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1/19/2016 1
DC Motor Types and Usage in Typical
Applications February 3, 2015
Presented by: Dr. Urs Kafader
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Introducing your Moderator Carrie Hitchner
Marketing Manager, Motion Control Association
734.994.6088
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Introducing your Presenter Dr. Urs Kafader
Technical Training Manager, Maxon Motor
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Thanks to Our Sponsors
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Climate control system
© maxon motor group
Brushed – brushless ?
Flat – long ?
Slotted – slotless winding ?
Torque – speed ?
Size and weight restrictions ?
Ambient?
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What are we talking about? DC motors with permanent magnets Small size: below 1 horse power or approx. 700 Watts
1. Motor designs 2. Brushed or brushless? 3. Slotted or slotless? 4. Motor selection
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1. Motor designs for high speed or high torque?
… and the role of gears and mechanics
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Speed
Torque 0.3 Nm 3 Nm
1000 min-1
10000 min-1
0.03 Nm
100 min-1
High speed designs
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Grinders and drills.
Brushless Slotless
Long, autoclavable
Source: driven 2/14
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Respiratory therapy
© iStock Photo
Brushless Slotless
Long
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0.3 Nm 3 Nm
10000 min-1
0.03 Nm
1000 min-1
100 min-1
Medium speed and torque
Speed
Torque
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Air Cushion System
© 2012 Lantal
Brushless Slotted
Flat
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Pocket-sized Delta robots
© Asyril
Brushless Slotted
Multi-pole direct drive
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0.3 Nm 3 Nm
10000 min-1
0.03 Nm
1000 min-1
100 min-1
Where do typical stepper motors fit into
this diagram?
Speed
Torque
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0.3 Nm 3 Nm
10000 min-1
High torque low speed applications
0.03 Nm
1000 min-1
100 min-1
High torque design
Speed
Torque
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0.3 Nm 3 Nm
10000 min-1
0.03 Nm
1000 min-1
100 min-1
Gearhead for high torque
Speed
Torque
Use of mechanics (gears)
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Autonomous robots at logistics companies
© YLOG GmbH
Brushless Slotless
Long + gear
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Example: Bionics
Sou
rce:
driv
en 3
/13
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0.3 Nm 3 Nm
10000 min-1
0.03 Nm
1000 min-1
100 min-1
Where do typical stepper motors fit into
this diagram?
Speed
Torque
hybrid stepper motor
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2. Brushed or brushless? Selection criteria for going
brushed or brushless
Brushed DC maxon DC
Brushless DC BLDC
maxon EC
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Service life
100 1000 10 000 Service life [hours]
rate of failure
Standard expectations
Worst case Optimum
100 1000 10 000 Service life [hours]
rate of failure
Standard ball bearing life
Higher life More predictable
current speed
cw-ccw vibrations
Brushed DC
Life limited by brushes
EC, brushless DC
Longer life limited by bearings
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Motorized caddy for the green
© YuCAD
Brushed Slotless
Long + gear
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Snake arm robot
© OC Robotics
Brushed Slotless
Long + ceramic gear
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Speed and torque
torque M
speed n
100 000
50 000
25 000
10 000
75 000
torque M
speed n
100 000
50 000
25 000
10 000
75 000
2-pole
4-pole
multi-pole 2-pole
Brushed DC
EC, brushless DC
high speed application
brushed motor operated at high speeds
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Grinders, drills
Brushless Slotless
Long
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Hull cleaning robot
© Sea Robotics
Brushless Slotted
Flat + gear
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Speed and torque
torque M
speed n
100 000
50 000
25 000
10 000
75 000
torque M
speed n
100 000
50 000
25 000
10 000
75 000
2-pole
4-pole
multi-pole 2-pole
Brushed DC
EC, brushless DC
high speed application
reduced life more vibrations and brush fire more audible noise
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Special Ambient Conditions Brushed DC
Complications
EC, brushless DC
Easier to adapt for special ambient
Brushfire electromagnetic noise explosive environments Graphite brushes clean room applications use in optical systems high and ultra-high vacuum Lubricant of metal brushes high and ultra-high vacuum
Sterilizable (autoclavable) motors Vacuum, clean room low outgassing level high temperature no graphite dust
Down-hole drilling: Heavy duty motors high temperature high pressure high vibration / shocks
Mercury 167°C
Venus 464°C
Earth 15°C
Mars -63°C
Jupiter -108°C
Saturn -138°C
Uranus -197°C
Neptun -200°C
Pluto -229°C
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Heavy Duty motors in down hole drilling
Brushless Slotless
Long + gear
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Heavy Duty motors in particle accelerator
© Diamond Light Source (DLS)
Brushless Slotless
Long
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Implantable pump system
© iStock Photo
Brushless Slotless
Long Sterilizable
Bio compatible
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Operation and control Brushed DC
Simple operation
EC, brushless DC
Needs electronics
additional cost for electronics more cables
+ +
or
or …
+
DC or EC
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Automatic wind deflector
© Mercedes Benz AG
Brushed Slotless
Long + gear
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3. Windings with and without iron core
Slotted and slottless
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Brushed: Slotted vs. coreless conventional, slotted
e.g. Dunkermotor
coreless e.g. maxon
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Brushless: Slotted vs. slotless
slotted e.g. maxon EC flat
slotless e.g. maxon EC motor
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What makes coreless motors special? no cogging smooth motor running even at low speed less vibrations and audible noise smooth position control behavior
DC motors - overview
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Surgical robot
© 2010 Intuitive Surgical Inc
Metal brushed Slotless
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Hobby-Eberly-Telescope (Texas)
© 2012 HET
Brushless Slotless
Long + encoder + brakes
+controller
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What makes coreless motors special? no iron losses => high efficiency
Why is high efficiency important for hand-held tools?
Bild Handgerät
driven 2/14
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Battery driven drive systems for surgery.
Brushless Slotless
Long, autoclavable
Source: driven 2/14
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Dosing systems
8mm brushed Slotless
Long + gear + encoder
6mm brushless Slotless
Long + gear
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driven 2/14
What makes coreless motors special? no iron losses => high efficiency
Why is high efficiency important for hand-held tools?
Bild Handgerät
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What makes coreless motors special? stronger magnets possible high torque and power density small rotor mass inertia high dynamics
Coreless maxon RE 30 Ø 30 x 68mm
85 mNm 33.7 gcm2
260g 3 ms
Conventional, with iron core Ø 45 x 70mm 38 mNm 71 gcm2
390g 12 ms
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Research robots
© Robotis
Brushed Slotless
Long + gear
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Kenshiro: Robot with 160 muscles and 93 maxon motors
© maxon motor group
Brushless Slotless
Long
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4. The perfect maxon motor
Selection of “motor size” based on load torque and speed Winding selection
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Application: Load operating points
torque M
e.g. continuous operation at constant speed and friction torque
e.g. high torque needed for short-term acceleration e.g. maintaining a
position against gravity
speed n
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Application: Load key values
torque M
Extreme operation point: max. load speed and load torque (limited time)
Key load data
speed n
RMS average load torque (continuous)
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Motor torque and speed limit
torque M
RMS average load torque (continuous)
Nominal torque MN
nmax
Continuous operation
Short term operation
speed n
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Overload MN 2 MN 3 MN
Short term operation
torque M
RMS average load torque (continuous)
Nominal torque MN
nmax
Continuous operation
Short term operation
speed n
Duration approx. 5 τW 0.3 τW
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Winding series of a motor type
resistance increases from left to right
low resistance
winding
high resistance
winding
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The perfect speed constant
torque M
speed n
current I Mmot
nmot
𝑘𝑘𝑛𝑛 > 𝑘𝑘𝑛𝑛,𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 =𝑛𝑛𝑚𝑚𝑚𝑚𝑚𝑚 + ∆𝑛𝑛
∆𝑀𝑀 ∙ 𝑀𝑀𝑚𝑚𝑡𝑡𝑡𝑡
𝑈𝑈𝑚𝑚𝑚𝑚𝑚𝑚 =
8000 + 110 ∙ 5024
= 563𝑟𝑟𝑟𝑟𝑚𝑚𝑉𝑉
8‘000 rpm 50 mNm
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Summary
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Brushed DC EC
brushless DC
Multipole
Service life
Special conditions
Operation and Control
Approx. < 3000 hrs
Approx. > 10’000 hrs
< 10 000 rpm
< 100 000 rpm
haptic
Speed / Torque
with gear with gear
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Climate control system
© maxon motor group
Reliable, long service life => brushless
Varying ambient conditions (temperature, humidity, pressure) => brushless
Valves: Rather low speed but higher torque => multipole, slotted
Size and weight restrictions => flat, low weight gear
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Thank you!
Visit also www.maxonmotor.com/academy www.maxonmotorusa.com/academy www.electromate.com
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Questions?
Contact: Urs Kafader
maxon motor ag
6072 Sachseln (Switzerland)
Phone +41 41 666 16 74
Email [email protected]
Thank you!
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