Direct Drive Motion Control Solutions April 15 th & 16 th, 2014 1
What is Direct Drive Rotary? Direct coupling of the load to the motor For DDR (Direct Drive Rotary) 2 2
Why Customers Want Direct Drive To gain Benefits of Eliminating Mechanical Transmissions Clean mechanical assembly Lower parts count Reduce assembly time Improved servo performance Increase accuracy up to 50 times Greater servo performance and higher bandwidth No need for inertia matching Zero maintenance No Belts to tighten or adjust No gears to lubricate or leak Reduce machine down time no mechanical transmission parts to break Hollow shaft option Through-bore for process air or tooling Quiet performance up to 20db noise reduction 3 3
DDR Product Formats As the leader in DDR product technology, Kollmorgen provides three Direct Drive solutions to match best with your machine DDR Product Format Fully housed DDR Best Application Fit Easy to integrate, package size fixed Apply for indexing or where load needs to be supported Cartridge DDR Easy to integrate, package size fixed Apply where bearings already exist in machine Frameless KBM Rotor/Stator part set Significant design integration, best mechanical package fit Apply for maximum torque in minimum volume 4 4
Housed DDR Product Overview Housed motor with factory aligned feedback and precision cross roller bearings functions as the core of a rotary indexer Encoder or Resolver Feedback Encoder for optimum precision Resolver for harsh environments and larger through bore Precision cross roller bearings Performance far exceeding mechanical indexers or variable reluctance technology Drive with AKD, S700 Drive for ultimate flexibility and performance 5 5
Housed DDR Product Details Technical Information Four frame sizes: D06, D08, D10, D14 Three lengths for each frame size Continuous torque from 5 to 340 Nm Peak torque from 13 to 1340 Nm Index speed up to 800 RPM Load inertia mismatch up to 4000:1 Options Sine encoder or resolver 115 VAC, 208 VAC, 380 VAC, or 480 VAC operation Through bore IP65 or IP67 sealing 6 6
Housed DDR Indexer Customer Load Wheel 4 Feet Diameter 250 Pounds 96 Steel pegs 3.75 degrees per peg Total Inertia 15 lb-ft-s 2 S620 Drive Amplifier 240 or 480 Vac 20 A Continuous, 40 Peak DH143M Goldline DDR 250 Lb-ft Continuous 989 Lb-ft Peak 7 7
Single Peg Index Velocity Profile Single Peg Index (3.75 Degree Move) Total Move Time 97 ms Settling Time 13 ms 8 Velocity Profile 8
Single Peg Index Video 9 9
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 10 10
Repeatability Test Video 11 11
DDR Advantages over Mechanical Indexer Customers 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 Ability to easily change DDR index angle, speed, and dwell DDR provides better overall value 12 12
Cartridge DDR Product Line What s a cartridge DDR? It combines the best features of a frameless motor and a fully housed DDR Unique, First in Industry Has NO Bearings, Uses machine s bearings It has no bearings but it has everything else Includes rotor, stator, factory aligned sine encoder Innovative compression coupling / shipping clamp It is a single part number ready to mount by the customer 13 13
Kollmorgen Cartridge DDR Award Winning DDR technology!! 14 14
Kollmorgen Cartridge DDR Continuous torque range of 4.6-510 Nm 5 frame sizes 4.25, 5.4, 7.4, 9.8, and 13.7 square Speeds to 2500 rpm 230, 400/480V options Simple coupling arrangement Very simple mounting process Sine encoder feedback 134,217,728 counts per rev AKD standard drive systems Through bore option on C09 and C13 15 15
Cartridge DDR TM success story! Stamping Press Feed Increased accuracy Reduced parts count Reduced assembly time Best total cost solution Success Story Cartridge DDR Motor Improves Stamping Press Before Conventional Motor / Gearbox / Belt After Cartridge DDR Solution 16 16
Cartridge DDR TM Application Success 17 Before After 17
Re-Designed Die Station Advantages Parts Eliminated: Cartridge DDR TM Advantages: 2 Spur Gears 2 helical Gears Hub City Gear Box Winsmith Gear Box Gear Oil Bath Tandler Phaser Fairchild Phaser 8 Pulleys 4 HT Timing Belts 2 Bearing Blocks 5 Mounting Brackets 102 Pieces of Hardware Digital Accuracy (50 times more accurate) 20 db Quieter Maintenance Free 18 18
OEM s DDR Experience New Re-designed machine was the smoothest start-up ever. Increased performance resulted in their customer being ahead of production schedule.until they took on additional business to utilize the extra capacity. Re-designed machine has caused increased market interest and increased sales. Improved DDR performance increased the quality of the product and the throughput. 19 19
Using Technology as a differentiator This is an ingenious motor. I m glad they have such smart engineers. It s very well designed, very well thought out. It s stupidly simple. Gilbert Peterson, Manager of Electrical Engineering, I-Webb Raving Fan Customer s Perspective 2 hrs/axis set up time savings 25% overall cost savings Reduced BOM from 60 to 6 parts Better machine performance Users can replace motor and tune with no factory involvement 2 axis Die-cutter 20 20
Print Station Old Print Station 21 21
Cartridge DDR Die Cutter CH133, die cutter station 22 22
Conventional Gear/Cartridge Comparison Converting machine replacing gears with CDDR 23 Conventional Servo with gears note mechanical complexity of this solution Cartridge DDR.eliminated over 2000 components simple and clean 23
CRS2020 Print Stations 24 24
ServoGrafix Print Station 25 25
KBM Frameless Motor Technology Product Overview Frameless motor part set that is closely integrated into the customer machine housing and directly onto the machine shaft Smallest possible motor package for load Separate Stator and Rotor components Feedback selected by customer Absolutely minimized machine inertia for highest bandwidth Minimal parts count highest reliability 26 Drive with AKD, S700 Drive for ultimate flexibility and performance 26
KBM Frameless Motor Technology Product Details Technical Information Fourteen frame sizes: 2.3 to 33.5 Up to five lengths for each frame size Continuous torque from 0.5 to 3445 Nm Peak torque from 1 to 12812 Nm Motor speed up to 20,000 RPM Load inertia mismatch up to 4000:1 UL / CSA / CE Agency Certifications Options Optimized windings for bus voltage variations, low voltage DC through 480 VAC operation Hall effect sensors for commutation or sensorless Through bore and bolting variations available Avalanche or Linear thermal sensors 27 27
Mounting Considerations Embedded Motion Technology - Frameless Mounting Considerations The benefits of Improved System Performance, Reduced Maintenance, Smaller Mechanical Footprint, Higher System Efficiency are understood Customer still has a key question in mind I like the frameless design concept but how do I mount the motor components into my machine? 28 28
Mounting Considerations Mechanical Mounting Considerations Customer s own bearings Customer s shafting / drivetrain Bearing precision and machining tolerances are dependent more on customer machine requirements than frameless motor mounting requirements Run-out more dependent on customer requirements Air gap of 0.015 0.075 (0.38 mm 1.9 mm) each side of rotor needed for frameless motor Mounting; Bonding, Clamping, and Bolting options are discussed in some detail in the KBM Selection Guide 29 29
Radial Running Clearance AirGap Source: KBM Selection Guide p.89 KM_SG_00073_RevE_EN 30 30
KBM-43X03 Mounting Example Bonding Customer Throughbore type Encoder KBM-43X03 Stator Customer Duplex Bearing KBM-43X03 Rotor Customer Machine Shaft Customer Housing 31 31
KBM-43X03 Mounting Example Bonding Customer Housing with Stator embedded Customer Shaft with Rotor 32 32
KBM-43X03 Mounting Example Bonding Customer Housing KBM Stator Customer Shaft 33 KBM Rotor 33
KBM-43X03 Mounting Example Bonding Customer Housing Housing / Stator Exploded View 34 KBM Stator 34
KBM-43X03 Mounting Example Bonding Housing / Stator Assembly See Detail A 35 3D to 2D 35
KBM-43X03 Mounting Example Bonding Depth stop shoulder feature Detail A Stator / Housing 0.10/0.05 mm gap per side, slip fit Insert Stator 2 mm min. end turn to housing clearance Recommended Structural Epoxy 3M Scotchweld 2214 Hysol EA934NA 0.26/0.13 mm additional adhesive groove, 50+% 36 of surface 36
KBM-43X03 Mounting Example Bonding Recommended for KBM Frame size 118XX and smaller Recommended Structural Epoxy: 3M Scotchweld 2214 Hysol EA934NA Design Recommendations Cylindrical cup shape customer housing Locating shoulder for precise location Lead in chamfer to aid in assembly operation Maintain clearance over potted winding surfaces > 2 mm Slip fit with housing of 0.1-0.2 mm over stator OD max Adhesive grooves with extra slip fit gap of 0.13-0.26 mm Parts will self-center during cure by orienting in vertical axis Maximum Cure temperature of 155 C to prevent insulation damage Please Note that: Adhesive manufacture guidelines should be followed Other adhesives can be used Customer ultimately responsible for proper design of: Housing dimensions accounting for thermal effects Proper surface preparation and application of adhesive 37 37
KBM-43X03 Mounting Example Bonding Customer Shaft Rotor 38 Rotor / Shaft Exploded View 38
KBM-43X03 Mounting Example Bonding Rotor / Shaft Assembly 3D to 2D See detail B 39 39
KBM-43X03 Mounting Example Bonding Rotor Recommended Retaining Compound: Loc-Tite 640 No adhesive grooves with Retainer Compound mounting configuration 0.05/0.025 mm gap per side, precise location slip fit Shaft Fit depth to shoulder Bolt-on Mounting also practical for removable rotor 40 Detail B Rotor / Shaft Assembly 40
Mounting Considerations Bonding with Structural Adhesives Bearing precision and machining tolerances are dependent more on customer machine requirements than frameless motor mounting requirements Structural adhesives represent a cost-effective, industry proven, and mechanically sound approach to frameless motor mounting Several mounting options; Bonding, Clamping, and Bolting options are discussed in some detail in the KBM Selection 41 Guide 41
KBM-43X03 Mounting Example Clamping & Bolting Customer Throughbore type Encoder KBM-43X03 Stator Customer Duplex Bearing KBM-43X03 Rotor Customer Machine Shaft Customer Housing 42 42
KBM-43X03 Mounting Example Clamping & Bolting Customer Housing with Stator embedded 43 Customer Shaft with Rotor 43
KBM-43X03 Mounting Example Clamping & Bolting Customer Housing KBM Stator Customer Shaft Stator Clamp Ring Rotor Bolt Flange 44 KBM Rotor 44
KBM-43X03 Mounting Example Clamping & Bolting Customer Housing KBM Stator 45 Stator Clamp Ring 45
KBM-43X03 Mounting Example Clamping & Bolting Customer Housing KBM Stator Stator Clamp Ring w/ 12 evenly spaced bolts Actual number may vary with motor and load conditions 46 46
KBM-43X03 Mounting Example Clamping & Bolting Housing / Stator / Clamp Ring Assembly 47 3D to 2D 47
KBM-43X03 Stator Clamping Example Depth stop shoulder feature 2 mm min. end turn to housing clearance Detail A Stator / Housing Clamp ring needs to have gap behind to allow compression of stator shoulder 0.05/0.025 mm gap per side, precise location slip fit Clamp ring with bolts, must engage at least half of stator shoulder, with 2mm gap to endturn encapsulation Insert Stator 48 48
Clamping Recommended for KBM Frame size 118XX and smaller Designed for easy removal or maintenance access Design Recommendations Cylindrical cup shape customer housing Locating shoulder for precise location Lead in chamfer to aid in assembly operation Maintain clearance over potted winding surfaces > 2 mm Precise Location Slip Fit with housing of 0.10-0.05 mm over stator OD typical Maintain gap behind clamp ring to allow for compression on stator Engage at least half of the stator shoulder with the clamping ring Please Note that: Engineering Best Practices should be followed for determining the number and size of clamping ring bolts as required for the torque capacity of motor 49 49
KBM-43X03 Mounting Example Clamping & Bolting Customer Shaft Rotor 50 Rotor / Shaft Exploded View 50
KBM-43X03 Mounting Example Clamping & Bolting Rotor / Shaft Assembly 3D to 2D See Detail B 51 51
KBM-43X03 Rotor Bolting Example 0.05/0.025 mm gap per side, precise location slip fit Detail B Rotor / Shaft Assembly Rotor Bolt-on Mounting from either side of rotor Fit depth to shoulder Customer Shaft 52 Bolt-on Mounting practical for easily removable rotor 52
Mounting Considerations Clamping & Bolting : Bearing precision and machining tolerances are dependent more on customer machine requirements than frameless motor mounting requirements Clamping and bolting represent a cost-effective, easily removable, and mechanically sound approach to frameless motor mounting Several mounting options; Bonding, Clamping, and Bolting options are discussed in some detail in the KBM Selection 53 Guide 53
KBM Frameless Motor Technology Where you see : Servo driving high performance Belt and Pulley Usually Single Stage Reduction - 3:1 ratio or less 54 54
KBM Frameless Motor Technology Router Machines Replacing precision belt/pulley driving rotating nut ballscrew system and fixed screw Increased performance, cutting speeds in excess of 4000 ipm w/ 40x40 ballscrew Compact drive design Quieter No Maintenance 55 55
KBM Frameless Motor Technology Assumes: Two 4 Dia. Steel Pulleys 1:1 Gear Ratio Driving 72, 2 Diam. 2 / rev Ballscrew 56 56
KBM Frameless Motor Technology AKM63N Motion Profile 60 Traverse in 995mSec 95 msec Accel 57 702 in/sec 2 = 1.82 Gs Accel 57
KBM Frameless Motor Technology Max Performance with AKM63N 4.03 HP Cont. 11.28 HP Peak 58 58
KBM Frameless Motor Technology Using KBM35 No Pulleys Motion Profile 60 Traverse in 967 msec 67 msec Accel Time Lower Cost and Higher Performance 59 1000 in/sec 2 = 2.59 Gs Accel 59
KBM Frameless Motor Technology Max. Performance w/ KBM-35H01 3.26 HP Cont. 10.62 HP Peak 60 60
KBM Frameless Motor Technology Higher Performance KBM Frameless Motors Available for Significantly Improved Machine Capability 61 61
KBM Frameless Motor Technology KBM-35H01 AKM-63N Difference % Improvement Motor List $ $1,015 $1,645 $330 * 20% Accel Time 66.7 msec 95.0 msec 28.3 msec 30% Gs Accel 2.59 G 1.82 G 0.77 G 42% Gs Accel / HP 0.244 0.161 0.083 52% Weight # 10.3 # 24.5 # 14.2 # 58% - Excellent $$ savings - Increased system performance - Higher power efficiency, More "Green" * with $300 Resolver or Encoder - Significant machine space and weight savings 62 - No inertia matching limitations 62
KBM Frameless Motor Technology Direct Drive Technology Story This could be a Belt & Pulley, Planetary Gearhead, Rotating Nut or Driven Ballscrew Get rid of the; Inertia, Lost Motion, Part Count, Weight, Maintenance Improve; Bandwidth, Machine Performance, System Stiffness 63 63
KBM Frameless Motor Technology Direct Drive Technology Story This could be a Belt/Pulley, Planetary Gearhead, Rotating Nut or Driven Ballscrew Get rid of the; Inertia, Lost Motion, Part Count, Weight, Maintenance Improve; Bandwidth, Machine Performance, System Stiffness Go Embedded, Go KBM 64 64
Direct Drive Technology Summary Do you want your machine to have. Increased Accuracy Increased Throughput No Maintenance Increased Reliability Lower Parts Count Reduced Machine Assembly Time Quiet Operation Smaller Footprint 65 Kollmorgen Direct Drive Motion Technology 65