High-Reliability Motors For OEMs. Permanent Magnet DC AC Induction Brushless DC AC/DC Universal Motor Components OEM Customization

Transcription

1 Fractional HP Motors Integrated Motion Solutions High-Reliability Motors For OEMs Permanent Magnet DC AC Induction Brushless DC AC/DC Universal Motor Components OEM Customization

2 FRACTIONAL HORSEPOWER MOTORS Reliable and Quality-Driven Groschopp, Inc. was founded over 70 years ago and since its beginning, has been focused on providing the most progressive motion solutions technologies for OEMs and customized motor applications. We are proud to have earned a reputation for superior engineering craftsmanship and innovative, dependable, and cost-effective solutions in motors, gearmotors, reducers and integrated motion assemblies. Behind every Groschopp product is a team of people from applications engineering, to testing and design, through materials sourcing, manufacturing and delivery who believe that it is our job to get it right, to deliver quality, and to make sure that your schedule is our schedule. Our unique commitment to quality, integrity and involvement in your business is why many of the world s most demanding OEMs have placed their trust in us for decades and still do today. 2

3 Capabilities & Expertise Groschopp s engineering expertise ranges from full OEM prototyping to highly technical MOTORTEC performance assessments. Our industry-leading design and configuration database literally puts over 7,000 standard products and 90,000 possible designs at your fingertips in a matter of minutes. Quick Reference Chart Comparison of the four motor types a starting point in the motor selection process. Permanent Magnet AC Induction Brushless DC Universal Voltage DC AC AC, DC (Control) AC, DC Speed 1,000-5,000 1,350-3,400 1,000-5,000 8,000-20,000+ Horsepower Medium Low-Medium High Very High Effi ciency 60% - 70% 40% - 80% 65% - 80% 55% - 70% Life Medium Very High Very High Low Maintenance Medium Very Low Very Low High Noise Medium Quiet Very Quiet Noisy Speed Regulation Fair Good Excellent Poor Starting Torque Very High Low - Medium Very High High Customization To perfectly match the motor to an application, there are a number of physical and electrical characteristics of a standard motor that can be customized to tailor the motor s performance and mechanical interface. Typical customizations might include: Output Shaft End Brackets / Mounting Face Housing Foot Mount Custom Performance Add-ons such as Brakes, Encoders, and Power Cords To effectively evaluate and optimize motor performance, a MOTORTEC performance specifi cation report can be generated on any motor confi guration. Based on Groschopp s motor design database of over 90,000 proven platforms, MOTORTEC data can be viewed directly on the Groschopp web site. MOTORTEC Performance Data Sheets are available for all Groschopp products at. See pages for more detailed information on customization. 3

4 PMDC Permanent Magnet DC Characteristics Straight line speed torque curve Medium speed operation 1,000 5,000 rpm Effi ciency 60% to 75% High starting torque, 8 10 times rated torque Operates on DC voltage Standard brush life of 2,000+ hours (varies by application) Totally enclosed construction typical Advantages Works well with gearboxes Operates on DC without control Speed control attainable with inexpensive controls Low cost Considerations Maintenance requirement Medium noise Cogging may occur at low speeds (less than 300 rpm) Loss of signifi cant power on full wave rectifi ed voltage High starting torque can damage gearboxes PMDC 4

5 Permanent Magnet DC PMDC FRAME SIZE 60 APPLICATIONS The Permanent Magnet DC is a good fi t for applications that require a high starting torque, such as a motorized hospital bed. 12, 24, 90, 130, 180 VDC, 115 FWR 1,000-5,000 RPM lb-in Rated Torque 1/15 to 1/8 HP The high torque allows it to reliably lift heavy loads, and the intermittent operation requirement means that even with a brush design, the motor can be expected to have a long life. Through proprietary design techniques, the motor has been customized for extremely quiet operation. SPECIFICATIONS Motor Type Frame Size Voltage Speed (RPM) Power (hp) Torque (lb-in) PMDC FWR FRAME SIZE 60 PMDC Dimensions in inches Model L PM PM (60 mm) 5 PMDC

6 PMDC Permanent Magnet DC FRAME SIZE 80 12, 24, 90, 130, 180 VDC, 115 FWR 1,000-5,000 RPM lb-in Rated Torque 1/8 to 1/6 HP APPLICATIONS The automatic shifter of a heavy-duty truck transmission requires the exceptionally high starting torque of the PMDC. Shifting the transmission under power, or when the gears are preloaded, demands a PMDC s characteristic starting torque. When packaged in a customized IP66 housing for a rugged environment, and fi tted with special mounting brackets and automotive connectors, it is a highly reliable, cost-effective integrated solution. SPECIFICATIONS Motor Type Frame Size Voltage Speed (RPM) Power (HP) Torque (lb-in) PMDC FWR FRAME SIZE 80 PMDC Dimensions in inches (80 mm) Model L PM PM PMDC 6 6

7 Permanent Magnet DC PMDC FRAME SIZE , 24, 90, 130, 180 VDC, 115 FWR 1,000-5,000 RPM lb-in Rated Torque 1/5 to 1/3 HP APPLICATIONS Loading bay doors, automated doors/screens and pump applications benefi t from the PMDC s ability to run directly from a DC power source, and its high initial starting torque which is required to set a heavy load into motion. In these low operating speed applications, the PMDC works well with gear reducers and has much quieter operation. SPECIFICATIONS Motor Type Frame Size Voltage Speed (RPM) Power (HP) Torque (lb-in) PMDC FWR FRAME SIZE 108 PMDC Dimensions in inches (108 mm) Model L PM PM PMDC

8 AC AC Induction Characteristics Relatively fi xed speed operation, 3400 RPM maximum Effi ciency 40% to 70% Low (single phase) to medium (three phase) starting torque Operates on AC voltage Life 20,000+ hours Totally enclosed construction is typical Advantages Long life No control required Maintains speed over wide range of torque Works well with gearboxes Low starting current Suitable for speed control Quiet operation Considerations Requires capacitor (single phase only) Can have diffi culty starting (single phase) Low power levels for size Higher cost per horsepower AC 8

9 AC Induction AC FRAME SIZE & 230 VAC 1,350-3,400 RPM lb-in Rated Torque 1/125 to 1/15 HP Single or Three-Phase Inverter Duty Standard APPLICATIONS Extremely quiet and reliable operation makes the AC motor a solid fi t for relatively low speed applications such as commercial baking ovens, cooking rotisseries and other conveyor and continuous motion machines, since the AC motor maintains speed over a wide range of torque. The AC can be customized for applications requiring speed control and works well with a variety of gear confi gurations. SPECIFICATIONS Motor Type Frame Size Voltage Phase Poles Hz Speed (RPM) Power (hp) Torque (lb-in) / / AC / / / / FRAME SIZE 65 AC Induction Dimensions in inches Model L AC6540NV 5.22 AC6540FC 6.15 FC = Fan-Cooled (shown) NV = Non-Vented 9 AC

10 AC AC Induction FRAME SIZE & 230 VAC 1,350-3,400 RPM lb-in Rated Torque 1/30 to 3/8 HP Single or Three-Phase Inverter Duty Standard APPLICATIONS The AC induction motor has no common wear parts such as brushes and commutators, so it is highly reliable, featuring long life potential and low maintenance. These attributes are critically important with diagnostic medical equipment applications such as MRI and X-Ray machines which need the motor to reliably run the cooling systems often continually, for 24 hours a day. SPECIFICATIONS Motor Type Frame Size Voltage Phase Poles Hz Speed (RPM) Power (hp) Torque (lb in.) / / AC / / / / FRAME SIZE 80 AC Induction Dimensions in inches Model L AC8040NV 5.31 AC8040FC 6.68 AC8060NV 6.10 AC8060FC 7.47 AC 10 FC = Fan-Cooled (shown) NV = Non-Vented

11 AC Induction AC FRAME SIZE & 230 VAC 1,350-3,400 RPM lb-in Rated Torque 1/12 to 1/2 HP Single or Three-Phase Inverter Duty Standard APPLICATIONS Fuel vapor recovery systems are growing more common every day. Standard mounting and customization techniques, when applied to the four standard AC motor frame size motors, provide a wide range of options for retrofi ts and upgrades of existing vapor recovery system pumps. Having both single and three-phase design options provides for multiple, cost-effective choices depending on the supply voltage and control requirements. SPECIFICATIONS Motor Type Frame Size Voltage Phase Poles Hz Speed (RPM) Power (hp) Torque (lb in.) / / AC / / / / FRAME SIZE 90 AC Induction Dimensions in inches Model L AC9060NV 6.27 AC9060FC 7.66 FC = Fan-Cooled (shown) NV = Non-Vented 11 AC

12 AC AC Induction FRAME SIZE & 230 VAC 1,350-3,400 RPM lb-in Rated Torque 1/8 to 3/4 HP Single or Three-Phase Inverter Duty Standard APPLICATIONS An AC induction motor, while inherently designed for long life, can be customized for exceptionally long life to exceed 50,000 hours. Using special capacitors, bearings, lubricants and construction techniques, AC motors are supplied to MRI cooling pump applications where failure would be intolerable and extremely costly. A standard frame-size motor modifi ed as described has been proven to meet non-standard performance expectations. SPECIFICATIONS Motor Type Frame Size Voltage Phase Poles Hz Speed (RPM) Power (hp) Torque (lb in.) / / AC / / / / FRAME SIZE 100 AC Induction Dimensions in inches Model L AC10060NV 6.53 AC10060FC 7.99 AC10080NV 7.32 AC10080FC 8.78 AC 12 FC = Fan-Cooled (shown) NV = Non-Vented

13 Brushless DC BLDC Characteristics Variable speed operation High effi ciency between 65% - 80% High starting torque Requires a control to operate Life 20,000+ hours Similar speed torque characteristics to PMDC Advantages Totally enclosed (typical) Long life Low maintenance High power density Suitable option for lower voltage applications (batteries) Works well with gearboxes Can be used in variable speed applications Considerations Controls selection can vary performance Cogging may occur at low speeds < 300 rpm 13 BLDC

14 BLDC Brushless DC FRAME SIZE 65 12, 24 and 163 VDC 2,500 RPM lb-in Rated Torque 1/7 to 1/3 HP APPLICATIONS The power density and small size of Brushless DC (BLDC) motors make it a good design choice for continuous duty, battery-powered applications. Extremely effi cient, the BLDC also boasts long life and low maintenance, because there are no brushes to wear or change out. These motors work well with gearboxes, and can be used in variable speed applications. SPECIFICATIONS Motor Type Frame Size Voltage Speed (RPM) Power (hp) Torque (lb-in) Brushless DC FRAME SIZE 65 Brushless DC Dimensions in inches Model L BL BL BL BLDC 14

15 Brushless DC BLDC FRAME SIZE 80 24, 163 VDC 2,500 RPM lb-in Rated Torque 1/7 to 1/3 HP APPLICATIONS Variable speed and high reliability are a reason Brushless DC motors are found in applications such as personal transport systems, respiratory devices, and highly-critical pump applications. Because a control is always used with a BLDC motor, the motor performance can be customized through the proper choice of an application-specifi c control. r SPECIFICATIONS Motor Type Frame Size Voltage Speed (RPM) Power (hp) Torque (lb-in) Brushless DC FRAME SIZE 80 Brushless DC Dimensions in inches Model L BL BL BL BLDC

16 UNIVERSAL Universal Characteristics Operates on AC and DC Effi ciency between 55% to 70% High speed 8,000 20,000+ rpm Speed is independent of frequency High starting torque, 4 6 times rated torque Life Hours Advantages High power density Excellent choice for portable applications No control required Low cost Considerations Higher maintenance due to brushes Poor speed regulation Typically requires air-through ventilation High speed may create noise Cogging may occur at low speeds Less effi cient at low voltages (less than 100V) Burns out quickly in stall condition UNIVERSAL 16

17 Universal UNIVERSAL FRAME SIZES 62 THROUGH AC/DC Up to 20,000 RPM 1/4 to 1-1/2 HP 2-Pole APPLICATIONS When the application calls for high starting torque, power and speed all combined in a small package the Universal Motor (UM) often emerges as the clear choice. Standard frame sizes can be fi tted with application-specifi c housings to accommodate special mounting, so that they can be dropped into existing applications. As an example, customized commutators can withstand vibration-sensitive applications and increase overall service life. SPECIFICATIONS Motor Type Frame Size O.D. (inches) Length between bearings less Stack Length Power (max. hp) UM Up to 1/5 UM Up to 2/5 UM - Universal UM Up to 7/8 UM Up to 1 3/4 UM Up to 2 1/4 17 UNIVERSAL

18 MOTOR COMPONENTS Motor Components Groschopp has over four decades of experience in providing high reliability, high performance motor sub-assemblies and components to world-class OEMs. Motor components assemblies are custom engineered to allow OEMs to maintain their mounting schemes and desired product confi gurations, while still benefi ting from Groschopp s motor design and volume manufacturing expertise. The products presented on this page are typical examples of the types and general ranges of motor components that Groschopp designs and supplies to tailor the motor solution to the OEM requirements. DC Permanent Magnet Sets/Armatures VDC 1,000-5,000 RPM Meets or exceeds UL UM Motor Part Sets AC/DC Up to 20,000 RPM 1/5 to 2-1/4 HP 2-Pole Meets or exceeds UL Features & Considerations Ball and sleeve bearing Custom performance Custom shafts Rugged mechanical construction Two-plane dynamic balancing High thermal characteristics Exothermic polymer resin: trickle impregnation Diamond-turned commutators for longer brush life High temperature magnet wire Computer-assisted testing Noise evaluation Pre-impregnation testing Easy brush access Custom voltage, speed, torque, duty cycle, etc. Options Assembled into customer-supplied housing Staked and fused commutators Class A-F insulation Double insulated designs Uni- or Bi-directional rotation Armatures for PMDC Thermal protection RFI suppression AC Stator/Rotor Sets 115 & 230 VAC 1,700 and 3,500 RPM Meets or exceeds UL MOTOR COMPONENTS 18

19 Customization Motor Solutions Designed to Match Your Application Demands Impact wrenches on military vehicles require the same ruggedness, quality and ultimate reliability as the vehicles themselves. Military-issue impact wrench kits depend on Groschopp universal motor components, as well as their exceptional service and dependable delivery, to keep the show on the road. 19 CUSTOMIZATION CUSTOMIZATION

20 OEM Customization Custom vs. Customization Groschopp customers value the motor and engineering design expertise that we bring to their applications. The goal of customization is to match the motor to your application as closely as possible. This catalog presents our standard frame sizes. Working from a standard frame size is often the most cost effective way to buy a motor. When using a standard frame size the motor can still be customized to your application. And, when a standard pre-tooled frame size can be used, it can signifi cantly speed up the delivery time for prototypes and initial production runs. There are times when a completely custom motor over the life and scale of your project will have an overall lower production cost with a relatively short payback time as you re paying specifi cally for the motor you need. This weighing of the Customized Standard versus the Blank Sheet Custom Design is where Groschopp can help you weigh the options and make the right choices. Customizing a Standard Motor: Output Shaft End Brackets / Mounting Face Housing Foot Mount Custom Winding / Performance Accessories (brake, encoder, power cord, etc.) Blank Sheet Custom Design: New lamination Special tooling may be required No compromise designs Most cost effective for higher volume applications Application Checklist Use this checklist, along with the Ingress Protection (IP) and Temperature Class charts, to gather data about your application. The Speed vs. Torque comparison graph is helpful in selecting the right motor type. All of this information is essential to refi ning the motor selection and customization process and achieving a maximized, overall motion system solution. Input Power Source Voltage Frequency Current (Effi ciency) Control Environment Ingress Protection (IP) rating Temperature (indoor / outdoor) Motor Specs Size and Weight Motor Life Expectancy / Maintenance Noise Motor Performance Speed & Torque Starting / Stall Torque Duty Cycle Permanent Magnet DC Planetary Gearmotor provides high torque and exceptionally quiet operation for a medical/patient lift. Gearbox reconfi gured to adapt to OEM mounting scheme. CUSTOMIZATION 20

21 Ingress Protection (IP) Specifying the application environment is critical to selecting the right motor for maximum performance and life. Use the IP rating to accurately communicate your application environment. First number (Protection against solid objects) 0 No protection 1 Protected against solids objects over 50mm (e.g. accidental touch by hands) 2 Protected against solids objects over 12mm (e.g. fi ngers) 3 Protected against solids objects over 2.5mm (e.g. tools and wires) 4 Protected against solids objects over 1mm (e.g. tools, wires and small wires) 5 Protected against dust limited ingress (no harmful deposit) 6 Totally protected against dust Second number (Protection against liquids) 0 No protection 1 Protected against vertically falling drops of water 2 Protected against direct sprays up to 15 o from the vertical 3 Protected against direct sprays up to 60 o from the vertical 4 Protected against sprays from all directions limited ingress permitted 5 Protected against low pressure jets if water from all directions limited ingress permitted 6 Protected against strong jets of water e.g. for use on ship decks limited ingress permitted 7 Protected against the effects of temporary immersion between 15cm and 1m. Duration of test 30 minutes 8 Protected against long periods of immersion under pressure Temperature Classes Temperature Class is very important. For every 10 degrees Celsius that the application exceeds the motor s maximum temperature rating, the motor life is reduced by one half. UL 1446 Temperature Classes Maximum Temperature at hottest spot B 130 C (266 F) F 155 C ( 311 F) H 180 C (356 F) N 200 C (392 F) R 220 C (428 F) S 240 C (464 F) >240 C over 240 C (over 464 F) Customized Right Angle Gearmotor for IP66, Class B harsh environment application in a heavy automotive (bus) transmission shifter. Dual commutator design for emergency backup and ultimate reliability 21 CUSTOMIZATION

22 OEM Customization Motor Types: Speed vs. Torque Comparison This graph maps the speed-torque curves of all four motor types on one graph, using the same scale to clearly illustrate the differences between the motors. As an example, note the dramatically higher no-load speed of a Universal motor and the signifi cantly higher starting torques of PM and Brushless DC motors. Standard Customization Options Bearings Drive End High Temp Lubricant Drive End Seal Lead End High Temp Lubricant Lead End Seal End Bell Drill and Tap on edge Drill and Tap for Encoder, Brake or Special Modifi cations Machine Pilot Shaft Double-ended Drill and Tap Additional Flat Keyway - Woodruff Keyway - Straight Crosshole Thread - Internal Thread - External Diameter Rectifi er 115 V 230 V Terminal Box With or without Blocks Leads (12 inches standard) Grommets 2-Core Cord 3-Core Cord Extra Length Nameplates Special Marketing (CE) Customized Nameplate Miscellaneous Drain Holes Environmental IP Rating Insulation Housings, Paints & Finishes CUSTOMIZATION 22 Mounting (standard fl ange included) Special Flange PM Foot RFI Suppression

23 Application Data Worksheet Motor Type PM AC UM Brushless DC Other NOTES Life Requirements Hours UM and PM 500 to 3000 AC and Brushless DC up to 20,000 Voltage Volts AC/DC Phase Control Yes Type (SCR, PWM, VFD, etc.) No Rated Speed RPM Rated Torque lb-in or n-m Rated Power Watts or HP Duty Cycle Continuous Off Time Intermittent On Time Speed Reducer (Gearbox) Parallel Shaft (PS) Right Angle (RA) Planetary (PL) Right Angle Planetary (RP) Overhung Load Yes How much? No What distance from motor? Brake Yes Voltage No Holding Torque Optical Encoder Yes Counts / Revolution No Agency Approvals UL CSA CE RoHS Other 23 CUSTOMIZATION

24 Gears & Gearmotors Our complete range of stand-alone gears - including Parallel Shaft, Right Angle, Planetary and Right Angle Planetary are available in a wide range of ratios, mounting confi gurations and performance levels. Our existing engineering design portfolio includes tens of thousands of gearmotor confi gurations. Specifi cations and MOTORTEC TM Performance Data Sheets providing speed, torque, thermal ratings and intermittent duty are available for these products on our website. Controls Groschopp offers a complete line of AC and DC drives and accessories. Our Sales Applications Engineers can assess your application, and recommend the right control and accessory package to maximize your application, and simplify your job. 3D Solid Model downloads FREE ON EVERY PRODUCT PAGE Groschopp, Inc th Street NE Sioux Center, IA USA (712) Phone (800) Toll-Free (712) FAX 2012 Groschopp, Inc. FRACTIONAL HORSEPOWER MOTORS Integrated Motion Solutions RoHS Compliant ISO 9001:2008 CERTIFIED QUALITY MANAGEMENT SYSTEM REGISTERED Fractional Mo otors CAT-05-12l HP