Kollmorgen benefits of direct drive technology

Benefits of Direct Drive Technology

ELECTROMATE

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Toll Free Phone (877) SERVO98
Toll Free Fax (877) SERV099
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sales@electromate.com

Putting the Best Solution Together

Connecting
Operator

Feedback
the Load
Interface & Speed Rotary To
Architecture Machine Motion Control Amp Motor Torque Linear
Control Path Gen Position Velocity Torque Matching Conversion

Gearboxes
PLC-Based

Bearings
Multi-Axis
Standalone
Screws

Couplings
PC-Based Motors

1-Axis
Standalone

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ELECTROMATE
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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
Ease of Use
Formats
Frameless DDR Significant integration,
(Parts set) best package fit

Easy to integrate,
Cartridge DDR™
package size fixed

Fully housed Easy to integrate,
DDR package size fixed
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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 Sold & Serviced By:

ELECTROMATE
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DDR: Direct Drive Rotary

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GOLDLINE DDR Features

• Housed motor with bearings Typical application:
and integrated feedback • Rotary indexing table

• To replace any mechanical
• Resolver or sine encoder transmission that is high
feedback maintenance or has short life.

• Single or double bearing
version

• Large thru bore
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The Benefits of DDR Technology
To gain Benefits of Eliminating Mechanical Transmissions
• Zero maintenance • Clean mechanical
– No Belts or gears assembly
• Reliability – Lower parts count
– Reduce down time – Reduce assembly
– No transmission parts to time
break
• Improved performance • Smooth and quiet
– Increase accuracy up to
50 times • Hollow shaft option
– Eliminate resonance – Run process thru the
and oscillation problems motor Sold & Serviced By:

ELECTROMATE
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Lifetime Cost – DDR vs. Mechanical

Lower
Throughput

Unscheduled
Downtime

Belt/gearbox
replacements

Belt/gearbox
maintenance
Purchase Price
Purchase Price
(all components)
DDR
n
Mechanical Transmissio
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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
• Eliminates significant
• Feedback is pre-mounted and pre- engineering design
alignedat the factory through advanced
mechanical design
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• Single part number ready to mount ELECTROMATE
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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 Sold & Serviced By:

ELECTROMATE
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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 Indexer
Customer Load Wheel 96 Steel pegs
4 Feet Diameter 3.75 degrees per peg
250 Pounds Total Inertia 15 lb-ft-s2

S620 Drive Amplifier DH143M Goldline DDR Sold & Serviced By:

ELECTROMATE
240 or 480 Vac 250 Lb-ft Continuous Toll Free Phone (877) SERVO98
20 A Continuous, 40 Peak 989 Lb-ft Peak www.electromate.com

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

Velocity Profile Sold & Serviced By:

ELECTROMATE
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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
Sold & Serviced By:
• File name is “DDR One Peg Index.wmv”, click Slide Show icon to view
ELECTROMATE
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One Revolution Index

• 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
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• File name is “DDR One Revolution Index.wmv”, click Slide Show icon to view ELECTROMATE
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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
0.8 Arc Seconds / division
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ELECTROMATE
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Repeatability Test Video

• 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
Sold & Serviced By:
• File name is “DDR Repeatability Test.wmv”, click Slide Show icon to view
ELECTROMATE
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DDR vs. Mechanical Indexer
Customer 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 value
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ELECTROMATE
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Direct Drive Linear

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Linear vs. Standard Rotary Motors

Linear motor - rotary motor rolled out flat!
stator

windings
moving coil
N

S air gap

magnets magnetic way
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Rotating rotor Toll Free Phone (877) SERVO98
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Comparative Technologies

Mechanical Transmission Advantages Disadvantages

Timing Belt Speed Compliance, Accuracy
Wear, Contamination
Maintenance

Rack and Pinion Speed Backlash, Wear
Long Travel Audible
Contamination

Ball Screw High Force Limited Speed
Settling Time
Wear, Maintenance

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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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ELECTROMATE
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Comparison of DDL Motors

Iron Core
– high peak force
– patented anti-cogging design
– high force density
– Up to 15000 N peak force

Ironless
– zero cogging
– zero attractive force
– ultra-high acceleration
– very smooth motion
– Up to 1600 N peak force Sold & Serviced By:

ELECTROMATE
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Kollmorgen benefits of direct drive technology

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Kollmorgen benefits of direct drive technology