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Precision Sub-Fractional Motor Technologies: How to Match the Best Technology for Your Application Day 1: Brushless PM Motors, Advantages/Disadvantages, Examining Selected Precision Application Examples for SubFractional Motors Sponsored by: The largest trusted community of design engineering professionals Motor Technology in Precision Applications Using Small Motors Day 1- Brushless DC PM You are here Day 2- Brush DC PM Day 3- Stepper (focus on PM) Sponsored by: The largest trusted community of design engineering professionals 2 Brushless DC PM Technology Review Outline Introduction History: Concept to Commercialization Motor Technology Advantages Motor Technology Disadvantages Expected Enhancements, Changes, etc. Suppliers of Note Application List and/or Examples Sponsored by: The largest trusted community of design engineering professionals 3 Introduction Focus on precision motion using smaller motors, generally 200 watts and smaller. Over the next 3 days we will discuss technology attributes-advantages-disadvantages-applications for three motor technologies: Brushless PM Brush DC pm Stepper Sponsored by: The largest trusted community of design engineering professionals 4 History: Concept to Commercialization of Brushless PM Motors Most new technologies need a champion — an individual or company willing to risk time and capital to introduce them to their customers and the world. IBM was such a company. Millions of IBM disk drives substituted brushless motor technology in place of brush DC motors for spindle drives in the 1970s. Beyond IBM, GE was an early adopter of the technology, producing an integrated brushless motor and drive for appliance applications in the mid-1970s. What brought brushless PM motor technology to commercial viability at this time? Sponsored by: The largest trusted community of design engineering professionals 5 History: Concept to Commercialization of Brushless PM Motors Higher strength rare earth magnets and Lower cost, higher power semiconductor transistors Sponsored by: The largest trusted community of design engineering professionals 6 History: Concept to Commercialization of Brushless PM Motors After brushless motor commercial introduction, it took 20 years before our clients changed their primary question from “Is it real?” to “How far and how fast?” Sponsored by: The largest trusted community of design engineering professionals 7 Brushless DC PM Basics: Advantages and Disadvantages Sponsored by: The largest trusted community of design engineering professionals 8 Brushless DC PM Advantages Sponsored by: The largest trusted community of design engineering professionals 9 Brushless DC PM Advantages Greater torque per volume or power per volume than other popular motor technologies. Wide performance range (speed, torque, power) than competing technologies. Higher efficiency than other technologies, capable of 90+%. Sponsored by: The largest trusted community of design engineering professionals 10 Brushless Motor Cross Section Sponsored by: The largest trusted community of design engineering professionals 11 Cutaway, Exploded Views of Different Brushless Motor Configurations Sponsored by: The largest trusted community of design engineering professionals 12 Brushless DC PM Motor Cutaway Commutation Board Magnets Bearings Sponsored by: The largest trusted community of design engineering professionals 13 Brushless DC PM Motor Cutaway View Electronic Commutation Board Bearings Sponsored by: The largest trusted community of design engineering professionals 14 Brushless DC PM Advantages Synchronous operation: no slip (compared to AC induction) or missed steps (compared to steppers), with speed varying directly with applied voltage. No particle contamination compared with brush DC motors. No sparking or electromagnetic contamination generated from metal-on-metal friction (brushes traveling on metal commutator). Sponsored by: The largest trusted community of design engineering professionals 15 Linear Device: Easier to Control, More Predictable Speed Increases Linearly with Voltage Sponsored by: 16 Linear Device: Easier to Control, More Predictable Stall Current Torque Increases Linearly with Current Sponsored by: 17 Trade-offs Are Inevitable Sponsored by: 18 Brushless PM Motor Torque/Speed Curve No Load Speed CONTINUOUS TORQUE ZONE Peak Torque Intermittent Torque Zone Sponsored by: 19 Brushless DC PM Disadvantages Sponsored by: The largest trusted community of design engineering professionals 20 Brushless DC PM Disadvantages Requires electronic control to operate compared with AC induction and brush DC PM technology, thus is more costly, with all other things being equal. Requires permanent magnets that often are the “weak” link in the motor, where they can be either temperature limited, environmentally limited, or expensive (especially as the power requirements increase over 20kW). Sponsored by: The largest trusted community of design engineering professionals 21 Next two slides show relative complexity of Brushless control compared to Brush DC motor control <Toggle back and forth to Illustrate> Sponsored by: The largest trusted community of design engineering professionals 22 Brushless DC PM Motor, Drive, Feedback Connections Drive, Control Circuitry Sponsored by: Rotating Magnets 23 Brush DC PM Motor, Drive, Feedback Connections Rotating Windings Brush Drive, Control Circuitry Stationary Magnets Sponsored by: The largest trusted community of design engineering professionals 24 Enhancements, Improvements, etc., to Brushless DC PM Technology Sponsored by: The largest trusted community of design engineering professionals 25 Brushless DC PM The major improvements to all electric motor performance, over the last 10 years and going forward, has been and will be the application of sophisticated electronic controls and software. Brushless technology has led the way because it has required, from its inception, electronic control to operate. Sponsored by: The largest trusted community of design engineering professionals 26 Brushless DC PM Material improvements in magnets (stronger, more rugged), iron (better steels), and insulation (magnet wire, potting, slot liners, separators) will continue to evolve, raising motor performance characteristics. Application of new, higher performing plastics and other materials to replace aluminum and metal parts will help lower manufacturing costs. Sponsored by: The largest trusted community of design engineering professionals 27 Brushless DC PM Suppliers of Note Sponsored by: The largest trusted community of design engineering professionals 28 Major Suppliers of BLDC PM Motors BLDC PM Motor Supplier Mabuchi (J) Affiliate Company or HQ Country Aeroflex Motion Control Cobham AMC AMP AO Smith API-Gettys API-Harowe Applimotion Astromec Baldor Baumueller Bayside MFM Beckoff Automation BEI Kimco Bison Gear Bodine Electric Bosch Canon C. I. Kasei Custom Motors USA Tamagawa Seiki Regal-Beloit Danaher Danaher USA USA ABB Germany Parker Germany Schneider Electric USA USA Germany Japan Japan Parker Electromechanical Sponsored by: 29 Major Suppliers of BLDC PM Motors BLDC PM Motor Supplier Dynetic Systems Electrocraft ElectroMech Emerson-Hurst Emotec Engel ETEL (Heidenhain) ETM (wka Motor Excellence) Fanuc Fastech Golden Motor Groschopp Hans Motors Hitachi Indramat (Bosch) Infranor Affiliate Company or HQ Country USA EAD TransDigm Group Nidec Allied Motion Germany Switzerland (Germany) USA Japan Korea China Germany China Japan Germany Switzerland Sponsored by: Mabuchi (J) 30 Major Suppliers of BLDC PM Motors BLDC PM Motor Supplier Japan Servo (Nidec) Just Motion Control Kollmorgen Loher LS Mecapion Magmotor Maxon Motors MICROMO (FAULHABER Group) Mitsubishi Moog Motion Component Group MTI Namiki Precision NMB Northern Magnetics Oriental Motor Pac-Sci Panasonic Papst EBM Parker Electro-Mechanical (Compumotor) Pittman Motors PMI (Kollmorgen) Mabuchi (J) Affiliate Company or HQ Country Japan China Danaher Germany China USA Switzerland USA, Germany Japan USA Parker Electromechanical Japan Japan Baldor Japan Danaher Japan Germany USA Ametek Danaher Sponsored by: 31 Major Suppliers of BLDC PM Motors Affiliate Company or HQ Country Portescap (Danaher) Switzerland Rockwell-Anorad USA Sankyo Seiki (Nidec) Japan Sanyo Denki Japan Sanyo Denki Japan SEM (Heidenhain) UK (Germany) Shinano Kenshi Japan Siemens Energy & Automation Germany Sinano Electric Japan Moog Motion Component Skurka Motors Group Specialty Motors USA Teerth India Toshiba Japan Trilogy Linear Motors Parker Electromechanical Unique Mobility USA Vernitron Axys Technology USA Yaskawa Electric Japan Yoko Automation China BLDC PM Motor Supplier The largest trusted community of design engineering professionals Sponsored by: 32 Applications for Brushless DC PM Motors Sponsored by: The largest trusted community of design engineering professionals 33 Application Characteristics Favorable to Brushless DC Motors BLDC motors are most often employed when the performance of the application cannot be met by competing, less expensive technologies, such as brush DC, AC induction, or stepper. Applications requiring higher acceleration and deceleration are areas where brushless DC PM motors excel. Higher speed applications often use slotless brushless DC PM motors where speeds of 50,000 rpm and higher are required. Sponsored by: The largest trusted community of design engineering professionals 34 Application Characteristics Favorable to Brushless DC Motors Applications that benefit from motors with high torque or power per volume or weight will seriously consider brushless DC PM technology. Applications where weight is at a premium, such as aerospace, benefit from brushless DC PM technology. Where batteries are the power source, higher efficiency brushless DC PM motors often make sense. Sponsored by: The largest trusted community of design engineering professionals 35 The Universe of Application Segments Brushless DC PM technology is now broadly used in many major application segments: Computers and Business Equipment Disk Drive and Other Rotating Memory Equipment Copiers, Printers Cooling Devices Factory Automation Machine Tools Semiconductor Processing Equipment Web processing (continuous movement of material) Sponsored by: The largest trusted community of design engineering professionals 36 The Universe of Application Segments Brushless DC PM technology…more application segments with broad penetration: Factory Automation (cont.) Packaging General Industrial Equipment Special Industrial Equipment Medical Equipment Air-moving (sleep apnea, ventilators, respirators, etc.) Diagnostic Equipment (centrifuges, scanning machines, etc.) Tools, Handhelds, Surgery, and Dental Mobility Equipment Heating, Ventilating and Air Conditioning Sponsored by: The largest trusted community of design engineering professionals 37 The Universe of Application Segments Brushless DM PM technology application segments with moderate penetration: Aerospace Commercial Aviation Military Aviation Missiles/Drones/UAVs Military/Defense Vehicles UAVs and UGVs Sponsored by: The largest trusted community of design engineering professionals 38 The Universe of Application Segments Brushless DC PM technology application segments newly adapting: Transportation Personal Vehicles Commercial Vehicles Off-Road Vehicles Home Appliances Hand Tools Alternative Energy Sponsored by: The largest trusted community of design engineering professionals 39 Precision Applications Using Small Motors Sponsored by: The largest trusted community of design engineering professionals 40 Commercial Aircraft Applications: Aircraft Seat Adjustment Challenge? Increase comfort and convenience for high-end travelers by automating seat adjustment, seat access window shades, tray tables, and electronic equipment storage. Motor Need? Highly reliable, lighter weight, small, higher torque per volume. Motion Solution? Brushless motors with integrated controls. The largest trusted community of design engineering professionals Sponsored by: 41 Semiconductor Processing Equipment: Wafer Handling Challenge? Increase wafer processing throughput; reduce waste; increase reliability; handle safely for two-sided wafers, all to make the process better quality and reduce costs. Motor/Motion Need? Highly reliable, fast acceleration, high-precision positioning. Motion Solution? Brushless motors with integrated encoder and motor drive in a compact package. Sponsored by: The largest trusted community of design engineering professionals 42 UAV Camera Stabilization Challenge? UAV mounted cameras are subject to unpredictable weather and wind conditions. How do you stabilize the camera with a motorized gimbal in real time under changing conditions? Motor/Motion Need? Fast acceleration, light, efficient motion system. Motion Solution? Eliminate the weight and delay of brush DC geared systems with a smaller, lighter direct drive brushless motor and control. The largest trusted community of design engineering professionals Sponsored by: 43