Hans-Dieter Stölting Eberhard Kallenbach Wolfgang Amrhein. Handbook of Fractional-Horsepower Drives

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2 Hans-Dieter Stölting Eberhard Kallenbach Wolfgang Amrhein Handbook of Fractional-Horsepower Drives

3 Authors Prof. Dipl.-Ing. Dr. Wolfgang Amrhein Johannes Kepler University Linz, Austria Prof. Dr.-Ing. habil. Hans-Jürgen Furchert University of Applied Sciences Gießen-Friedberg, Germany Prof. Dr.-Ing. Friedrich Wilhelm Garbrecht University of Applied Sciences Gießen-Friedberg, Germany Dr.-Ing. Elmar Hoppach mecatronix GmbH, Darmstadt, Germany Prof. Dr.-Ing. habil. Hartmut Janocha Saarland University Saarbrücken, Germany Prof. Dr.-Ing. habil. Eberhard Kallenbach Steinbeis-Transfercenter Mechatronics Ilmenau, Germany Prof. Dr.-Ing. habil Dr. h. c. Werner Krause Technical University Dresden, Germany Dr.-Ing. habil. Andreas Möckel Technical University Ilmenau, Germany Prof. Dr.-Ing. habil. Dieter Oesingmann Technical University Ilmenau, Germany Dr.-Ing. habil. Christian Richter Saia Burgess Dresden GmbH, Germany Dr.-Ing. Thomas Roschke Saia Burgess Dresden GmbH, Germany Prof. Dr.-Ing. Wolfgang Schinköthe University Stuttgart, Germany Dipl.-Ing. Dr. Siegfried Silber Johannes Kepler University Linz, Austria Prof. Dr.-Ing. Hans-Dieter Stölting Leibniz University Hannover, Germany Prof. Dr.-Ing. Heinz Weißmantel Technical University Darmstadt, Germany

4 Hans-Dieter Stölting Eberhard Kallenbach Wolfgang Amrhein Handbook of Fractional- Horsepower Drives With 462 Figures and 33 Tables 123

5 Prof.Dr.-Ing.habilEberhardKallenbach Steinbeis-Transfercenter Mechatronics Werner-von-Siemens-Str. 12 D Ilmenau Germany Prof.Dr.-Ing.Hans-DieterStölting Leibniz University Hannover Institute of Drive Systems and Power Electronics Welfengarten 1 D Hannover Germany stoelting@ial.uni-hannover.de Prof. Dipl.-Ing. Dr. Wolfgang Amrhein Austrian Center of Competence in Mechatronics (ACCM) Johannes Kepler University Linz Institute of Electric Drives and Power Electronics Altenberger Str. 69 A-4040 Linz Austria wolfgang.amrhein@jku.at Authorized translation of the German original edition, published at Carl Hanser Verlag, München Stölting/Kallenbach (Hrsg.): Handbuch Elektrische Kleinantriebe, 3. Auflage Copyright 2006 Carl Hanser Verlag, München All rights reserved. ISBN Springer Berlin Heidelberg New York Library of Congress Control Number: This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer. Violations are liable for prosecution under the German Copyright Law. Springer is a part of Springer Science+Business Media springer.com Springer-Verlag Berlin Heidelberg 2008 The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Typesetting and Production: le-tex publishing services ohg, Leipzig Cover: WMXDesign GmbH, Heidelberg SPIN /3180/YL Printedonacid-freepaper

6 Preface As a result of continually increasing mechanization and automation, electric fractional-horsepower drives have achieved immense application variety today. On the one hand, improvements made in material technology, microelectronics, power electronics, and automatic control science and technology have produced exceptional design diversity of drives; on the other hand, modern calculation, simulation and measurement methods lead to novel, improved drives. These developments allow us to avoid motors with expensive production engineering and to adjust instead the drive characteristics via easily variable control electronics. Even if the trend seems to converge toward simple motor designs, a generic motor will never be produced because the range of application demands is too heterogeneous and too contradictory. Usually there are several solution possibilities for a drive problem. Therefore a user of small electrical drives must possess knowledge and judgment to find a solution to a problem with regard to function, form, integration in the driven apparatus, operation, maintenance, reliability, safety, economic efficiency, noise and balance quality, and especially costs. This is true above all for the assessment of competing offers and for discussions between users and manufacturers of small electrical drives. This book strives to help in selecting a drive and in estimating which technical expenditures and which costs will be necessary to optimally fulfil the respective demands. In order to enable a complete solution, we provide an overview not only of motors but also of electronic open-loop and closed-loop control systems with low power and of the mechanical transmission elements. The latter is rising in importance as future motor manufacturers will increasingly supply not only the motor, the drive circuit and the gearing, if required, but also apparatus components. The development and production of electrically driven mechanical assembly groups are partly shifting from the apparatus manufacturer to the drive manufacturer. In addition to rotational drives, this book covers linear-motion drives in a detailed description of the special qualities of the different drive possibilities for short motions; this is intended to alleviate the literature s omission in this

7 VI Preface area. Furthermore, these direct drives require very narrow adaptation to the driven mechanical system making it more important to know the different characteristics of the numerous design variants. Above all, electromagnetic motors are presented here. However, we felt obliged to present the most important unconventional drives, the piezoelectric actuators, too. Finally, tips are given on drive configurations and on the solution of typical drive tasks, including some examples. Many bibliographical references and the most important regulations and standards help the reader to delve deeper into the technology, if necessary, or to use a drive that meets technical regulations. This book is suitable for engineers who want to employ small electrical drives to solve configuration tasks, e.g. in automotive engineering, machinetool engineering, household appliance engineering, office and data processing, medicine, laboratory engineering, robotics, and consumer electronics. It is also recommended for students in the fields of electrical engineering, precision mechanics, mechanical engineering and mechatronics. The authors of this book come from industry and universities and have compiled their knowledge and experience in a concise form for a presentation as uniform as possible. Nevertheless, the foci have been set individually by the authors of the various subjects, which are also responsible for the content of their contributions. This book is based on the third edition of the Handbuch Elektrische Kleinantriebe published of Hanser-Verlag, Leipzig, in The authors and editors thank Springer-Verlag for their support and the appealing layout of this book. Hans-Dieter Stölting, Hannover, Germany Eberhard Kallenbach, Ilmenau, Germany Wolfgang Amrhein, Linz, Austria

8 Contents 1 Introduction 1.1 GeneralView TheElectromagneticDriveSystem DriveUnits Motors ElectronicCircuits... 8 References Motors for Continuous Rotation 2.1 MotorswithCommutator ElectricallyExcitedDCMotors PermanentMagnetDCMotors CommutatorSeriesMotor(UniversalMotor) ContactSystemandCommutation NoiseBehaviour Radio Interference Suppression BrushlessPermanentMagnetMotors Introduction DesignFeatures DynamicModeloftheBrushlessACMotor Electronic Suppression of Torque Ripples MotorCharacteristics SensorTechnology Special Designs of Brushless Permanent Magnet Motors SwitchedReluctanceMotor MagneticCircuitry Operation Commutation Control Strategies and Motor Performance SensorlessModesofOperation Characteristics...124

9 VIII Contents 2.4 Rotating-FieldMotors AsynchronousMotors SynchronousMotors References Electromagnetic Stepping Drives 3.1 Overview ClassificationofSteppingMotors Claw-PoledSteppingMotor DiskRotorSteppingMotor ReluctanceSteppingMotor HybridSteppingMotor ControlofSteppingMotors OperatingBehaviourofSteppingMotors StepAngle Torque PositioningAccuracy Step vs TimeCharacteristic OperatingCharacteristics ResonanceFrequencies MicroStepping AssigningReferencePosition MotionSequences ClassifiedMotionSequences CloserExaminationofDynamicOperation References Drives with Limited Motion 4.1 Electromagnets ElectromagnetsasDriveSections DirectCurrentMagnets AlternatingCurrentMagnets PolarizedElectromagnets Project Planning of Electromagnets and Magnetic Drives DesignofMagneticDrives ElectrodynamicLinearandMulti-CoordinateDrives WorkingPrincipleandBasicStructure Configurations of Electrodynamic Linear Motors Types of Construction of Integrated Electrodynamic Multi-Coordinate Drives With Single-Mass Armatures for xy-, xϕ-, xyϕ- andxyϕz-travel Behaviour of Electrodynamic Linear and Multi-Coordinate Motors Control of Electrodynamic Linear andmulti-coordinatemotors...288

10 Contents IX 4.2.6CommerciallyOfferedSystems LinearandPlanarHybridSteppingMotors LinearHybridSteppingMotors Multi-CoordinateHybridSteppingMotors Dynamic Properties of Linear Hybrid Stepping Motors PrincipleofMicrostepping Linear Hybrid Stepping Motors asnon-linearmagneticdrives References Piezoelectric Drives 5.1 PhysicalEffect PiezoelectricComponents PiezoelectricMaterials PiezoelectricElements PiezoelectricActuators StackTranslator(StackedDesign) LaminarTranslators BendingElements TubeElements DisplacementAmplification PiezoelectricMotors InchwormandWalkingMotors UltrasonicMotors DrivingElectronics PowerAmplifier InverseControl ImplementationExamples PositioningSystemwithPiezoDrives ClampingElementsforInchwormMotors References Open-Loop and Closed-Loop Control of Electric Fractional-Horsepower Motors 6.1 Introduction CircuitComponentsandPulse-WidthModulation Circuits for Indirect Coupling and Voltage Level Adapting Control Elements for DC and Rotating-Field Motors ControlElementsforStepper Motors Modulation Methods for Three-Phase Motors ControlElements Open-LoopControlofRotationalSpeed Control Elements and Power Sections for Universal Motors Open-Loop Rotational Speed Control of DC Motors