor 1 4 2 Protective Ground The protective ground is a safety conductor used to ground the motor case The protective ground conductor must have a current carrying capacity at least equal to that of the motor wires The insulation is standard Green Yellow and must be rated for the maximum voltage applied to the motor winding The protective ground wire is usually bundled along with the motor wires but system requirements may be that a separate protective ground wire is needed 1 4 3 Over Current Protection Motors need to be provided with over current protection to prevent motor overheating Over current protection can be accomplished using programmable current limits traps over current protection circuitry or fusing Fuse values should be selected according to the RMS current rating of the motor For most applications slow blow type fuses should be used When the motor is part of an Aerotech system utilizing an Aerotech controller and drive the Amp continuous current rating of the motor must be used to set the motor over curr
9. 3 11 12 01 6 00 12 45 24 91 16 10 32 20 20 02 40 03 Force Constant Ib Ampy 1 40 0 70 2 70 1 35 2 80 5 60 3 62 7 24 4 50 9 00 Sine Drive 9 8 81 4 40 16 98 8 49 17 61 35 23 22 77 45 54 28 31 56 61 Ib AMPyms 1 98 0 99 3 82 1 91 3 96 7 92 5 12 10 24 6 36 12 73 Motor Constant ea 2 59 0 58 3 55 0 80 5 28 1 19 6 16 1 39 6 91 1 55 Ohms 5 5 1 4 10 9 2 7 5 3 21 2 6 5 26 0 8 0 32 0 25 C line line mH 2 90 0 73 6 50 1 63 3 50 14 00 448 17 92 5 30 21 20 line line C W 1 92 1 20 0 66 0 47 0 38 No Cooling Maximum Bus Voltage VDC 340 Mechanical Specifications Coil Weight kg Ib 0 50 1 10 0 84 1 85 1 10 2 42 1 40 3 08 1 70 3 74 Coil Length mm in 81 0 31 9 142 2 5 60 264 2 10 40 325 1 12 80 386 1 15 20 100x100x13 150x150x13 300x300x13 150x100x13 400x400x13 Heatsink mm in 4x4x0 5 6x6x0 5 12x12x0 5 14x14x0 5 16x16x0 5 Magnet Track Weight kg m lb ft 4 75 3 19 Magnetic Pole Pitch mm in 30 00 1 18 Notes 1 Performance is dependent upon heat sink configuration system cooling conditions and ambient temperature 2 Values shown 100 C rise above a 25 C ambient temperature with motor mounted to the specific aluminum heat sink 3 Peak force assumes correct rms current consult Aerotech 4 Force constant and mo
10. LH Remove HED sensor from forcer coil B Optional winding V Vacuum prepared Flat Channel Magnet Tracks MTF series for BLMFS motors MTF240 240 mm 9 4 in length MTF360 360 mm 14 2 in length MTF480 480 mm 18 9 in length MTFx Custom lengths available consult the factory www aerotech com Flat Linear Motor Hardware Manual Table 1 6 BLMFS Motor Part Number and Ordering Example Ordering Example BLMFS 81 A Where Forcer Coil Length Winding Options 81 A Table 1 7 BLMFS Motor Options Brushless Linear Servomotors BLMFS 79 A Flat linear motor coil steel lamination design for higher force with HED and temperature switch Fcont 28 0 6 3 Ib no cooling Flat linear motor coil steel lamination design for higher force with BLMFS 142 A HED and temperature switch Fcont 48 0 10 8 Ib no cooling Flat linear motor coil steel lamination design for higher force with BLMFS 264 A HED and temperature switch Fcont 97 1 21 8 Ib no cooling Flat linear motor coil steel lamination design for higher force with BLMFS 325 A and temperature switch Fcont 134 5 30 2 Ib no cooling Flat linear motor coil steel lamination design for higher force with BLMFS 386 A HED and temperature switch Fcont 159 4 35 8 Ib no cooling Options LH Remove HED sensor from forcer coil
11. Not to be used in hydrogen atmospheres www aerotech com Flat Linear Motor Hardware Manual 1 9 Motor Specifications Introduction The specifications for the BLMF series brushless motors are listed in Table 1 1 Table 1 2 and Table 1 3 Table 1 1 BLMFI Ironless Series Linear Motor Specifications Motor Model Units 5 81 5 142 5 264 5 325 5 386 Performance Specifications ied N Ib 18 7 4 2 324 73 64 8 14 6 90 2 20 3 112 1 25 2 Peak Force N Ib 74 7 16 8 129 7 29 2 259 1 58 2 360 7 81 1 448 4 100 8 Attraction Force N Ib 0 0 0 0 0 Electrical Specifications Winding Designation A B A B A B A B A B BEMF Constant V m s 7 16 3 58 13 81 6 90 14 32 28 63 18 51 37 02 23 01 46 02 line line max V in s 0 18 0 09 0 35 0 18 0 36 0 73 0 47 0 94 0 58 1 17 Continuous Current AMPpx 3 0 6 00 2 70 5 40 5 20 2 60 5 60 2 80 5 60 2 80 No Air 2 2 12 4 24 1 91 3 82 3 68 1 84 3 96 1 98 3 96 1 98 Peak Current Stall 9 AMPpx 12 00 24 00 10 80 21 60 20 80 10 40 22 40 11 20 22 40 11 20 8 49 16 97 7 64 15 27 14 71 7 35 15 84 7 92 15 84 7 92 N AmPpx 6 23
12. addition the track can be the stationary or moving part of the machine With the forcer stationary and the magnet track moving the load generally increases but the cable management system is simplified A stationary forcer usually allows for increased heat transfer from the forcer www aerotech com 1 5 Introduction 1 6 Flat Linear Motor Hardware Manual 1 3 4 Track Stacking To increase the linear motor travel distance magnet tracks can be stacked end to end as shown in Figure 1 3 Magnet Track 2 Magnet Track 1 Figure 1 3 Stacking Tracks 1 3 5 Position Transducer Resolution The motion controller requires the use of a position transducer for all forms of motion control This is typically a linear encoder The specific application determines the encoder resolution 1 3 6 Cable Management A high flex cable management system must be used to connect the forcer and feedback signals to the stationary motion controller The cable that exits the BLMF forcer is not a high flex type therefore it must terminate before entering the cable management system see Figure 1 4 Termination of the forcer and encoder cable is in most cases through a D shell connector A mating D shell connector serves as the termination point of the high flex cable in the cable management track Bearing Detail showing Linear Encoder Scale Linear Motor 5 Buueeg Cable Management System CMS Hardcover Remove
13. extend the original warranty period After Aerotech s examination the buyer shall be notified of the repair cost At such time the buyer must issue a valid purchase order to cover the cost of the repair and freight or authorize the product s to be shipped back as is at the buyer s expense Failure to obtain a purchase order number or approval within 30 days of notification will result in the product s being returned as is at the buyer s expense Repair work is warranted for 90 days from date of shipment Replacement components are warranted for one year from date of shipment At times the buyer may desire to expedite a repair Regardless of warranty or out of warranty status the buyer must issue a valid purchase order to cover the added rush service cost Rush service is subject to Aerotech s approval www aerotech com Appendix B Laser Products Return Procedure Returned Product Warranty Determination Returned Product Non warranty Determination Rush Service B 1 Appendix B On site Warranty Repair On site Non warranty Repair Company Address B 2 Flat Linear Motor Hardware Manual If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts and cannot be returned to the Aerotech service center for repair and if Aerotech determines the problem could be warranty related then the following policy applies Aerotech will p
14. force and duty cycle to calculate the rms force required by the application The resistance to motion between two surfaces in contact with each other A standard protocol analogous to RS 232 for transmitting digital information The G P I B interface IEEE 488 transmits data in parallel instead of serial format See IEEE 488 Appendix A Appendix Gain Grating Period Hall Effect Sensors HED HMI Home Home Switch Hysteresis y o IEEE 488 Incremental Move Inertia Lead Error Lead Screw Life Limit Switch Limits Linear Motor Load Carrying Capability Master Slave Flat Linear Motor Hardware Manual Comparison or ratio of the output signal and the input signal In general the higher the system gain the higher the response Actual distance between graduations on an encoder Feedback device HED used in a brushless servo system to provide information for the amplifier to electronically commutate the motor Hall Effect Device See Hall Effect Sensors Human Machine Interface Used as a means of getting operator data into the system Also refered to as an MMI Reference position for all absolute positioning movements Usually defined by a home limit switch and or encoder marker A sensor used to determine an accurate starting position for the home cycle A component of bidirectional repeatability Hysteresis is the deviation between actual and commanded positio
15. providing an enclosure around the operating components which when opened removes power to the drive The motor may also be contained in a grounded mechanical system positioning stage which restricts direct access to the high voltage motor components The drive electronics must monitor current and servo position error See user manual for RMS current level settings Position error detection is application dependent and should be set to the minimum value allowed by the application The motor over temperature sensor must be monitored by the drive and used to shut down the drive in the even of excessive motor temperatures Motor frame is safety grounded with a conduct equal in size to the phase conductors The drive must contain a properly sized fuse matched to the motor cable wire size David F Kincel 5 0 Pittsburgh PA Quality Assurance Manager December 2006 Alex Weibel Moy Noku ew Engineer Verifying Compliance www aerotech com Electrical Safety Information Electrical Safety Information Flat Linear Motor Hardware Manual X www aerotech com Flat Linear Motor Hardware Manual Introduction CHAPTER 1 INTRODUCTION 1 1 Product Overview The BLMF flat linear motor is a unique transmission system that provides extremely fast response with speeds up to 400in sec 10m sec and exceptional positioning accuracy Resolution and accuracy of the motors are limited only by the user s position transducer bearing an
16. the tabletop is oriented in the horizontal plane Axial runout is defined as the total indicator reading on a spherical ball positioned 50 mm above the tabletop and centered on the axis of rotation A centerline about which rotation occurs The voltage generated when a permanent magnet motor is rotated This voltage is proportional to motor speed and is present whether or not the motor windings are energized is the non of input A component of bidirectional responsiveness of the system command repeatability it load to reversal A precision device for translating rotary motion into linear motion A lead screw is a low cost lower performance device performing the same function Unit consists of an externally threaded screw and an internally threaded ball nut The linear distance a carriage will travel for one revolution of the ball screw lead screw A measurement expressed in frequency hertz of the range which an amplifier or motor can respond to an input command from DC to 3dB on a frequency sweep The number of bits transmitted per second on a serial communication channel such as RS 232 or modem Binary Coded Decimal A number system using four bits to represent 0 15 Appendix Appendix Bearing Bidirectional Repeatability CAM Profile Cantilevered Load Closed Loop CNC Coefficient of Friction Cogging Commutation Commutation 6 Step Commuiation Modified 6 Step
17. 1 13 65 36 45 18 22 Water Cooling 206 1196 5 98 19 31 9 65 2577 12 89 Continuous Current 9 14 4 57 14 76 7 38 19 70 9 85 No Cooling 2 AMPs 646 3 23 10 44 522 13 93 6 97 Peak Current Stall AMPpx AMPrms Us 5 ee ae 27 1 19 13 38 25 19 13 38 25 19 13 38 25 Force Constant Ib Ampy 4 30 8 60 4 30 8 60 4 30 8 60 Sine Drive 9 9 N Amprs 27 05 54 10 27 05 54 10 27 05 54 10 Ib Ampras 6 08 12 16 6 08 12 16 6 08 12 16 Motor Constant 2 6 N VW Ib NW 14 40 3 24 20 37 4 58 24 94 5 61 2 Ohms 1 7 6 7 0 8 34 0 6 22 mH 9 90 39 60 4 95 19 80 3 30 13 20 line line C W 0 20 0 15 0 13 Thermal Resistance C W 0 68 0 52 0 44 No Cooling Maximum Bus Voltage VDC 340 Mechanical Specifications Coil Weight kg Ib 1 42 3 12 2 31 5 08 3 81 8 38 Coil Length mm in 142 0 5 59 262 0 10 31 382 0 15 04 Heat Sink mm in 380x380x13 15x15x0 5 Magnet Track Weight kg m lb ft 4 40 2 95 Magnetic Pole Pitch mm in 30 00 1 18 Notes 1 Performance is dependent upon heat sink configuration system cooling conditions and ambient temperature 2 Values shown 100 C rise above a 25 C ambient temperature with motor mounted to the specific aluminum heat sink 3 Peak force assumes correct rms current consult Aerotech 4 Force constant and motor constant specified at stall 5 All perfor
18. 4 00 10 80 21 60 20 80 10 40 22 40 11 20 22 40 11 20 Peak Current Stall AMpms 8 49 16 97 7 64 15 27 14 71 7 35 15 84 7 92 15 84 7 92 N Amp x 9 34 4 67 17 79 8 90 18 68 37 36 24 02 48 04 28 47 56 93 Force Constant Ib Amp x 2 10 1 05 4 00 2 00 4 20 8 40 5 40 10 80 6 40 12 80 Sine Drive 9 N Ampims 13 21 6 60 25 16 12 58 26 42 52 84 33 97 67 94 40 26 80 52 Ib AMPrms 2 97 1 48 5 66 2 83 5 94 11 88 7 64 15 27 9 05 18 10 Motor Constant 2 5 3 89 0 87 5 26 1 18 7 92 1 78 9 19 2 07 9 82 2 21 2 Ohms 55 14 109 27 53 212 65 260 80 320 25 C line line TUM mH 4 50 1 13 10 40 2 60 5 70 22 80 7 40 29 60 8 75 35 00 line line C W 1 92 1 20 0 66 0 47 0 38 No Cooling Maximum Bus Voltage VDC 340 Mechanical Specifications Coil Weight kg Ib 0 60 1 32 1 02 2 24 1 90 4 18 2 31 5 08 2 76 6 07 Coil Length mm in 81 0 31 9 142 2 5 60 264 2 10 40 325 1 12 80 386 1 15 20 100 100 13 150 150 13 300 300 13 150 100 13 400 400 13 Heat gink mm in 4x4x0 5 6 6 0 5 12x12x0 5 14 14 0 5 16x16x0 5 Magnet Track Weight kg m Ib ft 4 75 3 19 Magnetic Pole Pitch mm in 30 00 1 18 Notes 1 Performance is dependent upon heat sink configuration system cooling conditions and ambie
19. ACK M4 x 0 7 x 6 0 DP gt 53 10 2 09 2 MTG HOLES STD 4 MTG HOLES LH OPTION MODEL A B D E F 6 45 0 25 BLMFS5 142 1420 400 80 0 6 55 262 262 0 80 0 120 0 200 0 8 BLMFS5 382 382 0 80 0 160 0 240 0 320 0 10 Figure 1 11 www aerotech com BLMFS5 Model Dimensions 1 19 Introduction 1 20 Flat Linear Motor Hardware Manual 1 11 Part Number and Ordering Information Table 1 4 BLMFI Motor Part Number and Ordering Example Ordering Example BLMFI 81 A Where Forcer Coil Length Winding Options 81 A Table 1 5 BLMFI Motor Options Brushless Linear Servomotors Flat linear motor coil ironless design for zero cogging with HED and temperature switch Fcont 18 7 N 4 2 Ib no cooling BLMFI 142 A Flat linear motor coil ironless design for zero cogging with HED and temperature switch Fcont 32 4 N 7 3 Ib no cooling BLMFI 264 A Flat linear motor coil ironless design for zero cogging with HED and temperature switch Fcont 64 8 N 14 6 Ib no cooling BLMFI 325 A Flat linear motor coil ironless design for zero cogging with HED and temperature switch Fcont 90 2 N 20 3 Ib no cooling BLMEI 386 A Flat linear motor coil ironless design for zero cogging with HED and temperature switch Fcont 112 1 N 25 2 Ib no cooling Options
20. Flat Linear Motor Hardware Manual P N EDA138 Revision 2 00 00 Dedicated to the Science of Motion Aerotech Inc 101 Zeta Drive Pittsburgh PA 15238 AEROTECH Phone 412 963 7470 Fax 412 963 7459 www aerotech com Product Registration Register online at http www aerotech com prodreg cfm Technical Support United States Phone 412 967 6440 Fax 412 967 6870 Email service aerotech com United Kingdom Phone 44 118 9409400 Fax 44 118 9409401 Email service aerotech co uk Germany Phone 49 911 9679370 Fax 49 911 96793720 Email service aerotechgmbh de Japan Phone 81 0 47 489 1741 Sales Phone 81 0 47 489 1742 Service Fax 81 0 47 489 1743 Email service aerotechkk co jp Revision History 2 00 00 October 29 2007 1 02 September 2 2001 1 01 September 20 2000 1 00 September 28 1997 Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies Aerotech Inc 2007 Flat Linear Motor Hardware Manual Table of Contents TABLE OF CONTENTS ELECTRICAL SAFETY INFORMATION ix CHAPTER 1 INTRODUCTION cun DIS c 1 1 1 1 Product te nt 1 1 1 2 Safety 1 2 1 3 Motor Assembly and 1 4 1 3 1 Bearing System
21. RMS Abbe Error Abbe Offset Absolute Move Absolute Programming AC Brushless Servo Acceleration Accuracy Accuracy Grade ASCII Axial Runout Axis of Rotation Back emf Kemf Backlash Ball Screw Ball Screw Lead Bandwidth Baud Rate BCD www aerotech com The positioning error resulting from angular motion and an offset between the measuring device and the point of interest The value of the offset between the measuring device and the point of interest A move referenced to a known point or datum A positioning coordinate reference where all positions are specified relative to a reference or home position A servomotor with stationary windings in the stator assembly and permanent magnet rotor AC brushless generally refers to a sinusoidally wound motor such as BM series to be commutated via sinusoidal current waveform see DC brushless servo The change in velocity as a function of time An absolute measurement defining the difference between actual and commanded position reference to an encoder grating accuracy grade is the tolerance of the placement of the graduations on the encoder scale American Standard Code for Information Interchange This code assigns a number to each numeral and letter of the alphabet Information can then be transmitted between machines as a series of binary numbers Positioning error of the rotary stage in the vertical direction when
22. cessary where the environment warrants their use 1 4 6 Thermal Protective Device The motor s thermal protection device is a positive temperature coefficient thermistor This device exhibits a rapid increase in resistance as the motor temperature approaches the device s transition temperature see Figure 1 7 The nominal resistance is 100 ohms at 25 C At the set point the nominal resistance increases rapidly to 1 000 ohms This thermistor can be used in a variety of different electronic interfaces A precaution when using this type of device in an interface circuit is to avoid self heating effects An excessive amount of current through the thermistor will cause its temperature to rise False triggering will then occur See Figure 1 8 for a typical interface circuit www aerotech com Introduction 1 9 Introduction Flat Linear Motor Hardware Manual Rs f 0 To jt MEME 2 2 2 Z 10 20 10 0 10 C Figure 1 7 Thermal Sensor Resistance as a Function of Temperature Qyat Response Temperature 5V 5V Logic Interface Thermal Sensor 2 0 1uF V V Figure 1 8 Typical Thermistor Interface Circuit www aerotech com Flat Linear Motor Hardware Manual Introduction 1 5 Effect Operation and Motor Phasing In linear ser
23. ch com Flatness 1 1 5 Forcer Thermal Protection Device 1 9 H Hall Effect Device Wiring 1 9 Hall Effect 1 11 Linear encoder oiim 1 6 Linear 1 1 Magnet Track Arrangement sees Cable Management Stacking niai erp Manmntenarce cornetto Models BLMFSS5 Motor Heating Motor Options BLMFS5 P Motor Phasing esee 1 11 Motor Power Conductors 1 8 BLEMESS5 ener rires Motor Wiring Customer supplied wiring BEOIGGE ce e eto eerte Hall Effect Device Wiring Motor Power Conductors Over Current Protection Protective Ground Thermal Protective Device 1 9 Thermistor Wiring ss 1 9 Wiring Guidelines Mounting Configurations 1 5 Order information sess 1 20 Index Index Flat Linear Motor Hardware Manual Ordering Example BLMEFSS Over Current Protection P Part Number Information 1 20 Position 1 6 Product Overview Protective 1 8 Safety Information
24. ch incorporates additional terms for greater system performance Angular motion of a carriage around an axis perpendicular to the motion direction and perpendicular to the yaw axis Positioning error resulting from a pitching motion Programmable Logic Controller A programmable device that utilizes ladder logic to control a number of input and output discrete devices Appendix A Appendix PWM Quadrature Radial Runout Ramp Time Range RDC Repeatability Resolution Retroreflector Roll of travel Roll Error Rotor RS 232C RS 274 RS 422 Runout Servo System Flat Linear Motor Hardware Manual Pulse Width Modulation Switch mode technique used in amplifiers and drivers to control motor current The output voltage is constant and switched at the bus value 160 VDC with a 115 VAC input line Refers to the property of position transducers that allows them to detect direction of motion using the phase relationship of two signal channels A 1000 line encoder will yield 4000 counts via quadrature Positioning error of the rotary stage in the horizontal direction when the tabletop is oriented in the horizontal plane Radial runout is defined as the total indicator reading on a spherical ball positioned 50 mm above the tabletop and centered on the axis of rotation Time it takes to accelerate from one velocity to another The maximum allowable travel of a positioning stage Resolver t
25. clude but is not limited to the following make frequent checks for excessive or abnormal motor heating excessive motor vibrations loose motor to machine couplers obstructed air flow to the motor burning smells an accumulation of debris on the motor etc Motors should be wiped with a clean dry cloth to remove any grease dirt or other material that has accumulated on the motor Fluids and sprays are not recommended for chance of internal motor contamination Cleaning the motor labels should be avoided to prevent their removal Non ferrous tools should be used when working around the magnet track www aerotech com Introduction Introduction Flat Linear Motor Hardware Manual 1 8 Environmental Specifications The environmental considerations for motor operation are given below Deviating from these specifications may lead to motor failure or an unsafe operating condition Contact Aerotech for information concerning motor operations under conditions deviating from these environmental specifications Temperature Humidity Altitude Use Atmosphere Operating 0 to 25 C consult Aerotech for performance deration for elevated ambient temperatures Storage 20 C to 85 C Ambient conditions need to be such that condensation on the motor does not occur The motors are not to be used in wash down environments Up to 1000 m Consult Aerotech for deration considerations for altitudes above 1000 m Indoor use only
26. d Figure 1 4 Linear Motor with Tape Scale Encoder and Cable Management www aerotech com Flat Linear Motor Hardware Manual 1 4 Motor Wiring The forcer is supplied with flying leads for the motor winding Hall effect devices and thermal overload sensor The customer supplies all external wiring to interface with these devices This supplied wiring must meet certain requirements to provide for safe and reliable operation The wiring must be able to supply the rated current without overheating The wire insulation must be rated for the voltage and temperature at which the motor is operating And efforts must also be made to reduce EMI emissions and to increase EMI immunity through proper cable selection and installation In addition to supplying the external wiring the customer is also responsible for providing over current protection for the motor Guidelines are given below to help with the selection and installation of the wiring Feedback Connector Signal Common black Thermistor black white Thermistor Motor Connector Phase Phase C Neutral Frame Ground Controller Neural none Frame Ground green see Figure 1 4 for more information Figure 1 5 Wiring Overview www aerotech com Introduction 1 7 Introduction 1 8 Flat Linear Motor Hardware Manual Phase A Phase B black red Blue Brown and Yellow electrically tied to form
27. d servo control The motor construction consists of a forcer and a rare earth magnet track that eliminates backlash windup and wear most commonly associated with ball screws belts or racks Flat linear motors can be incorporated into gantry systems or positioning stages with mechanical or air bearings and they are well suited for both general purpose positioning and ultra precision applications such as PC Board Insertion Machinery Pick and Place Robots Laser Marking X ray and E beam Lithography Semiconductor Laser Direct Writing Precision Diamond Cutting Figure 1 1 Flat Linear Motors Flat linear motors consist of one forcer and one or more magnet tracks The BLMFI models consist of a flat forcer that is a non magnetic epoxy based design These models are best suited for applications where cogging forces cannot be tolerated The BLMFS models consist of a flat forcer that is epoxy based with steel laminations This design is best suited for applications where increased force is required and the magnetic attractive force between the forcer and the track can be tolerated The BLMFSS models are an epoxy encapsulated steel core forcer This design is best suited for applications which provide high force per unit volume and where increased cogging and magnetic attractive forces between the forcer and the track can be tolerated www aerotech com 1 1 Introduction Flat Linear Motor Hardware Manual 1 2 Safety Informat
28. d that does not degrade the listed specifications for a mechanical stage Type of coordinated motion control where the master axis position is used to generate one or more slave axis position commands www aerotech com Flat Linear Motor Hardware Manual MMI Motion Profile Motor Brush Motor Brushless Motor Stepping NC NEMA Non Volatile Memory Open Collector Open Loop Operator Interface Optical Encoder Opto isolated Orthogonality Overshoot PID Pitch of travel Pitch Error PLC www aerotech com Man Machine Interface used as a means of getting operator data into the system See HMI A method of describing a process in terms of velocity time and position The conductive element in a DC brush type motor used to transfer current to the internal windings Type of direct current motor that utilizes electronic commutation rather than brushes to transfer current Specialized motor that allows discrete positioning without feedback Used for noncritical low power applications since positional information is easily lost if acceleration or velocity limits are exceeded Numerical Control Automated equipment or process used for contouring or positioning See CNC Also Normally Closed referring to the state of a switch National Electrical Manufacturer s Association Sets standards for motors and other industrial electrical equipment Memory in a system that maintains in
29. dware Manual www aerotech com Flat Linear Motor Hardware Manual LIST OF TABLES Table 1 1 BLMFI Ironless Series Linear Motor Specifications 1 15 Table 1 2 BLMFS Steel Laminated Series Linear Motor Specifications 1 16 Table 1 3 BLMFS5 Steel Laminated Series Linear Motor 1 17 Table 1 4 Motor Part Number and Ordering Example 1 20 Table 1 5 BLMFI Motor 1 20 Table 1 6 BLMFS Motor Part Number and Ordering Example 1 21 Table 1 7 BLMFS Motor Options 1 21 Table 1 8 BLMFS5 Motor Part Number and Ordering Example 1 22 Table 1 9 BLMFS5 Motor Options 1 22 www aerotech com List of Tables vii List of Tables Flat Linear Motor Hardware Manual viii www aerotech com Flat Linear Motor Hardware Manual ELECTRICAL SAFETY INFORMATION Manufacturer s Name Aerotech Inc and Address 101 Zeta Drive Pittsburgh PA 15238 2897 Intended Use This product is intended for light industrial manufacturing or laboratory use Safety Information All BLMFI XXX motors pass hi pot tests per IEC 61010 using test voltages of 2880VAC and 4080VDC All BLMFS XXX motors pass hi pot tests per IEC 61010 using test voltages of 1830VAC and 2590VDC User must restrict user access to motor coil wires while energized This is accomplished by
30. e maximum rotation speed before resonance occurs This speed limit is a function of the screw diameter distance between support bearings and bearing rigidity www aerotech com Flat Linear Motor Hardware Manual Current Command Current Peak Current rms Cycle DC Brushless Servo Deceleration Duty Cycle Dwell Time Efficiency Electronic Gearing Encoder Marker Encoder Resolution Encoder Incremental Feedback Flatness of travel Force Continuous Force Peak Friction G P I B www aerotech com Motor driver or amplifier configuration where the input signal is commanding motor current directly which translates to motor torque force at the motor output Brushless motors can be commutated directly from a controller that can output current phase A and B commands An allowable current to run a motor above its rated load usually during starting conditions Peak current listed on a data sheet is usually the highest current safely allowed to the motor Root Mean Square Average of effective currents over an amount of time This current is calculated based on the load and duty cycle of the application When motion is repeated move and dwell such as repetitive back and forth motion A servomotor with stationary windings in the stator assembly and permanent magnet rotor See AC Brushless Servo The change in velocity as a function of time For a repetitive cycle the ratio of
31. efects in workmanship and material and is voided for all laser power supplies plasma tubes and laser systems subject to electrical or physical abuse tampering such as opening the housing or removal of the serial tag or improper operation as determined by Aerotech This warranty is also voided for failure to comply with Aerotech s return procedures Claims for shipment damage evident or concealed must be filed with the carrier by the buyer Aerotech must be notified within 30 days of shipment of incorrect materials No product may be returned whether in warranty or out of warranty without first obtaining approval from Aerotech No credit will be given nor repairs made for products returned without such approval Any returned product s must be accompanied by a return authorization number The return authorization number may be obtained by calling an Aerotech service center Products must be returned prepaid to an Aerotech service center no C O D or Collect Freight accepted The status of any product returned later than 30 days after the issuance of a return authorization number will be subject to review After Aerotech s examination warranty or out of warranty status will be determined If upon Aerotech s examination a warranted defect exists then the product s will be repaired at no charge and shipped prepaid back to the buyer If the buyer desires an airfreight return the product s will be shipped collect Warranty repairs do not
32. ent protection fault If the motor is being installed in a system not configured by Aerotech the customer is responsible for providing the necessary over current protection www aerotech com Flat Linear Motor Hardware Manual 1 4 4 Hall Effect Device and Thermistor Wiring The insulation of these wires should have a rating for at least the maximum voltage applied to the motor winding The temperature rating of the wire insulation must also be sufficiently high to withstand the operating temperatures specific to the application 1 4 5 Wiring Guidelines The wiring guidelines given below can help to reduce EMI related problems which can result in poor overall system performance e Keep cable lengths as short as possible Long cable runs are more susceptible to EMI pickup than short runs e Use grounded shielded cables for both the motor power and signal wiring The use of twisted pair shielded cabling can help reduce magnetically induced currents Braided shield has a slightly better low frequency shielding capability than a foil shield Foil is often used where RF shielding is necessary e Do not bundle signal motor power cables or ac power lines within the same protective shield or conduit Rather use separate protective shields or conduits e Do not introduce multiple paths to ground from a grounding point Multiple paths to ground can create ground loops within the system use of EMI suppression devices may be ne
33. f switching motor phase current based on three Hall effect signals spaced 120 electrical degrees beginning 30 degrees into the electrical cycle This method is the easiest for commutation of brushless motors Also referred to as modified sine commutation The process of switching motor phase current based on three Hall effect signals spaced 120 electrical degrees beginning at 0 electrical degrees This method is slightly more difficult to implement than standard 6 step but more closely approximates the motor s back emf The result is smoother control and less ripple Aerotech s BA series self commutate using this method The process of switching motor phase current based on motor position information usually from an encoder In this method the three phase currents are switched in very small increments that closely resemble the motors back emf Sinusoidal commutation requires digital signal processing to convert position information into three phase current values and consequently is most expensive to implement The result however is the best possible control All Aerotech controllers as well as the BAS series amplifiers commutate using this method Multi axis motion where the position of each axis is dependent on the other axis such that the path and velocity of a move can be accurately controlled Drawing a circle requires coordinated motion A term used in the specification of a lead screw or ball screw indicating th
34. formation when power is removed A signal output that is performed with a transistor Open collector output acts like a switch closure with one end of the switch at circuit common potential and the other end of the switch accessible Control circuit that has an input signal only and thus cannot make any corrections based on external influences Device that allows the operator to communicate with a machine A keyboard or thumbwheel is used to enter instructions into a machine See HMI or MMI A linear or angular position feedback device using light fringes to develop position information System or circuit that transmits signal with no direct electrical connections using photoelectric coupling between elements The condition of a surface or axis perpendicular offset 90 to a second surface or axis Orthogonality specification refers to the error from 90 from which two surfaces of axes are aligned In a servo system referred to the amount of velocity and or position overrun from the input command Overshoot is a result of many factors including mechanical structure tuning gains servo controller capability and inertial mismatch A group of gain terms in classical control theory Proportional Integral Derivative used in compensation of a closed loop system The terms are optimally adjusted to have the output response equal the input command Aerotech controllers utilize the more sophisticated PID FVFA loop whi
35. g A Disconnect electrical power to the motor before performing maintenance procedures addition uncouple or otherwise prevent motor coupled machinery from moving WARNING the motor during servicing gt Linear motors are capable of very high speeds and acceleration rates Always avoid being in the direct path of moving machinery gt 1 2 www aerotech com Flat Linear Motor Hardware Manual DANGER The motor case temperature can pose a burn hazard Do not touch the motor until it has cooled sufficiently These motors are not rated for use in explosive atmospheres They are not to be operated in the presence of potentially explosive mixtures of air borne dust or combustible vapors Motors and their associated drives cabling etc are Sources of electromagnetic fields Persons with external or implanted medical devices need to evaluate the risks associated with these devices before entering an area where they are in use www aerotech com Introduction Introduction Flat Linear Motor Hardware Manual 1 3 Motor Assembly and Installation The linear motor can be configured in two different ways The magnet track can be held stationary while the forcer moves or the forcer can be held stationary while the magnet track moves Use extreme caution when mounting the BLMFS amp BLMFS5 forcer The forcer will clamp to the track with extreme force if allowed to do so Attach the forcer rigidly in its mounting
36. ion Read this manual in its entirety before installing operating or servicing this product If you do not understand the information contained here contact an Aerotech representative before proceeding Strictly adhere to the statements given in this section and other handling use and operational information given throughout the manual to avoid injury to you and damage to the equipment Aerotech s Flat Linear Motors are meant to be part of a drive package consisting of an amplifier and controller The motor relies on the drive package for all manners of fault protection Aerotech Inc does not approve their WARNING motors for use in any other manner gt ok To prevent electrical shock hazards only allow qualified persons to install and service this equipment Equipment grounds must be in place and maintained to reduce the risk of potentially fatal or serious injury from electrical shock gt Never install operate equipment that appears to be damaged gt Use extreme caution when handling the magnet track The magnet track will clamp to any ferrous surface with extreme force If you are unsure of the proper methods of handling or installing the magnet track do not attempt to do DANGER so gt Use extreme caution when mounting the BLMFS amp BLMFS5 forcer above the track The forcer will clamp to the track with extreme force if allowed to do so Fixtures DANGER need to be in place to prevent this from occurrin
37. mance and electrical specifications 10 6 Maximum winding temperature is 125 C 7 Ambient operating temperature range 0 C 25 C consult Aerotech for performance in elevated ambient temperatures 8 All Aerotech amplifiers are rated Apk use torque constant in N m Apk when sizing www aerotech com 1 17 Introduction 1 18 Flat Linear Motor Hardware Manual 1 10 Brushless Motor Dimensions The following figures show the outline dimensions of each model A Magnet Track Eire 5 X0 8 X4 6 0 18 Dp L Places 25 0 0 98 6 35 0 25 Magnet Track U udi 0 49 t 1 Cable Lengths Nt ouod 762 30 Lg amc pam H4d iim 7 RE EE m 4 a tl tate 4 5 0 17 Dia Thru 30 0 1 18 60 0 2 36 8 7 0 34 X 2 5 0 10 opas K Pieces J Places aces Total 60 0 2 36 NOSE Forcer Width Typ C Places 65 4 2 57 25 0 0 Qu 2 57 Typ F Places 25 0 0 d Hall Sensors 4 0 33 H 2 E Places k ii o i rim 1 9 1 33 0 05 35 6 1 40 i Air Gap ELA EV EE E Magnet Track 27 5 1 08 M5X0 8 X 13 0 50 Dp 55 0 2 17 G Places Both Sides H Places Total 66 0 2 60 Dimensions millimeters inches Magnet Track Width Magnet Track Forcer Model No Model No
38. n and is created by the elastic forces in the drive systems Input Output The reception and transmission of information between control devices using discrete connection points A set of codes and formats to be used by devices connected via a parallel bus system This standard also defines communication protocols that are necessary for message exchanges and further defines common commands and characteristics See G P 1 B A move referenced from its starting point relative move The physical property of an object to resist changes in velocity when acted upon by an outside force Inertia is dependent upon the mass and shape of an object The deviation of a lead screw or ball screw from its nominal pitch A device for translating rotary motion into linear motion Unit consists of an externally threaded screw and internally threaded carriage nut See Ball Screw The minimum rated lifetime of a stage at maximum payload while maintaining positioning specifications A sensor used to determine the end of travel on a linear motion assembly Sensors called limits that alert the control electronics that the physical end of travel is being approached and motion should stop A motor consisting of 2 parts typically a moving coil and stationary magnet track When driven with a standard servo amplifier it creates a thrust force along the longitudinal axis of the magnet track The maximum recommended payloa
39. nication standard for sending signals over distances up to 4000 feet Standard line driver encoder interfaces utilize RS 422 because of the noise immunity The deviation from the desired form of a surface during full rotation 360 degrees about an axis Runout is measured as total indicated reading TIR For a rotary stage axis runout refers to the deviation of the axis of rotation from the theoretical axis of rotation Refers to a closed loop control system where a command is issued for a change in position and the change is then verified www aerotech com Flat Linear Motor Hardware Manual Settling Time Shaft Radial Load Shaft Runout Slotless Stator Stiction Straightness of Travel Torque Torque Continuous Torque Peak Torque rms Torque Stall Total Indicated Reading TIR Tuning Unidirectional Repeatability Velocity Command Wobble Yaw of travel Yaw Error www aerotech com via a feedback system Time required for a motion system to cease motion once the command for motion has ended Maximum radial load that can be applied to the end of the motor shaft at maximum motor speed Deviation from straight line travel Describes the type of laminations used in a motor that eliminates cogging torque due to magnetic attraction of the rotor to the stator slots Non rotating part of a magnetic structure In a motor the stator usually contains the mounting surface bearing
40. nt temperature 2 Values shown 100 C rise above a 25 ambient temperature with motor mounted to the specific aluminum heat sink 1 16 Peak force assumes correct rms current consult Aerotech Force constant and motor constant specified at stall All performance and electrical specifications 10 Maximum winding temperature is 125 C Ambient operating temperature range 0 25 C consult Aerotech for performance in elevated ambient temperatures All Aerotech amplifiers are rated Aj use torque constant in N m Apk when sizing www aerotech com Flat Linear Motor Hardware Manual Introduction Table 1 3 BLMFS5 Steel Laminated Series Linear Motor Specifications Motor Model Units BLMFS5 142 BLMFS5 262 BLMFS5 382 Performance Specifications 9 Water Cooling 2 N Ib 323 4 72 7 522 3 117 4 697 1 156 7 Continuous Force No Air N Ib 174 8 39 3 282 3 63 5 376 8 84 7 Peak Force N Ib 699 3 157 2 1129 2 253 9 1507 2 338 8 Cogging Force N Ib 57 8 13 0 62 3 14 0 67 2 15 1 Attraction Force N Ib 2410 542 4446 1000 6482 1457 Electrical Specifications Winding Designation A B A B A B BEMF Constant Vimis Vlinis 21 99 43 97 21 99 43 97 21 99 43 97 line line max 0 56 1 12 0 56 1 12 0 56 1 12 Continuous Current 16 91 8 45 27 3
41. o Digital Converter Electronic component that converts the analog signals from a resolver transmitter type into a digital word representing angular position The maximum deviation from the mean each side when repeatedly approaching a position Unidirectional repeatability refers to the value established by moving toward a position in the same direction Bidirectional repeatability refers to the value established by moving toward a position in the same or opposite direction The smallest change in distance that a device can measure An optical element with the property that an input light beam is reflected and returns along the same angle as the input beam Used with laser interferometers Angular motion of a carriage around an axis parallel to the motion direction and perpendicular to the yaw axis Positioning error resulting from a roll motion The rotating part of a magnetic structure In a motor the rotor is connected to the motor shaft Industry standard for sending signals utilizing a single ended driver receiver circuit As such the maximum distance is limited based on the baud rate setting but is typically 50 100 feet This standard defines pin assignments handshaking and signal levels for receiving and sending devices Industry standard programming language Also referred to as G code machine programming A command set specific for the machine tool industry that defines geometric moves Industry commu
42. or dimension drawings updated Ordering part numbers updated www aerotech com Appendix C C 1 Appendix 2 Flat Linear Motor Hardware Manual C 2 Archived Changes Version Section s Affected Description 1 XX All previous version changes updates not recorded www aerotech com Flat Linear Motor Hardware Manual INDEX SV Logic Interface sess 1 10 Applications eese 1 1 Bearing system see 1 5 BLMFI Dimensions eee 1 18 Motor Options eee 1 20 Motor Specifications Ordering Example Tolerances rere BLMFS Dimensions eene 1 18 Motor Options eee 1 21 Motor Specifications T Ordering Example 1 21 Tolerances 2 retten 1 5 BLMFS5 Dimensions 2 41 19 Motor Options 1 22 Motor Specifications 1 17 Ordering Example 1 22 Tolerances n etes 1 5 C Cable 1 6 Configurations eee 1 5 D Dimensions Environmental Specifications Altit de cn iioii 1 14 Atmosphere 55 5 erret e 1 14 Humidity sisisi sorsia 1 14 Temperature 1 14 Operating 1 14 Storage 1 14 USO X 1 14 www aerote
43. ow wires together EOM Connect io TP4 Connect to TP4 Figure 1 9 Linear Motor Phasing www aerotech com 1 11 Introduction 1 12 Flat Linear Motor Hardware Manual 1 6 Motor Heating The motor s temperature rise above ambient establishes a limit on the amount of force producing current allowed through the motor winding The thermal characteristics of the motor the effectiveness of the surrounding medium to transfer heat away from the motor and any supplemental cooling determine the operating conditions The motor specification tables give the continuous motor current that will result in a predetermined temperature rise of the motor This temperature rise is based on a single set of operating conditions as noted on the motor specifications The use of supplemental cooling allows for increases in continuous motor current and therefore increased force The motor s thermal limit will not be exceeded so long as the minimum environmental and thermal conditions exist Poor heat transfer away from the motor excessive loading elevated ambient temperatures etc are situations that will cause excessive motor heating and failure The importance of motor overload and thermal protection devices as described in previous sections becomes apparent www aerotech com Flat Linear Motor Hardware Manual 1 7 Maintenance Installation problems usually reveal themselves early in the installation Regular preventative maintenance should in
44. position working away from the track not above it The forcer and track have to be rigidly mounted DANGER before allowing the forcer to move into position over the track Devices need to be in place so that intentional or unintentional disruption of electrical power doesn t result in unexpected motion The motion could possibly result in bodily injury or damage to equipment This is especially important in vertical applications where the use of a fail WARNING safe brake needs to be incorporated in the event of a power disruption Listed below are some installation topics of special concern that need to be addressed when installing a linear motor e Bearing System e Straightness and Flatness Requirements of the Motor Installation e Mechanical Arrangement of the Magnet Track e Track Stacking e Position Feedback Device Requirements e Thermal Management of the Motion System e Cable Management Needs 1 4 www aerotech com Flat Linear Motor Hardware Manual Introduction 1 3 1 Bearing System The flat linear motor arrangement and load must be supported by a linear bearing system The bearing system must be capable of supporting the forcer the load and in the case of using BLMFS BLMFS5 forcers a considerable magnetic attractive force between the forcer and the magnet track 1 3 2 Straightness and Flatness Requirements Straightness and flatness tolerances are deviations from a straight line in two dimensions There are
45. r between the actual axis of rotation and the theoretical axis of rotation Rotation about the vertical axis perpendicular to the axis of travel Angular movement error that affects straightness and positioning accuracy Positioning error resulting from a yaw motion Appendix A Appendix Flat Linear Motor Hardware Manual A 8 www aerotech com Flat Linear Motor Hardware Manual APPENDIX WARRANTY AND FIELD SERVICE Aerotech Inc warrants its products to be free from defects caused by faulty materials or poor workmanship for a minimum period of one year from date of shipment from Aerotech Aerotech s liability is limited to replacing repairing or issuing credit at its option for any products that are returned by the original purchaser during the warranty period Aerotech makes no warranty that its products are fit for the use or purpose to which they may be put by the buyer where or not such use or purpose has been disclosed to Aerotech in specifications or drawings previously or subsequently provided or whether or not Aerotech s products are specifically designed and or manufactured for buyer s use or purpose Aerotech s liability or any claim for loss or damage arising out of the sale resale or use of any of its products shall in no event exceed the selling price of the unit Aerotech Inc warrants its laser products to the original purchaser for a minimum period of one year from date of shipment This warranty covers d
46. rovide an on site field service representative in a reasonable amount of time provided that the customer issues a valid purchase order to Aerotech covering all transportation and subsistence costs For warranty field repairs the customer will not be charged for the cost of labor and material If service is rendered at times other than normal work periods then special service rates apply If during the on site repair it is determined the problem is not warranty related then the terms and conditions stated in the following On Site Non Warranty Repair section apply If any Aerotech product cannot be made functional by telephone assistance or purchased replacement parts and cannot be returned to the Aerotech service center for repair then the following field service policy applies Aerotech will provide an on site field service representative in a reasonable amount of time provided that the customer issues a valid purchase order to Aerotech covering all transportation and subsistence costs and the prevailing labor cost including travel time necessary to complete the repair Aerotech Inc Phone 412 963 7470 101 Zeta Drive Fax 412 963 7459 Pittsburgh PA 15238 2897 V VV www aerotech com Flat Linear Motor Hardware Manual APPENDIX C TECHNICAL CHANGES C 1 Current Changes Revision 2 00 00 Section s Affected Description All Complete Manual Revision Motor specification tables updated Mot
47. s and non rotating windings Friction encountered when accelerating an object from a stationary position Static friction is always greater than moving friction and limits the smallest possible increment of movement Measure of the side to side deviation of a stage as it travels a horizontal plane Rotary equivalent to force Equal to the product of the force perpendicular to the radius of motion and distance from the center of rotation to the point where the force is applied Torque needed to drive a load over a continuous time Maximum amount of torque a motor can deliver when the highest allowable peak currents are applied Root Mean Square is a mathematical method to determine a steadfast or average torque for a motor The maximum torque without burning out the motor The full indicator reading observed when a dial indicator is in contact with the part surface during one full revolution of the part about its axis of rotation In a servo system the process of optimizing loop gains usually PID terms to achieve the desired response from a stage or mechanism from an input command See Repeatability Motor driver or amplifier configuration where the input signal is commanding motor velocity Motors with analog tachometers are normally driven by this driver configuration An irregular non repeatable rocking or staggering motion of the table top of a rotary stage Wobble is defined as an angular erro
48. tor constant specified at stall 5 All performance and electrical specifications 10 6 Maximum winding temperature is 125 C 7 Ambient operating temperature range 0 C 25 C consult Aerotech for performance in elevated ambient temperatures 8 All Aerotech amplifiers are rated use torque constant N m Apk when sizing www aerotech c om Introduction Flat Linear Motor Hardware Manual Table 1 2 BLMFS Steel Laminated Series Linear Motor Specifications Motor Model Units BLMFS 81 BLMFS 142 BLMFS 264 BLMFS 325 BLMFS 386 Performance Specifications ape aa N Ib 28 0 6 3 48 0 10 8 97 1 21 8 134 5 30 2 159 4 35 8 Peak Force N Ib 112 1 25 2 192 2 43 2 388 6 87 4 538 0 121 0 637 7 143 4 Attraction Force N Ib 134 30 232 52 427 96 535 120 629 141 Electrical Specifications Winding Designation A B A B A B A B A B BEMF Constant V m s 10 74 5 37 20 45 10 23 21 47 42 95 27 61 55 22 32 72 65 45 line line max Viin s 0 27 0 14 0 52 0 26 0 55 1 09 0 70 1 40 0 83 1 66 Continuous Current AMP px 3 0 6 00 2 70 5 40 5 20 2 60 5 60 2 80 5 60 2 80 No Air 2 AmPrms 2 12 4 24 1 91 3 82 3 68 1 84 3 96 1 98 3 96 1 98 3 12 00 2
49. two separate alignment tolerances straightness side to side and flatness air gap of the motor that need to be maintained over the length of travel Mounting surface flatness has to be held to specific tolerances to maintain desirable motor performance Straightness The forcer may deviate left or right 0 030 in 0 76 mm from the magnet track centerline during motion see Figure 1 2 Generally the BLMF motor operates regardless of straightness provided the forcer does not contact the magnet track during motion Flatness The nominal air gap between the forcer and magnet track surfaces is 0 030 in 0 76 mm for the BLMFSS forcer and 0 050 in 1 27 mm for the BLMFI and BLMFS forcers The air gap has a tolerance specification of 40 010 in 0 000 0 25 mm 0 00 mm Larger gaps result in a decrease of output force from the motor Smaller gaps result in a significantly increased magnetic attractive force of the forcer to the track Center Line 1 coocoocodcmg Flatness Magnet Gap 55 0 030 in 0 76 mm Nominal BLMFI 0 050 in 1 27 mm Nominal BLMFS 0 050 in 1 27 mm Nominal Maximum Deviation 40 010 0 25 mm 0 000 in 0 00 mm Straightness Magnet Gap Maximum Deviation 30 030 in 0 76 mm Nominal Figure 1 2 BLMF Straightness and Flatness Tolerances 1 3 3 Mechanical Arrangement of the Magnet Track The track can be mounted in a horizontal or vertical orientation In
50. vomotors one popular method of commutation is with Hall effect sensors They sense the presence of a magnetic field and provide an output as a function of the forcer position Aerotech linear motor Hall sensors provide a unique set of Hall sensor outputs every sixty electrical degrees The forcer position can be resolved to any of six segments over 360 electrical degrees The Hall sensors used in the linear motors have an open collector output Figure 1 9 shows the motor BEMF versus hall signal relationship if observed as noted in the figure Test Setup Configuation Brushless Motor 10K OHM 4 O Wye Configuration Power Supply COM 9 45V pe 5V 60 UE SEP EUNT B B 5 Hall 1 6 e Hall 2 Hall 3 mags 19 O 0 922 000 o nnm CHOIR AL FO 5 2 aocolaoolaoolaoo alg oola oola oojg Positive or CW Motor Rotation BOscilloscope Oo J All voltage measurements are made with reference to TP4 ji Jj PRI NES n i Channel 1 Probe Channel 2 Probe Plus forcer motion is motion in a direction opposite the forcer wire exit end _ six lead forcer connect the blue brown and yell
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