selection of industrial motors - stork...

Selection of industrial motorsStork Drives Seminar Malmö / Odense | April 2017

All rights reserved © Apr-17/ Dunkermotoren GmbH

Selection of industrial motors

Selection of linear solutions

Selection of integrated drives

Agenda

2

All rights reserved © Apr-17/ Dunkermotoren GmbH 3

(1) About Dunker


About Dunker

4

Headquarter

Bonndorf/ Germany

Factories

Bonndorf/ Germany

Subotica/ Serbia

Taicang/ China


Market Segment Industrial Automation

5

Tailored system solutions from one single source

Intelligent motors with integrated electronics

Easy integration into customers systems

Good price/performance ratio

Typical application:

» Intralogistics

» Packaging Machinery

» Semiconductor

» Printing

» Food & Beverage

» Paper & Wood machinery

» Textile & Plastic Industry


(2) Selection of industrial motors


Electrical drives at a glance

7

Electrical motors

DC motor AC motor

Serieswound Shunt-wound Synchronous motor Asynchronous motor

Slip ring

rotor

Short circuit

rotor

External

excitedPermanent

magnetRelutance

Seri

es-w

ound

moto

r

External

excited

Permanent

magnet

Shun

t-w

ound

moto

r

Perm

ane

nt

magne

t

DC

moto

r

Exte

rnal excited

DC

moto

r

3-p

hase A

C m

oto

r

3-p

hase A

C m

oto

r

Capacitor

moto

r

Shad

ed p

ole

moto

r

Sin

uso

ida

l

co

mm

uta

tio

n

Sin

usoid

al

com

muta

tion

Blo

ck c

om

muta

tion

Hyb

rid

ste

pp

er

mo

tor

Relu

cta

nce

ste

pper

moto

r

Relu

cta

nce

mo

tor


Electrical drives and control device

8

Series-w

ou

nd

mo

tor

Shunt-

wo

un

d

mo

tor

Pe

rma

nent m

agn

et

DC

mo

tor

DC-

Grid

Contactor

control

Exte

rna

l e

xcite

d

DC

mo

tor

Pulseconverter

Thyristor

converter

Direct current (DC)

Re

lucta

nce m

oto

r

Re

lucta

nce

ste

pp

er

mo

tor

Hyb

rid

ste

pp

er

mo

tor

Ste

pper

moto

r

Blo

ck

co

mm

un

ica

tio

n

Sin

uso

ida

l

co

mm

un

ica

tio

n

Sin

uso

ida

l

co

mm

un

ica

tio

n

Sh

ad

ed

po

le

mo

tor

Ca

pa

cito

r m

oto

r

3-p

ha

se

AC

mo

tor

3-p

ha

se

AC

mo

tor

Stepper motor

controller

ServoFrequency

Converter

AC-

Grid

Frequency

converter

Soft

starter

Contactor

control

Alternating current (AC)

Control devices


Motor Selection

9


Motor Selection

10


» Which operating mode is used (continuous operation = S1 or intermittent operation = S5)?

» What is the expected working life of the motor?

» How much space is available for the motor?

» Are there special environmental conditions (temperature, humidity, vibration, ...)?

» To what degree can heat be conducted away from the motor?

» Are there exceptional axial and radial shaft loads to be considered?

» What are the requirements for the motor control electronics?

» Is the motor to be controlled online via a bus system?

» Do you need a brake or an encoder?

» Are there any safety requirements?

…

Further factors to be considered

11


Brushless vs. brushed DC motors

12

Brushless DC motors

Highest power density

Excellent dynamic performance

Extreme overload capability

Very long lifetime

Maintenance free

Brushed DC motors

High power density

High efficiency

Smooth motion & Low cogging

Robust design

Easy implementation


DC Motor Characteristic – Speed & Torque

13


EXAMPLE

What is the effective torque?

1. Segment: 40 Ncm, 2 sec.



4. Segment: -50 Ncm, 3 sec.


Continuous Output Power – Peak Power

14

-60

-50

-40

-30

-20

-10

0

10

20

30

40

50

0 2 4 6 8 10 12 14

Diagrammtitel

M [Ncm]

t [s]


What is the effective torque in this case?

𝑴𝒆𝒇𝒇=𝑴𝟏²∗𝒕𝟏+𝑴𝟐²∗𝒕𝟐+...𝑴𝒙²∗𝒕𝒙

𝒕𝒕𝒐𝒕𝒂𝒍

𝑴𝒆𝒇𝒇=40 𝑁𝑐𝑚²∗2𝑠+10𝑁𝑐𝑚2∗3𝑠+ −50𝑁𝑐𝑚 2∗3𝑠

𝟏𝟐𝒔

𝑴𝒆𝒇𝒇= 30,27 Ncm

A motor that is operated continuously with this torque profile,

needs to provide 30,27 Ncm continuous

Continuous Output Power – Peak Power

15

-60

-50

-40

-30

-20

-10

0

10

20

30

40

50

0 2 4 6 8 10 12 14

Diagrammtitel

M [Ncm]

t [s]


Accessoires

16

MotorsIntegrated Controller GearboxesBrakesEncoders


Selection of Gears

17

Gears

Straight

Spur

Planetary

Helical planetary

Angular

Bevel

Worm

Hypoid / Spiroid


Selection of Gearboxes

18

Planetary gearbox

Wide range of ratios

Highest torque to diameter ratio

In line shaft output

High efficiency

Several special versions:

Cost effective plastic

Low noise

Low backlash

Worm gearbox

Right angle output

Quiet operation

Self-locking available

Disadvantage

Low efficiency

Limited lifetime

Spirotec gearbox

Right angle gearbox with low offset

Very long lifetime for industrial use

Quiet operation

Disadvantage

Low efficiency

Cost


Selection of Brakes

19

Brakes

Power-on vs. power-off brakes

Spring-applied vs. permanent-magnet brakes

Alternatively: Self-locking gearbox


Selection of Encoders

20

Encoder

Speed Position

Absolut

Linear Rotational

Single turn Multi turn

Incremental

Linear Rotational

Tacho (TG)

TTL-/HTL-encoder (RE/ME)

Serial / parallel interfaces (AE)Resolver (R)

Sin-Cos-Encoder


(3) Selection of linear units


Product Speed Force Noise

level

Precision

and

control

Dynamic Efficiency

Energy

cost

Price Life-

time

Mainte-

nance

Motor + lead

screw

Low High Low-Mid. Good Low Mid. Low -

Mid.

Mid. Low

Motor + ball

screw

Medium High Low-Mid. Good Mid. Good Mid. / High Mid. /

High

Low

Motor + belt

drive

Medium Medium Mid. Good High Good Low - Mid. Low Mid.

Direct Linear

Motor

High Low Low Very Good High Good High High Low

Pneumatic High Medium High Bad High Bad Low Mid. High

Advantages vs. Disadvantages

22


Overview linear products – Series ST | CASM | LS

23

Tubular linear motors:

Force up to 1860 N

Max. speed up to 9.3 m/s

Extremely dynamic & precise

Very long life-time

With integrated bus interface

Complete positioning module

Electric cylinders:

Peak force up to 5.4 kN

Speed up to 1 m/s²

In-line and parallel adapter

Long life-time

Positioning via digital inputs

Strokes up to 800 mm

Linear Spindle Motor:

Force up to 680 N

Speed up to 300 mm/s

Cost-efficient design

Linear Positioning Actuator:

Dynamic positioning with acceleration and deceleration ramps

Force up to 220 N

Positioning resolution up to ± 5 μm

Strokes up to 1000 mm


Efficiency of Pneumatic System


Example Pneumatic:

63er Cylinder

6 bar Pressure -> ~ 1680N

400mm Stroke

15 Strokes per Minute

16 Hours/Day

-> Air consumption result of 238,7m³ per day -> based on 0,03€/m³ will give total costs of 7,16 € per day (w/o leakage!)

Electrical alternative: CASM40 with BG75x75

-> Max. ~0,5KWh x 0,16€/KWh x 16 Hours = 1,28 €

Energy costs at 225 working days (~1 year): CASM = 288.- € vs. Cylinder = 1611.- €

Energy cost

25


(4) Selection of integrated drives


Intelligent brushless DC motors – Series BG:

27

Easy to wire up, reduced installation cost

Protection against dust and humidity

Fit perfectly to decentrallization („4.0“)

Intelligent drive systems with integrated controls, sensors and field-bus interfaces

Easy to embed into customer´s systems

Motors carry out motion profiles autonomously

Inputs for local sensors

Condition monitoring and predictive maintenance

Innovative energy saving DC concepts

Safe Torque Off option


New Dunkermotoren Brushless Categories

28

dCorePlain motor with Hall sensors

dGoIntegrated commutation,

no speed control

dMoveSpeed and position control,

simple communication

dProHigh end applications


New Dunkermotoren Brushless Categories

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dCore dGo dMove dPro- Motor with integrated hall sensors for

position feedback

- In future: sensorless motors

- Motor with integrated commutation

electronic

- In future with PWM speed input (no

speed control)

- Integrated control electronics

- Speed/ Current/ Position control

- Low resolution

- Integrated control electronics

- Sinusoidal commutation

- Complex Motion Profiles

- High resolution encoder

- Robust isolation of bus

- Ballast circuit parameterizable

- Modular design with assembly

options FS, SSI, …

- I/O (parameterizable)

- CO (CANopen)

- RS485

- MB (Modbus)

- I/O (parameterizable or

programmable)

- CO (CANopen)

- RS485

- MB (Modbus)

- EC (EtherCat)

- PN (Profinet)

- PL (Powerlink)

- EN (Ethernet IP)

Replaces Hall motors Replaces KI motors Replaces SI motors and CI motors

without high resolution encoders

Replaces CI, PI and MI motors and SI

motors with high resolution encoders and

special features (like SSI interface)


For rotary and linear

Avaliable free of charge at www.dunkermotoren.com

Demonstration of DA3.0

Drive Assistant Software

30

http://www.dunkermotoren.com/


Thank you for your attention.

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