Theory, Application & Operation of Frameless Motor Technology Webinar 02-23-2016

February 23, 2016
Theory, Application & Operation

of Frameless Motor Technology
Tom S. Wood
Motor Product Specialist
Kollmorgen
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Toll Free Fax (877) SERV099
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sales@electromate.com
Meet The Presenter

Speakers
Texas Instruments & Ethernet POWERLINK Standardization Group
Tom S. Wood
Kollmorgen
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Thank You To Our Exclusive Sponsors
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Why Direct Drive Frameless ?

Direct Drive Frameless Story
This could be a Belt/Pulley,
Planetary Gearhead, Rotating
Nut or Driven Ballscrew
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Why Direct Drive Frameless ?

Direct Drive Frameless Story
This could be a Belt/Pulley,
Planetary Gearhead, Rotating
Nut or Driven Ballscrew
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Why Direct Drive ?
Clean mechanical assembly

Lower parts count
Reduce assembly time
Improved servo performance
Increase accuracy up to 50 times
Greater servo performance and higher bandwidth
No need for inertia matching
Zero maintenance
No Belts to tighten or adjust
No gears to lubricate or leak
Reduce machine down time no mechanical transmission parts to
break
Hollow shaft option
Through-bore for process air or tooling
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Quiet performanceup to 20db noise reduction
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Housed Direct Drive Motor

Customer Load Wheel
4 Feet Diameter
250 Pounds
96 Steel pegs
3.75 degrees per peg
Total Inertia 15 lb-ft-s2
Housed Direct Drive Motor

250 Lb-ft Continuous Toll FreeELECTROMATE
Phone (877) SERVO98
989 Lb-ft Peak
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Single Peg Index Velocity Profile

Single Peg Index
(3.75 Degree Move)
Total Move Time 97 ms
Settling Time 13 ms
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Velocity Profile

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Repeatability Test
Bar Clamped to Table
26 inch radius from

center
Indicator
1 Thousandth Inch / Number
1 Ten Thousandth Inch / division
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0.8 Arc Seconds / division
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Repeatability Test
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Embedding Frameless Motors
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Applications
Applications
Collaborative Robots
Surgical Robots
Semi Wafer-handling Machines
Manufacturing Automation
Machine Tools
Unmanned Autonomous Vehicles
Trends
Machines need to be smaller
smaller solutions
explore Direct Drive
Electric motors replacing hydraulics
Reduces weight (operating costs)
Reduces maintenance cost
in environmentally sensitivity
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Applications
Applications
Surgical Robots
Machine Tools
Trends
smaller solutions
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Applications
Applications
Surgical Robots
Machine Tools
Trends
smaller solutions
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Robotics: NREC Robot

DARPA Robotics Challenge is a competition to create
robots capable of assisting humans in a disaster
Benefits provided by frameless motor integration:
Small, compact integrated motor and gearing
actuate the robots 50 degrees of freedom
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Frameless Motor Mounting Video

Frameless Motor Mounting Video Customer Application
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Frameless Motor Mounting Video
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Frameless Motor Form Factor

KBM 10-35 Servo
Motor Shape
Classic Torquer Motor Shape
Stationary wound
armature
Rotating
permanent
magnet field
Stationary wound
armature
Rotating permanent
magnet field
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Frameless Motor Form Factor

D2L Rule
From
Continuous Torque
Capacity is Directly
Proportional to
Length:
To
2x
2 x Length = 2
x TC
But
From
Doubling the Diameter

(Moment Arm) Squares
the Continuous Torque
Capacity
To
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2x
2
Toll Free=
Fax (T
(877) SERV099
2 x Diameter
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C)
Frameless Motor Optimization

Design Elements
Data to Consider
Choose Largest Practical Diameter
Torque / Speed Load

Point(s)
Duty Cycle / Temp Details
Drive Amplifier Details
Low speed / higher torque suggests a larger

diameter - D2L rule
Stack Length Change
Wattage increases with stack length

Tc / Tpk will vary proportional to stack length
Optimize Winding Parameters
Increase system efficiency

Bus voltage will drive the winding choices based
on max speed needed
Water Jacket Cooling
Channel features on stator sleeve
Tubing integrated into back-iron design
Current & Voltage

Sine vs. 6 Step
Mechanical Envelope
Max Available Diameter

Max Available Length
Through Bore data
Mounting concept
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Position Feedback Considerations

Electrical and Control Considerations
Add feedback device [Frameless or shaft mounted]
Same type of feedback as conventional servos;
Encoder, Resolver, Absolute, Incremental available for
system use.
Often a Size 31 or 55 thru-bore resolver will easily adapt
to the mechanical system.
Resolvers rated to a standard 200 degree C level
Rated for high shock and vibration applications
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System Design Feedback

Options
Harowe large
through-bore
Resolver
Up to 140mm
OD with
93mm max
Bore
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System Design Feedback

Options
Typical large
through-bore
Encoder
Up to 390mm
Bore
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Mounting Considerations
Embedded Motion Technology Frameless Mounting Considerations
The benefits of Improved System Performance, Reduced
Maintenance, Smaller Mechanical Footprint, Higher
System Efficiency are understood
Customer still has a key question in mind
I like the frameless design concept but how do I mount
the motor components into my machine?
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Mechanical Mounting Considerations
Customers own bearings
Customers shafting / drivetrain
Bearing precision and machining tolerances are dependent
more on customer machine requirements than frameless
motor mounting requirements
Run-out more dependent on customer requirements
Air gap of 0.015 0.075 (0.38 mm 1.9 mm) each side
of rotor needed for frameless motor
25
Mounting; Bonding, Clamping, and Bolting options are
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discussed in some detail in the KBM Selection Guide
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Radial Running Clearance

AirGap
Source: KBM Selection Guide p.89 KM_SG_00073_RevE_EN

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KBM-43X03 Mounting Example

Bonding
Customer
Through-bore type
Encoder
Customer
Duplex
Bearing
KBM-43X03 Stator
KBM-43X03 Rotor
Customer
Machine Shaft
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Customer Housing
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Bonding
Customer Housing with
Stator embedded
Customer Shaft with Rotor

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Bonding
Customer Housing
KBM Stator
Customer Shaft
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KBM Rotor

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Bonding
Customer Housing
Housing / Stator Exploded View
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KBM Stator

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Bonding
Housing / Stator Assembly
See Detail A
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3D to 2D

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KBM-43X03 Mounting Example Bonding

Depth
stop
shoulder
feature
Detail A Stator / Housing

0.10/0.05 mm
gap per side,
slip fit
Insert Stator
2 mm min.
end turn to
housing
clearance
0.26/0.13 mm
additional
adhesive
groove, 50+%
of surface
Recommended Structural Epoxy
32
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3M Scotchweld 2214
Hysol EA934NA
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Recommended for KBM Frame size 118XX and smaller
Recommended Structural Epoxy:

3M Scotchweld 2214
Hysol EA934NA
Design Recommendations
Cylindrical cup shape customer housing

Locating shoulder for precise location
Lead in chamfer to aid in assembly operation
Maintain clearance over potted winding surfaces > 2 mm
Slip fit with housing of 0.1-0.2 mm over stator OD max
Adhesive grooves with extra slip fit gap of 0.13-0.26 mm
Parts will self-center during cure by orienting in vertical axis
Maximum Cure temperature of 155 C to prevent insulation damage
Please Note that:
Adhesive manufacture guidelines should be followed

Other adhesives can be used
Customer ultimately responsible for proper design of:
Housing dimensions accounting for thermal effects
Proper surface preparation and application of adhesive
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Bonding
Customer Shaft
Rotor
Rotor / Shaft Exploded View
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Rotor / Shaft Assembly
3D to 2D
See detail B
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Recommended Retaining
Compound: Loc-Tite 640
Rotor
No adhesive grooves with

Retainer Compound
mounting configuration
0.05/0.025 mm
gap per side,
precise location
slip fit
Fit depth to shoulder

Shaft
Bolt-on Mounting
also practical for
removable rotor
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Detail B Rotor / Shaft Assembly

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Bonding with Structural Adhesives
Structural adhesives represent a cost-effective, industry
proven, and mechanically sound approach to frameless
motor mounting
Several mounting options; Bonding, Clamping, and Bolting
options are discussed in some detail in the KBM Selection
Guide
37
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Clamping & Bolting
Customer Throughbore type Encoder
KBM-43X03 Stator
Customer
Duplex Bearing
KBM-43X03 Rotor
Customer
Machine Shaft
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Customer Housing
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Clamping & Bolting
Customer Housing
KBM Stator
Customer Shaft
Stator Clamp Ring

Rotor Bolt Flange
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KBM Rotor

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Clamping & Bolting
Customer Housing
KBM Stator
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Stator Clamp Ring

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Clamping & Bolting
Customer Housing
KBM Stator
Stator Clamp Ring w/ 12

evenly spaced bolts
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Actual number may vary

with 41
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motor and load conditions
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KBM-43X03 Mounting Example Clamping

& Bolting
Housing / Stator / Clamp Ring Assembly
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3D to 2D

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KBM-43X03 Stator Clamping Example

Detail A Stator / Housing
Depth
stop
shoulder
feature
2 mm min.
end turn to
housing
clearance
Clamp ring needs to

have gap behind to
allow compression of
stator shoulder
0.05/0.025 mm
gap per side,
precise location
slip fit
Clamp ring with bolts,
must engage at least
half of stator shoulder,
with 2mm gap to
endturn encapsulation
Insert Stator
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Clamping
Recommended for KBM Frame size 118XX and smaller
Designed for easy removal or maintenance access
Design Recommendations
Cylindrical cup shape customer housing

Locating shoulder for precise location
Lead in chamfer to aid in assembly operation
Maintain clearance over potted winding surfaces > 2 mm
Precise Location Slip Fit with housing of 0.10-0.05 mm over stator OD typical
Maintain gap behind clamp ring to allow for compression on stator
Engage at least half of the stator shoulder with the clamping ring
Please Note that:
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ELECTROMATE
Engineering Best Practices should be followed for determining the number and size
of
clamping ring bolts as required for the torque capacity of motor
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Clamping & Customer
Bolting
Shaft
Rotor
Rotor / Shaft Exploded View
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Clamping & Bolting
Rotor / Shaft Assembly
3D to 2D
See Detail B
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KBM-43X03 Rotor Bolting Example

Detail B Rotor / Shaft Assembly
Rotor
0.05/0.025 mm
gap per side,
precise location
slip fit
Bolt-on
Mounting from
either side of
rotor
Fit depth to shoulder
Bolt-on Mounting
47
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Toll Free
Phoneeasily
(877) SERVO98
practical
for
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removable
rotor
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Customer Shaft
Clamping & Bolting :
Clamping and bolting represent a cost-effective, easily
removable, and mechanically sound approach to frameless
motor mounting
Several mounting options; Bonding, Clamping, and Bolting
options are discussed in some detail in the KBM Selection
Guide
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Frameless Motor Sizing

Considerations
What do you do when the frameless motor
application needs are outside the range of the
standard catalog motor offering?
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Frameless Motor Sizing

Considerations
What do you do when the frameless motor
application needs are outside the range of the
standard catalog motor offering?
What do we do when the application requires a
motor rating [derating] at a specific ambient
temperature or amplifier capability?
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Frameless Motor Sizing Considerations

KBM/TBM Performance Curve Generator (Coming Soon)
Winding
Changes
Amplifier
Variations
Ambient
Temp
Variation
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Frameless Motor Sizing Considerations

Motioneering Online Motor Sizing Tool
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Questions?
Joanna Keel
Marketing & Membership Manager

Motion Control & Motor Association
jkeel@motioncontrolonline.org
+1-734-994-6088
Tom S. Wood

Kollmorgen
tom.s.wood@kollmorgen.com
+1-540-250-0399
Electromate Contact
1-877-737-8698
www.electromate.com
Thank you to our exclusive sponsors:
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Theory, Application &amp; Operation of Frameless Motor Technology Webinar 02-23-2016

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February 23, 2016

Theory, Application & Operation

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Meet The Presenter

Texas Instruments & Ethernet POWERLINK Standardization Group

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Thank You To Our Exclusive Sponsors

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Why Direct Drive Frameless ?

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Why Direct Drive Frameless ?

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Why Direct Drive ?

Clean mechanical assembly

Housed Direct Drive Motor

Housed Direct Drive Motor

Single Peg Index Velocity Profile

Sold & Serviced By:

Toll Free Phone (877) SERVO98

26 inch radius from

Toll Free Fax (877) SERV099

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Embedding Frameless Motors

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Robotics: NREC Robot

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Frameless Motor Mounting Video

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Frameless Motor Mounting Video

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Frameless Motor Form Factor

Classic Torquer Motor Shape

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Toll Free Phone (877) SERVO98

Frameless Motor Form Factor

Doubling the Diameter

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Toll Free Phone (877) SERVO98

Frameless Motor Optimization

Choose Largest Practical Diameter

Torque / Speed Load

Low speed / higher torque suggests a larger

Stack Length Change

Wattage increases with stack length

Optimize Winding Parameters

Increase system efficiency

Water Jacket Cooling

Channel features on stator sleeve

Theory, Application & Operation of Frameless Motor Technology Webinar 02-23-2016

Theory, Application & Operation of Frameless Motor Technology Webinar 02-23-2016