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ELECTROMATE
Benefits of Direct Drive Technology
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Putting the Best Solution Together
Operator Interface &
Machine Control
MotorAmpTorqueVelocityPositionPath Gen
PLC-Based
PC-Based
1-Axis Standalone
Multi-Axis Standalone
ArchitectureSpeed Torque
Matching
Rotary To Linear
Conversion
Con
nect
ing
the
Load
Feed
back
Motors
Gea
rbox
es
Screws
Bea
rings
Cou
plin
gs
Motion Control
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Why Direct Drive Technology?
• Direct coupling of the load to the motor
• No compliance between motor and load
• Inertia mismatch is irrelevant (theoretically)
• 1000:1 inertia mismatch applications in place (standard servo is 10:1)
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DDR Direct Drive Rotary Formats
DDR Product Formats Ease of Use
Frameless DDR (Parts set)
Significant integration, best package fit
Easy to integrate, package size fixedCartridge DDR™
Easy to integrate, package size fixed
Fully housed DDR
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Frameless -
Brushed
• Permanent magnet stator (stationary)• Wound armature/rotor (rotating)• Self-commutating
• Limited peak power due to mechanical switching that results in excessive sparking in DC motors.
• Least torque ripple of any motor design
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Frameless -
Brushless
• Wound stator (stationary)
• Permanent magnet armature/rotor (rotating - reduced inertia)
• Commutation is done based on rotor position such that synchronism is always maintained. This is referred to as self- synchronism. The motor maintains the ability to deliver torque regardless of the velocity error.
• High commutation frequencies = high speeds
• Good heat dissipation because the windings are on the outside• The ability to deliver current based on demand is a key feature of
servos. If the motor is at rest and there is no load, no current is consumed, and the motor can cool.
• High bus voltage to force current into the windings is available; mitigates the electrical time constant of the winding
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DDR: Direct Drive Rotary
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GOLDLINE DDR Features
• Housed motor with bearings and integrated feedback
• Resolver or sine encoder feedback
• Single or double bearing version
• Large thru bore
Typical application: • Rotary indexing table
• To replace any mechanical transmission that is high maintenance or has short life.
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To gain Benefits of Eliminating Mechanical Transmissions
The Benefits of DDR Technology
• Zero maintenance– No Belts or gears
• Reliability – Reduce down time – No transmission parts to
break• Improved performance
– Increase accuracy up to 50 times
– Eliminate resonance and oscillation problems
• Clean mechanical assembly– Lower parts count– Reduce assembly
time
• Smooth and quiet
• Hollow shaft option– Run process thru the
motorELECTROMATE
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Belt/gearboxmaintenance
Belt/gearboxreplacements
Unscheduled Downtime
Lower Throughput
Purchase PricePurchase Price
(all components)
Mechanical Transmission DDR
Unscheduled Downtime
Lifetime Cost –
DDR vs. Mechanical
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Cartridge DDR
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Cartridge DDR Product Line
• Best features of a frameless DDR and a fully housed DDR
• Direct drive servo performance & zero maintenance, in an easy to integrate package
• It has no bearings…but it has everything else
• Feedback is pre-mounted and pre- alignedat the factory
• Single part number ready to mount
• Eliminates significant engineering design through advanced mechanical design
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Cartridge DDR: Section
RINGFEDER
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Small Frame Cartridge DDR
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Small Frame vs
Large Frame
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CDDR Application Considerations
• Machine has existing bearings?• Through-bore required?• Fast, accurate motion is required?• Reliability and zero motor maintenance is a must?• Fast machine maintenance a requirement?
• Consider ...– Axial shaft movement– Shaft dimensions and TIR– Perpendicularity of mounting surface– Thermal capacity of machine structure
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Cartridge DDR Applications
• Any application where the machine has its own set of bearings, but still can benefit from the DDR performance advantages
• Converting:– Rollers, Coaters, Feeders, Die Cutters
• Other application examples– Injection molding: IM machine mold indexing– Press feed: Incremental motion
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DDR Videos
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GOLDLine DDR IndexerCustomer Load Wheel
4 Feet Diameter250 Pounds
DH143M Goldline DDR250 Lb-ft Continuous989 Lb-ft Peak
96 Steel pegs3.75 degrees per pegTotal Inertia 15 lb-ft-s2
S620 Drive Amplifier240 or 480 Vac20 A Continuous, 40 Peak
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Single Peg Index Velocity Profile
3.75 Degree Move)
Velocity Profile
Total Move Time 97 ms
Settling Time 13 ms
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Indexing a Single Peg
If the Video does not play:
• Right click inside Windows Media Player screen above and choose Properties
• Choose “SinglePeg WindowsMediaPlayer” from pull down and “Alphabetic” tab
• Click on button at the end of “(Custom)” row and “Browse” to file on CD-ROM
• File name is “DDR One Peg Index.wmv”, click Slide Show icon to viewELECTROMATE
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One Revolution Index
If the Video does not play:
• Right click inside Windows Media Player screen and choose Properties
• Choose “FullRevolution WindowsMediaPlayer” from pull down and “Alphabetic” tab
• Click on button at the end of “(Custom)” row and Browse to file location on CD-ROM
• File name is “DDR One Revolution Index.wmv”, click Slide Show icon to view ELECTROMATEToll Free Phone (877) SERVO98
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Bar Clamped to Table
Indicator1 Thousandth Inch / Number1 Ten Thousandth Inch / division0.8 Arc Seconds / division
26 inch radius from center
Repeatability Test
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Repeatability Test Video
If the Video does not play:
• Right click inside Windows Media Player screen above and choose Properties
• Choose “Repeatability WindowsMediaPlayer” from pull down and “Alphabetic” tab
• Click on button at the end of “(Custom)” row and “Browse” to file on CD-ROM
• File name is “DDR Repeatability Test.wmv”, click Slide Show icon to viewELECTROMATE
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DDR vs. Mechanical IndexerCustomer identified these advantages of the DDR over the mechanical indexer they used previously
– Improved Repeatability
– DDR Accuracy and Repeatability do not degrade over time as with the mechanical indexer
– Can immediately stop DDR motion if there is a process error
– Greatly reduced audible noise
– Easily change DDR index angle, speed, and dwell
– DDR provides better overall valueELECTROMATE
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Direct Drive Linear
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Linear vs. Standard Rotary Motors
Linear motor - rotary motor rolled out flat!
moving coil
magnetic way
air gap
Rotating rotor
windings
stator
N
S
magnetsELECTROMATE
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Mechanical Transmission Advantages Disadvantages
Timing Belt Speed Compliance, AccuracyWear, ContaminationMaintenance
Rack and Pinion Speed Backlash, WearLong Travel AudibleContamination
Ball Screw High Force Limited SpeedSettling TimeWear, Maintenance
Comparative Technologies
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Indicators for a Linear Motor Solution
• High Speeds - 200 in/sec (10 m/sec)• High Acceleration - 3-5 g's are typical• Fast Move and Settle• High Resolution • Long travel distances - 20 feet or more possible• Smoothness (zero cogging)• No maintenance (non-contact)• Zero backlash
• High dynamic stiffness, no compliance
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Comparison of DDL Motors
Ironless– zero cogging– zero attractive force– ultra-high acceleration– very smooth motion– Up to 1600 N peak force
Iron Core– high peak force– patented anti-cogging design– high force density– Up to 15000 N peak force
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