28

AC Compatible "SANMOTION" PBSystem

New Products Introduction

Eiichi Nishio Masao Nagasato Ryuuichi Yanagisawa Masayoshi Kaneko

1. Introduction

Sanyo Denki’s DC power supply input "SANMOTION" PB Seriessystems were initially introduced into the market as products to bridgethe gap between open loop stepping systems and AC servo systems. Inrecent years, the demand for a wider range of input AC powersupplies has grown due to the conditions of power sources for generalindustrial devices. At the same time, demand has also risen forequipment that is faster, without the increased vibration and noiseassociated with higher equipment torque.

This report provides an outline of the features of the"SANMOTION" PB Series system designed for compatibility withAC power supply inputs and developed in response to thecircumstances described above.

2. Product Outline

Fig. 1 shows the external appearance of the amplifier, Figs. 2 and 3contain the external circuit block diagrams, Table 1 describes thebasic specifications of the amplifier, and Table 2 shows the basicspecifications of the motor.

Two amplifier models have been developed, and are categorizedbased on their interface specifications:

- Pulse Train Input Type….Amplifier Model No. PB3A003P200- RS-485 / Parallel I/O ….. Amplifier Model No. PB3A003R200The "SANMOTION" PB Series lineup also includes five different

motor models for combination with the amplifier (see Table 2),including the newly developed 86mm sq. motor.

Both amplifiers can be combined with any of the motors.

Fig. 1: External Appearance of the "SANMOTION" PB-R system

SANYO DENKI Technical Report No.19 May 2005

Table 1: Basic Specifications of the AmplifierItem Specifications

Amplifier Model No. PB3A003R200 PB3A003P200

I/F RS-485 full-duplex Pulse train input parallel I/O （RS-232C）

Drive Mode PAM+PWM Control SIN Drive Mode

Input Power Source AC100～230V +10％，-15％

External Dimensions H150×W45×D120

Weight Approximately 0.9kg

Structure Tray-type

Positioning Resolution 500,1000,2000,4000,5000,10000P/R

Rotation Speed 0 to 4500min-1 (42mm sq., 60mm sq. motor)0 to 4000min-1 (86mm sq. motor)

Speed Command Unit 1min-1 －

Incorporated Holding Brake Brake Control Function

Functions Regeneration Control Function

Point Function Auto-micro

Program Function S-curve Function

Active Functions Positioning Action

Jog Operations

Automatic Homing Action

Push Action

Modulo Function －

Display LED display POW/ALM

Protective Functions Motor Overheating, Amplifier Overheating

Abnormalities in power supply voltage, sensor disconnection

Excessive Speed, RST Action

Abnormalities in CPU, EEPROM

Abnormalities with PAM Voltage

Abnormalities with Overloading, Deviation

Over-current Detection

Input Signal Point Number Pulse Input:

Functions Point Execution Signal (1-or 2-input method)

Execution Area Selection Hard Limit

Hard Limit External Home Position Signal

External Home Position Signal Emergency Stop

General Purpose Input Deviation Clearance

Emergency Stop ALMCLR

Temporary Stop Homing Function Activation

Alarm Cancellation

Homing Function Activation

Output Signal Normal Acceptance (Ack) SON Monitor

Functions Action Completed Homing Action Completed

Homing Action Completed ALM

ZONE In-Position

Alarm Sensor Signals

General Purpose Output （A,B,C）

*The input and output signal functions, as well as the logic, are set by communication for each function.

3. Product Features

3.1 Drive ModeThe new AC power supply input "SANMOTION" PB Series has an

enhanced sensor resolution of 500P/R (compared to 200P/R forconventional models), and offers a SIN drive mode by adoptingsoftware for the previously hardware-dependent control section. Inaddition, a PWM switching system has been adopted on top andbottom, to enhance responsiveness to electric currents and reduce the

effect from regenerative voltage while driving. All of themodifications listed here were made to the system in order to enhancethe following functions and capacities:(1) Positioning Resolution

To enhance convenience with linear mechanisms, resolution hasbeen set at 500P/R×n(where n = 1, 2, 4, 8, 10 or 20).(2) Command Resolution (for the "SANMOTION" PB-R Model)

Improving on the resolution of conventional speed command at18.75min-1, this new system is equipped with a speed commandresolution of 1min-1, enabling even more detailed speed control.

SANYO DENKI Technical Report No.19 May 200529

DC5̃24 V (+COM)

Phase-A Signal Output

-COM

Phase-C Signal Output

Phase-B Signal Output

2

19

18

In-position Signal

ALM Output

Homing Action �Completion Monitor

Negative Direction �Limit (SDN)

SON monitor

Positive Direction �Limit (SDN)

ALMCLR

STOP

Homing Function �Activation/ IN2

Deviation Clearance / IN1

12

16

17

15

14

13

9

11

10

8

7

2

(Pulse)

(Rotation Direction)

CW Pulse

CCW Pulse

NCNC

NCNC

NCNCGND

RXD

4

1

6

5

3

CN1

8910

76

45

3

GNDVcc

User Equipment

NC

TXD

Input Power SupplyAC100～230V

PB3A003P200

AC2AC1

NP3

1

4

21

5

CN5

CN4

Amplifier

Outer Shield Cable

Motor

＊）� Twisted-pair Wire

holding brake

4B

BRK-BRK+ 5

6

AAB

CN31

32 MO

1

C 6

5G

FGOH

5V

1110

78

BBC

AA

3

54

2OPTICALENCORDER

EN

CN2

CN7

*1

N.C

P.E（M4）�

*1 Reserved for adjustment by manufacturer

TH

Fig. 2: External Circuit Block Diagram (Pulse Train Input)

6

＊1 Reserved for adjustment by manufacturer

OUT5

SON MON/OUT3

OUT4

END/OUT2

-COM

ALMCLR

Point7/IN5

MotorOperation �MON

ALM

ZONE/OUT1

ACK

Point6/SDN/IN4

STOP

Point4/IN2

Point5/IN3

Point3/IN1

2

20

18

19

17

11

14

15

16

13

12

10

9

7

8

＊1

CN7

Exe

Point2

Point1

DC5～24V

N.C

N.CN.C

N.C

GND

N.CN.C

AC100V～230VInput Power Supply

User Equipment

FG 11

Twisted-pair WireOuter Shield Cable

Motorholding brake

5

4

3

1

CN1

＊）�

BRK+BRK-

+5V6

910

87

GND5

Vcc43

A 2

56

BB 4

3

1A

CN3

N.C 12

ENCORDEROPTICAL15

4

CN5,612

32

6C

5G

O.H 10N.C 9

75V8

TH

B 3

BC 5

4

A 2A

PB3A003R200CN4

Amplifier

CN2

EN

MO

BRK

P.E（M4）�

�

Fig. 3: External Circuit Block Diagram ("SANMOTION" PB-R)

Table 2: Basic Motor SpecificationsItem PBM423FXE20 PBM603FXE20 PBM604FXE20 PBM861FXE20 PBM862FXE20

Basic Maximum Stall Torque (N-m) 0.39 1.3 1.9 3.5 6.6

Specifications Rotor Inertia (kg-cm2) 0.056 0.4 0.84 1.48 3

Allowable Thrust Load (N) 9.8 14.7 14.7 60 60

Allowable Radial Load (N) 49 167 167 200 200

Motor Weight (kg) 0.35 0.85 1.42 1.9 3.1

Sensor Specifications Optical INC 500P/R A/B/C Channel

Option Retention Brake ○ ○ ○ × ×

Low Backlash Gear ○ ○ × × ×

Harmonic Gear ○ ○ × × ×

SANYO DENKI Technical Report No.19 May 2005 30

AC Compatible "SANMOTION" PB System

(3) Reduced vibrationThis improved "SANMOTION" PB Series system is not only free

of the resonance frequently observed in open loop stepping systems,but it has also achieved even more stable velocity variation propertiesby changing both the sensor resolution and control method.

Fig. 4 compares the new and conventional PB systems (the latterwith sensor resolution of 200P/R).(4) Reduced Noise

Motor noise has been significantly reduced, particularly in thefrequently-used speed range below 1000min-1.

Fig. 5 compares the noise levels of the new PB system and a typicalopen loop stepping system.

3.2 Voltage Control FunctionsIn general, when rectifier voltage is applied directly to a motor

connected to an AC power supply input amplifier, the PWM causes anexpanding current ripple, because the motor damping time constantfor stepping motors is small. This could result in heat dissipation fromthe motor iron, a potential problem. Depending on the drivingconditions, practical application could become difficult, especiallywith compact motors of small inductance.

To solve this problem, heat dissipation from the motor has beenreduced by equipping the PB amplifier with a step-down circuit, andby controlling the voltage through provision of an optimal motor typeand driving conditions. By doing so, we have achieved our goal of lowinductance for a 42mm sq. motor.

Furthermore, the input power supply voltage is compatible with a

wide range of input between AC100V and AC230V. At the same timethe system exhibits constant torque properties, since its dependence onthe input voltage has been eliminated, as heat dissipation and torquegenerated in the motor are controlled in the step-down circuit.

In contrast to a STEP system that continuously supplies constantcurrent, through PI control, only the necessary amount of electriccurrent is supplied to the motor in a "SANMOTION" PB amplifier;this control method is also effective for reducing heat dissipation.

Fig. 6 compares the operating temperatures of the new"SANMOTION" PB system with those of a typical open loop steppingsystem, with AC100V directly applied.

3.3 Torque PropertiesWe have achieved torque enhancement in the high-speed region

thanks to an optimum phase control that complements the rotationspeed and the increase in applied voltage attained by AC powersupply. Fig. 7 compares the velocity-torurue characteristic of the new"SANMOTION" PB system with the conventional "SANMOTION"PB DC power supply input model.

Incidentally, torque generated in the "SANMOTION" PB system iseffectively utilized due to the fact that the torque margin does notrequire consideration.

3.4 "SANMOTION" PB- R FunctionsThe amplifier is equipped with pulse generation function, as well as

non-volatile memory for mounting the point function (128 points) and

�

open stepPBM603

120

100

80

60

40

20

0

0 500 1000 1500 2000 2500 35003000

Velocity (min-1)

Motor Temperature Increase

Motor Surface Temperature Increase (k)

Continuous driving impossible from here due to motor overheating.

Fig. 6: Motor Temperature Increase(during No-Load Continuous Operation)

AC100V InputDC24V Input

14

12

10

8

6

4

2

0

0 1000 2000 3000 4000 5000

Velocity（min-1）�

PBM603 Velocity-Torque

Torque（kg-cm）�

Fig. 7: Comparison of velocity-torurue characteristic

200P/R (Conventional product)500P/R (New product)

14

12

10

8

6

4

2

00 200 400

Velocity (min-1)

Velocity Variation

Effective Value of Velocity Variation (min- 1)

600 800 1000

Fig. 4: Comparison of Velocity Variation(Equivalent to PBM603)

open stepPB（PBM603）�

70

60

50

40

30

20

10

00 500 1000 1500 2000 2500 3000

Velocity (min-1)

Noise

Noise（db）�

Fig. 5: Comparison of Motor Noise (Equivalent to PBM603)

AC Compatible "SANMOTION" PB System

SANYO DENKI Technical Report No.19 May 200531

program function (1 program x 1024 lines or 128 programs x 8 lines).Therefore, data previously stored in the non-volatile memory can becontrolled only by contact signals.

These measures should contribute toward reduction of the load ofarithmetic operations on the system, as well as the overall cost of thesystem.

For providing direct control by communication, the new"SANMOTION" PB utilizes the general - purpose RS-485 protocol.This simple communication protocol interfaces well with personalcomputers and other master devices, such as PLCs.

3.5 Features of Pulse Train InputSIN driving, even with low position command resolution, is

achieved through internal amplifier control; the processing time forcurrent loops has been reduced thanks to a faster CPU, giving smoothoperation even under extremely low-speed driving.

The S-curve control function is also added for smooth, application-oriented operation.

3.6 Additional Key Points- Since the amplifier is equipped with a retention brake control

function, a power supply and relay contact for the retention brake arenot necessary.

- The amplifier is also equipped with a regeneration controlfunction unique to PB systems, eliminating the need for an externalregeneration unit.

- Data settings for pressing torque and pressing displacement can bemade on the same command with normal displacement for the PB-Rmodel, enabling simple management of pressing control.

- The PB-R model includes a modulo function, providing short-cutcontrol for index tables and other applications.

- A diverse range of automatic home return functions have beenincorporated into the system, such as origin (edge) detection, homingby connecting to the amplifier’s external origin sensor, and more.

4. Conclusion

The development of the AC power supply input"SANMOTION" PB Series system will enhanced the speed andperformance of general industrial machines, as highly sophisticatedproducts with the versatility to handle various power source types andhigh cost performance, together with conventional DC power supplyinput "SANMOTION" PB Series systems.

The authors of this report pledge their intention to continue toimprove and enhance the performance of "SANMOTION" PB Seriessystems.

Eiichi NishioJoined Sanyo Denki in 1985

Servo Systems Division, 2nd Design Department

Area of Expertise: Development and design of servo

amplifiers

Masao NagasatoJoined Sanyo Denki in 1988.

Servo Systems Division, 2nd Design Department

Area of Expertise: Development and design of servo

amplifiers

Ryuuichi YanagisawaJoined Sanyo Denki in 1996.

Servo Systems Division, 2nd Design Department

Area of Expertise: Development and design of servo

amplifiers

Masayoshi KanekoJoined Sanyo Denki in 1992.

Servo Systems Division, 3rd Design Dept.

Area of Expertise: Design of stepping motor mechanisms