Micro Motor, Gears and Positioning Controller

Transcription

1 2014 Micro Motor, Gears and Positioning Controller 微型电机 齿轮及定位控制器 Enginesound Powered by maxon motor

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3 目录 1. Enginesound AC synchronous motor S series 擎声交流同步电机 S 序列 ) Technical specifications 技术概述 ) Rated speed 转速 Enginesound brushed DC motor R series / 擎声有刷直流电机 R 序列 ) Technical specifications 技术概述 ) Turning speed 转速 ) Winding / 绕组 ) Service time 寿命 Enginesound brushless DC motor E series 擎声无刷直流电机 E 序列 ) Technical specifications 技术概述 ) Bearings and service life 轴承及工作寿命 ) Electronica commutation 电子换向...14 Block commutation 方波换向...14 Sensorless block commutation 无传感器方波换向...15 Sinusoidal commutation 正弦波换向 ) Hall sensor circuit 霍尔传感器电路 ) Encoders 编码器...18 Optical incremental encoder 光电增量式编码器...18 Magnetic encoder 磁性编码器...18 Resolver 旋转变压器...19 Absolute encoder 绝对值编码器 Enginesound motor controllers 擎声电机控制器 ) Technical specifications 技术概述 ) Speed control 速度控制 ) Position control 位置控制 ) Current control 电流控制 ) IxR compensation IxR 补偿 ) Operation quadrants 工作象限 ) Set value specification 设定值特性

4 5. Notes of DC motor 关于直流电机的说明 ) The motor as an energy converter 电机中的能量转换 ) Electromechanical motor constants 电机的电机常数 ) Motor diagrams 电机的特性曲线 ) Speed-torque line 速度 - 转矩曲线 ) Derivation of the speed-torque line 转速 - 转矩曲线的推导 ) Current gradient 电流曲线 ) Efficiency curve 效率曲线 ) Rated working point 额定工作点 ) Motor diagrams, operating ranges 电机工作图表, 允许范围 Permanent operating range 连续运行范围 Short-term operating range 短时工作范围 Maximum continuous current (torque) 最大连续电流 ( 转矩 ) Maximum permissible speed 最高允许转速 Maximum winding temperature 绕组最高温度 ) Acceleration 加速过程 Start at constant current 恒电流起动 Start with constant terminal voltage 恒电压起动 ) Thermal behavior 热特性 Influence of temperature 温度的影响 ) Operation mode 电机工作制 Enginesound gears 擎声齿轮箱 ) Technical specifications 技术概述 Conversion 换算 Gears efficiency 齿轮箱效率 Service factor fb 服务系数 fb Service life 寿命 ) Selection of gears 齿轮箱选型 ) 齿轮箱定位精确度 Type of gears 齿轮箱类型

5 1) Technical specifications 技术概述 Spur gears GS 直齿轮箱 GS Planetary gears GP 行星齿轮 GP Enginesound Positioning Controller 擎声定位控制器 ) poscon ) poscon ) maxpos Enginesound AC synchronous motor S series ) Synchronous motor 35S-6 同步电机 35S ) Synchronous motor 35S-8 同步电机 35S ) Synchronous motor 35S-12 同步电机 35S ) Synchronous motor 42S-6 同步电机 42S ) Synchronous motor 42S-8 同步电机 42S ) Synchronous motor 42S-12 同步电机 42S ) Synchronous motor 58S-6 同步电机 58S ) Synchronous motor 58S-8 同步电机 58S ) Synchronous motor 58S-12 同步电机 58S Enginesound brushed DC motor R series ) R 25 Ø25 graphite brush 20W 石墨电刷 20W ) R 25 Ø25 graphite brush 20W 石墨电刷 20W ) R 30 Ø30 precious metal brush 15W 稀有金属电刷 15W ) R 30 Ø30 graphite brush 60W 石墨电刷 60W ) R 35 Ø35 graphite brush 70W 石墨电刷 70W ) R 40 Ø40 graphite brush 120W 石墨电刷 120W ) R 50 Ø50 graphite brush 200W 石墨电刷 200W ) R 65 Ø65 graphite brush 250W 石墨电刷 250W Enginesound brushless DC motor E series ) E 22 Ø22 brushless 40W 无刷 40W ) E 22 Ø22 brushless 100W 无刷 100W ) E 26 Ø26 brushless 120W 无刷 120W

6 4) E 30 Ø30 brushless 50W 无刷 50W ) E 35 Ø35 brushless 80W 无刷 80W ) E 43 Ø43 brushless 120W 无刷 120W ) E 58 Ø58 brushless 170W 无刷 170W ) E 60 Ø60 brushless 400W 无刷 400W ) E 44 Ø44 brushless 120W 4-pole 无刷 120W 4 极 ) E 43 Ø43 brushless 100W 8-pole 无刷 100W 8 极 Enginesound Gears ) Spur gears GS 直齿轮箱 GS GS05 / GS10 / GS50 technical data 技术数据 GS100 / GS300 technical data 技术数据 ) Planetary gears GP 行星齿轮箱 GP GP40 technical data 技术数据 GP60 technical data 技术数据 GP80 technical data 技术数据 Enginesound Positioning Controller ) POSCON ) POSCON ) MAXPOS 附录 M12 connector M12 连接器

7 Enginesound Automation Technology (Shanghai) Co., Ltd. is a manufacture of micro motors, small gears, and positioning controllers. We focus on long-term stability, high cost performance products and regard ourselves as your long-term partner ever since her establishment. 擎声自动化科技 ( 上海 ) 有限公司是一家微型电机 小模数齿轮及定位控制器的供应商 我们关注于产品的长期稳定性及高性价比 自建立之日起, 客户就是我们长期的伙伴 The motors have various types, such as brushed DC-motors, brushless DC-motors (shorten as BLDC motor, also called as EC motor) and single-phase AC synchronous motors. The performance of the motors is in a speed range of ,000 rpm, and a power range of 1 400W. The DC motors have very high dynamic functionality and ultra-high efficiency (up to 90%). Well as the single-phase AC synchronous motors have good speed stability, easy operation and high cost performance. Different encoders such as incremental encoder, magnetic encoder, resolver encoder and absolute encoder can be configured with DC motors. Furthermore, an electromagnetic brake is a must to hold the motor shaft while the motor is standstill in some cases. 我们的电机类型包括有刷直流电机 R 系列 无刷直流电机 ( 即 BLDC 电机, 也叫 EC 电机 )E 系列及单相交流同步电机 S 系列 电机的速度范围是 ,000 转 / 分, 功率范围是 瓦 直流电机具有非常高的动态性能, 超高效率 ( 高达 90%), 而单相交流同步电机具有非常好的速度稳定性, 控制简单, 高性价比的特点 对于直流电机, 可以配置不同的编码器, 包括增量式编码器, 磁性编码器, 旋转变压器以及绝对值编码器 此外, 有些场合必须在电机静止时使用电磁制动器来防止电机轴选择 The micro reducers are divided into two groups, spur gears and planetary gears. The spur gears are flexible with various gear ratios from tens to more than 2,000. Thanks to the modern powder metallurgical techniques, we can achieve a torque up to 30Nm with these spur gears. They are used for cost sensitive applications and suitable for mass production. Meanwhile, alloy steels grinded gears with optimized bearing design can offer better performance (such as higher rated input speed up to 6,000rpm and output torque up to 40Nm) than powder metallurgical gears. The planetary gears have better accuracy, higher input speed, higher overload capability and longer service life because of the case-hardened grinding helical gear. Thus the cost is higher than spur gears. 微型减速箱可分为直齿轮减速箱及行星齿轮减速箱两类 直齿轮箱的速比范围很宽, 从几十到两千多 由于采用了当前最先进的粉末冶金技术, 齿轮最高扭矩可以达到 30 牛. 米 这些齿轮用在价格敏感的地方, 也适合于大批量生产 另外, 采用合金钢磨齿加工的齿轮, 轴承设计同时优化, 它们的性能 ( 输入速度额定 6,000 转 / 分及输出扭矩 40 牛. 米 ) 比粉末冶金齿轮有大幅的提升 行星减速箱具有高精度 高输入转速 高过载能力及长寿命的特点, 所有齿轮采用斜齿轮硬齿面磨齿, 成本自然也比直齿轮高 Based on enginesound s know-how knowledge and derived from German engineering technology, the motors and gears are robust and precise designed for industrial applications such as textile machinery, solar energy, valve control, HAVC field, printing machines, packing machines, food-pharmaceutical machinery and so on. 基于擎声科技的 诀窍 知识和源自德国的工程技术, 电机及齿轮箱设计精密可靠 这些产品广泛应用于纺织机械 太阳能行业 阀门控制 暖通行业 印刷机械 包装机械以及食品医药机械等 Thanks to her experience with motors and gears, hardware (electronics) and software (motion control), enginesound is a leading supplier for positioning controllers. Depends on the different combinations with motors and gears, we can provide the torque up to 100Nm. The actual position is supervised by limit 7

8 switches, precise conductive plastic potentiometers or absolute encoders. The positioning controllers are very precisely integrated with motors, gears, sensors and electronic parts which offers very competitive price. 由于在电机及齿轮 电子硬件及运动控制软件方面的经验, 擎声科技是一家领先的定位控制器供应商 基于不同的电机和减速齿轮的组合, 我们可提供的产品最高扭矩高达 100 牛. 米 定位轴的实际位置通过限位开关 精密导电塑料电位器或绝对值编码器来反馈 定位控制器是集电机 齿轮箱 传感器及电子控制器于一体的精密部件, 价格极具竞争力 Except her standard products, we also offer different kind of customized types. In many cases, the applications are very special. Together with our customer, we analysis the request, discuss with them and offer the right solution. 除标准产品外, 我们同时提供各种客户定制化产品 很多情况下, 客户的应用是较特殊的 与客户一起, 我们分析其需求, 与其讨论, 最后提供合理的解决方案 Furthermore, lots of accessories for cabling are listed for our customer s convenience. This provides an easy, fast and safe solution for on-site commission. 另外, 便于客户方便, 目录中还可找到线缆附件部分 这些线缆提供现场的简单 高效及安全的解决方案 8

9 Enginesound AC synchronous motor S series 擎声交流同步电机 S 序列 Technical specifications 技术概述 Housing 端盖 Sleeve bearing 滑动轴承 3 Stator coil 定子线圈绕组 4 Claw poles 爪极 5 Permanent magnet 永磁体 6 Turning shaft 转轴 AC Single phase capacitor run 单相交流电, 电容运行 Permanent magnet 永磁体磁钢 No electromagnetic interference 无电磁干扰 Different operation voltage 不同电压等级 (24/115/230VAC) Different capacitor for different voltage 根据电压不同配置不同电容 Rated torque from 240g.cm to 1200g.cm 额定扭矩范围 240g.cm 1200g.cm Low temperature rise within 40K 温升低 (<40K) Long term stall operation 长期堵转也不会烧电机 High standstill torque while power off 断电静止保持力矩大 Fast startup within 50ms 启动快 (50 毫秒以内 ) Three size available 35/42/58mm 三种不同尺寸 35/42/58mm Compact structure and small size 结构紧凑, 尺寸小 Cost-effective and suitable for mass production 性价比高, 适合大批量生产 Rated speed 转速 Different rated speed 不同额定转速 (300/375/500rpm@50Hz) Constant speed 恒定转速 Reversible operation 正 / 反转运行 Frequent start & stop, forward & backward 可频繁起动 / 停止, 正 / 反转 Only power switch to the coiler is necessary for reversible operation 正 / 反转运行时只需切换供电线圈 9

10 Enginesound brushed DC motor R series / 擎声有刷直流电机 R 序列 Technical specifications 技术概述 Flange 法兰 2 Permanent magnet 永磁体 3 Housing (magnetic return) 外壳 ( 磁回路 ) 4 Shaft 轴 5 Winding 绕组 6 Commutation plate 换向盘 7 Commutator 换向器 8 Graphite brushes 电刷 9 Cover 端盖 10 Electrical connection 接线端 子 11 Ball bearing 滚珠轴承 No magnetic cogging 无齿槽效应 Low rotor inertia and good acceleration characteristics 转子惯量小, 加速特性好 Less electromagnetic interference 电磁干扰小 Low inductance 电感量小 Mechanical commutation with graphite or metal brush 石墨或金属电刷, 机械换向器 High efficiency up to 90% 效率高达 90% Linear voltage/speed curve 线性电压 / 转速曲线 Linear torque/speed curve 线性负载 / 转速曲线 Linear torque/current curve 线性负载 / 电流曲线 Small torque fluctuation due to multi segment 换向片数多, 转矩波动小 Short time overload 可短时过载 Compact structure and small size 结构紧凑, 尺寸小 Easily combined with other gearboxes and encoders 可与多种齿轮箱及编码器配合使用 Turning speed 转速 The optimal operating speeds are between 4000 rpm and 9000 rpm depending on the motor size. Speeds of more than 20,000 rpm have been attained with some special versions. A physical property of a DC motor is that, at a constant voltage, the speed is reduced with increasing loads. A good adaptation to the desired conditions is possible thanks to a variety of winding variants. At lower speeds, a gear combination is often more favorable than a slowly turning motor. 电机的最佳工作转速是在 4000rpm 9000rpm 之间, 取决于电机的尺寸大小 某些特殊型号的电机可达到 20,000rpm 以上的转速 直流电机的物理特性在于 : 在固定的电压下, 转速随着负载的增加而减小 10

11 可选择的多种绕组使得电机能很好地适应多种应用场合 在低转速应用场合, 与减速箱的组合使用要比 直接使用低速电机更有利 Winding / 绕组 Coreless motor winding 空心杯电机绕组 The heart of DC motor is the ironless winding. The motor principle has specific advantages. There is no magnetic detent, minimal electromagnetic interference, very high efficiency up to 90%. 直流电机的核心在于其空心杯绕组, 这种电机具有独特的优点 : 无齿槽, 电磁干扰小, 效率高达 90% Each motor has a different winding such as wire diameter and number of turns. This results in various terminal resistances. Thick wire winding has few turns and resistance, higher starting current and speed constants. Thin wire winding has more turns and resistance, lower starting current and speed constant. 每种电机都有不同的绕组规格, 它们具有不同的线径和匝数, 因此具有不同的引线端电阻 线径越粗, 绕组匝数少, 引线端电阻小, 电机的起动电流大, 速度常数大 ; 线径越细, 绕组匝数多, 引线端电阻大, 电机的起动电流小, 速度常数小 Service time 寿命 A general statement about service life cannot be made due to many influencing factors. Service life can vary between more than 20,000 hours under favorable conditions, and less than 100 hours under extreme conditions (in rare cases). Roughly 1000 to 3000 hours are attained with average requirements. 由于多种因数的影响, 对于电机的工作寿命, 很难给出一个通用的说明 良好状态下, 电机的工作寿命可达 20,000 小时, 而在极端条件下低于 100 小时 ( 这种情形非常少见 ) 平均工作寿命大约在 1,000 3,000 小时之间 The following have an influence: 1. The electric load: higher current loads result in greater electric wear. Therefore, it may be advisable to select a somewhat stronger motor for certain applications. 11

12 2. Speed: the higher the speed, the greater the mechanical wear. 3. Type of operation: extreme start/stop, left/right operation leads to a reduction in service life. 4. Environmental influences: temperature, humidity, vibration, type of installation, etc. 5. Combinations of graphite brushes and ball bearings lead to a long service life, even under extreme conditions. 影响工作寿命的因数 : 1. 电气负载 : 负载电流越大, 电气磨损越大 对于一个特定的应用, 选择出力大一点的电机可能更合理 2. 转速 : 转速越高, 机械磨损越大 3. 工作状态 : 频繁起动 / 停止, 正 / 反转会缩短寿命 4. 环境因数 : 温度 适度 振动及安装方式等等 5. 采用石墨电刷和滚珠轴承的组合, 有利于延长电机的寿命 12

13 Enginesound brushless DC motor E series 擎声无刷直流电机 E 序列 Technical specifications 技术概述 Flange 法兰 2 Housing 外壳 3 Laminated steel stack 磁轭 4 Winding 绕组 5 Permanent magnet 磁钢 6 Shaft 电机轴 7 Balancing disks 平衡环 8 Print with Hall sensors 霍尔 传感器印制板 9 Ball bearing 滚珠轴承 Long service life 工作寿命长 Highly efficient 效率高 Linear motor characteristics, excellent control properties 电机特性为线性, 控制性能极佳 Ironless winding with three phases in the stator 定子三相绕组为无槽 ( 空心杯 ) 绕组 Lowest electrical time constant and low inductance 电气时间常数小, 电感量低 No detent 无齿槽效应 Robust design 结构坚固 Good heat dissipation, high overload capacity 散热特性好, 过载能力强 Rotating Neodymium permanent magnet with 1 or 2 pole pairs 转子采用 NdFeB 磁钢,1 或 2 对极 Very high speed up to 20,000rpm 转速高达 20,000rpm Integrated Hall sensors 内置霍尔传感器 Bearings and service life 轴承及工作寿命 The long service life of the brushless design can only be properly exploited by using preloaded ball bearings. 无刷直流电机的长工作寿命只有在恰当地采用预载滚珠轴承的情况下才能得到充分利用 Bearings designed for tens of thousands of hours 轴承可工作几万小时 Service life is affected by maximum speed, residual unbalance and bearing load 工作寿命要受到最 大转速 剩余不平衡量和轴承预载的影响 13

14 Electronica commutation 电子换向 Block commutation 方波换向 Rotor position is reported by three in-built Hall sensors. The Hall sensors arranged offset by 120 provide six different signal combinations per revolution. The three partial windings are now supplied in six different conducting phases in accordance with the sensor information. The current and voltage curves are block-shaped. The switching position of each electronic commutation is offset by 30 from the respective torque maximum. 电机转子位置的检测是有安装在电机内部的三个霍尔传感器完成的 按照彼此之间相差 120 的 3 个霍尔传感器能在每一转中提供 6 种不同的信号组合 根据传感器的状态, 三相绕组可有 6 种不同的导通状态 电流和电压曲线为方波形 电子换向器的换向位置与每个最大转矩位置相差 30 Properties of block commutation 方波换向的特点 Relatively simple and favorably priced electronics 相对简单, 控制器价格合理 Torque ripple of 14% 转矩波动 14% Controlled motor start-up 电机起动可控 High starting torques and accelerations possible 可提供高起动转矩和加速度 Possible applications 应用场合 Highly dynamic servo drives 高动态性的伺服系统 Start/stop operation 起停控制 Positioning tasks 定位系统 14

15 Sensorless block commutation 无传感器方波换向 The rotor position is determined using the progression of the induced voltage. The electronics evaluate the zero crossing of the induced voltage (EMF) and commute the motor current after a speed dependent pause (30 after EMF zero crossing). 电机转子位置是通过检测感应反电动势来确定的 控制器电子电路估算出感应反电动势 (EMF) 的过零值, 经过一个由电机转速决定的延时后进行的电流换向 (EMF 过零后延时 30 ) The amplitude of the induced voltage is dependent on the speed. When stalled or at low speed, the voltage signal is too small and the zero crossing cannot be detected precisely. This is why special algorithms are required for starting (similar to stepper motor control). To allow BLDC motors to be commuted without sensors in a Δ arrangement, a virtual star point is usually created in the electronics. 感应反电动势的幅值与电机转速有关 在堵转和低速时, 反电动势信号电压太小, 不能确切的检测到过零点 因此, 在起动时需要采用特殊的算法 ( 类似于步进电机的控制 ) 为了能使绕组为三角形接法的无刷直流电机实现无传感器换向, 需要在电子线路中增加一个虚拟的星形连接中性点 1 星形接法中性点 2 时间延时 30 3 EMF 过零点 Properties of sensorless commutation 无传感器换向的特点 Torque ripple of 14% (block commutation) 转矩波动 14%( 方波换向 ) No defined start-up 起动过程不确定 Not suitable for low speeds 不适合低速运行 Not suitable for dynamic applications 不适合高动态性的场合 Possible applications 应用场合 Continuous operation at higher speeds 高速连续运行 Fans 风机 15

16 Sinusoidal commutation 正弦波换向 The high resolution signals from the encoder or resolver are used for generating sine-shape motor currents in the electronics. The currents through the three motor windings are related to the rotor position and are shifted at each phase by 120 degrees (sinusoidal commutation). This results in the very smooth, precise running of the motor and, in a very precise, high quality control. 电子控制器利用编码器或旋转变压器产生的高分辨率信号, 在电机绕组中产生正弦波电流 电机三个绕组中的电流取决于转子的位置 这使得电机的旋转非常平稳和精确, 可实现非常高精度 高质量的控制 Properties of sinusoidal commutation 正弦波换向的特点 More expensive electronics 电子控制器比较昂贵 No torque ripple 无转矩脉动 Very smooth running, even at very low speeds 运行非常平稳, 甚至是在非常低的转速下 Approx. 5% more continuous torque compared to block commutation 比方波换向可增加大约 5% 的连续转矩 Possible applications 应用场合 Highly dynamic servo drives 高动态性能的伺服系统 Positioning tasks 定位系统 16

17 Hall sensor circuit 霍尔传感器电路 The open collector output of Hall sensors does not normally have its own pull-up resistance, as this is integral in the controllers. 霍尔传感器的集电极开路输出电路通常不自带上拉电阻, 而是集成在控制器中 The power consumption of a Hall sensor is typically 4 ma (for output of Hall sensor = HI ). 霍尔传感器的耗电通常在 4mA( 当霍尔传感器的输出为高电平时 ) 17

18 Encoders 编码器 enginesound offers a series of encoders which can be used to determine the position of the rotor of DC motor. Their characteristics are: 擎声可提供一系列的编码器, 用于确定转子轴的位置 它们的特性如下 : Optical incremental encoder 光电增量式编码器 In the optical principle of the light barrier an LED sends light through a finely resolved impulse disc, which is mounted on the motor shaft. The receiver (photo transistor) changes light/dark signals into corresponding electrical impulses that are amplified and processed in the electronics. 光电增量式编码器通过 LED 发出的光透过一个牢固安装在电机轴上的码盘, 接收光电二极管把明暗交替的变化转换成相应的电子脉冲信号, 并在电子控制电路中进行放大后处理 Relative position signal suitable for positioning tasks 提供相对位置信号, 适合于定位应用场合 Rotation direction recognition 可判定旋转方向 Speed information from number of pulses per time unit 利用单位时间里检测的脉冲数来计算转速 Resolution from 256 to 4096 ppr 分辨率 线可选 Maximum turning speed up to 12,000rpm 最高转速 12,000rpm Wide temperature range: -20 C +85 C 宽温度范围 :-20 C +85 C Standard solution for many applications 对许多场合来说是标准的解决方案 Reference return must be performed since actual position not stored 不存储控制位置, 断电重启后需执行回参考点 Magnetic encoder 磁性编码器 This is a contactless magnetic angle encoder for accurate measurement up to 360. It is a system-on- chip, combining integrated Hall elements, analog front end and digital signal processing in a single device. To measure the angle, simply put one rotating bipolar magnet above or below the chip center. 18

19 这是一种无接触式磁旋转编码器, 用于精确测量整个 360 范围内的角度 此产品是一个片上系统, 在单 个封装内整合了集成式 Hall 元件 模拟前端和数据信号处理功能 要测量角度时, 只需简单地在芯片中 心的上方或下方放置 1 个旋转双极磁铁即可 Complete system-on-chip solution 完整的片上系统 Flexible solution provides absolute output, both digital and analog 灵活的系统解决方案, 同时提供绝对值串行输出和 PWM 输出 Angle measurement with software programmable range up to 软件支持的角度测量 High reliability due to non-contact magnetic sensing, ideal for applications in harsh environments 由于采用无接触式位置检测原理, 十分适合于苛刻环境下的应用 Robust system, tolerant to magnet misalignment, air gap variations, temperature variations and external magnetic fields 鲁棒系统, 耐磁体失准, 气隙的变化, 温度变化和外部磁场 Resolution depends on maximum turning speed 分辨率受最高转速影响 Total nonlinearity error less than ±1.4 非线性低于 ±1.4 Wide temperature range: -40 C +125 C 宽温度范围 :-40 C +125 C No calibration required 无需校准 Optimized for cost effective applications 适合于低成本的应用 Resolver 旋转变压器 The resolver is mounted on the motor s through shaft and adjusted according to the magnetic field of the motor rotor. The resolver has a rotating primary coil (rotor) and two secondary coils (stator) which are wound in an orthogonal relationship to each other. An alternating current connected to the primary coil is transferred to the two secondary coils. The amplitudes of the secondary voltages are sin θ and cos θ, where θ is the rotation angle. 旋转变压器安装在电机轴上, 可根据电机转子的磁场进行调节安装位置 旋转变压器有一个初级线圈 ( 转子 ) 和两个次级线圈 ( 在定子上, 两者空间上相互正交 ) 加在初级线圈上的交变电流被感应到两个次级线圈上, 两个次级线圈上输出的电压信号幅值分别是 sin θ 和 cos θ,θ 是转子的旋转角度 19

20 Working princple of Resolver 旋转变压器工作原理 Mathematics converter 数学变换 Analog rotor position signal 输出转子位置的模拟量信号 Analog speed signal via mathematics convertion 通过变换可得出转子转速的模拟量信号 Extensive evaluation electronics required in the control system 控制系统中需解码电路 For special solutions in conjunction with sinusoidal commutation in EC motors 适合无刷直流电机的正弦波换向 Appropriate for use in the strong vibration, high impact and / or extreme temperature environments 适合在高振动 大冲击负载和 / 或极端温度等恶劣环境中使用 Robust and reliable, for industrial use 坚固可靠, 适用于工业应用 Long service life due to no mechanical wear 寿命长, 无机械磨损 Maximum turning speed up to 20,000rpm 最高转速 20,000rpm Wide temperature range: -55 C +155 C 宽温度范围 :-55 C +155 C No sensitive electronics 没有敏感电子器件 Output signal can be transmitted over long distances without problems 输出信号可长距离传输 20

21 Absolute encoder 绝对值编码器 Unlike an optical incremental encoder which has only 2 channels A/B (or 3 plus I ), an absolute encoder has n channels (called as n bits) and the resolving capability is 2 n discrete angles. Since the absolute shaft angle information is available at all times due to the finely arranged code-wheel, this encoder type does not require that the position angle be initialized after power on. 与光电增量式编码器只有 2 个通道 A/B 相 ( 或加 I 相 3 通道 ) 不同, 绝对值编码器有 n 个通道 ( 通常叫 n 位 ), 并有 2 n 离散角度位置 由于有特殊排列的码盘, 轴的角度位置信息始终是可知的, 这种类型的编码器使用时不需要上电初始化找零位 For single turn absolute encoder, the absolute position information will be repeated each turn. By using mechanical gear transmission principle, the position information is still unique each turn. This extends the scope of application of absolute encoders. 使用单圈绝对值编码器时, 每转一圈都会重复绝对位置信息 多圈绝对值编码器利用机械齿轮传动原理, 可将多圈分开, 从而扩大了应用范围 Absolute position signal suitable for positioning tasks 提供绝对值位置信号, 适合于定位应用场合 Serial data interface for output position signal 输出位置信号为串行数据接口 High resolution up to 17 bits (single turn) 数据分辨率高达 17 位 ( 单圈 ) Maximum turning speed up to 12,000rpm 最高转速 12,000rpm Wide temperature range: -20 C +85 C 宽温度范围 :-20 C +85 C Reference return is not necessary since actual position is available all the time 当前位置信号即时读取, 断电重启后不需执行回参考点 High cost 成本高 21

22 Enginesound motor controllers 擎声电机控制器 Technical specifications 技术概述 enginesound motor controller contains speed control, position control and torque control for different applications. 擎声电机控制器包括速度控制 位置控制以及扭矩控制, 用于不同的场合 Speed control 速度控制 The function of a speed controller (or called as servo amplifier) is to keep the prescribed motor speed constant and independent of load changes. To achieve this, the set value (desired speed) is continuously compared with the actual value (actual speed) in the control electronics of the controller. The control difference determined in this way is used by the controller to regulate the power stage of the servo amplifier in such a manner that the motor reduces the control difference. This represents a closed speed regulating circuit. 速度控制器 ( 或伺服放大器 ) 的作用是使电机保持给定的速度, 而且不受负载变化的影响 在控制器内部, 设定值 ( 给定速度 ) 不断地和实际值 ( 实际速度 ) 相比较, 通过比较得到的偏差来调节伺服放大器的功率输出, 通过这种方式减小控制误差 这是一种速度闭环调节 22

23 Position control 位置控制 The positioning control ensures a match between the currently measured position with a target position, by providing the motor with the corresponding correction values, as with a speed controller. The position data are usually obtained from a digital encoder. 位置控制器不断进行当前实际位置与目标位置之间的偏差比较, 并将相应的修正值传递给电机, 这与速度控制器相同 实际位置信号通常来自数字编码器 Current control 电流控制 The current control provides the motor with a current proportional to the set value. Accordingly, the motor torque changes proportionally to the set value. The current controller also improves the dynamics of a superior positioning or speed control circuit. 电流控制器提供给电机一个和设定值成比例的电流 相应地, 电机输出转矩也随着设定值成比例地改变 电流控制器改善了位置环或速度环的动态特性 IxR compensation IxR 补偿 The motor is provided with a voltage that is proportional to the applied speed set value. The speed would drop with increasing motor load. The compensation circuitry increases the output voltage with increasing motor current. The compensation must be adjusted to the terminal resistance of the motor which depends on temperature and load. The attainable speed precision of such a system is subject to limits in the percent range. 施加到电机上的电压与速度设定值成正比例 当电机负载增大时, 电机转速会降低, 而电流会增大 通过补偿电路增大施加到电机上的电压 补偿必须按照电机的端电阻来进行调节, 而电机的电阻会随温度和负载的变化而变化 Favorably priced and space-saving 成本低, 占用空间小 No tacho-generator or encoder required 不需要测速机或编码器 Less precise control when there is a load change 负载有变化时控制精度不高 Only analog speed control possible 仅有模拟式速度控制 Ideal for low-cost applications without high demands on speed accuracy 当速度控制精度要求不高时, 是一个理想的低成本控制方案 23

24 Operation quadrants 工作象限 4-Q operation 4 象限运行 Controlled motor operation and braking operation in both rotation directions 控制电机实现正反两个方向上的电动和制动功能 A must for positioning tasks 位置伺服系统所必需 1-Q operation 1 象限运行 Only motor operation (Quadrant I or Quadrant III) 仅使电机运转 ( 象限 I 或象限 III) Direction reverse via digital signal 通过数字信号改变旋转方向 Typical: amplifier for EC motors 典型的 EC 电机放大器 Set value specification 设定值特性 Servo controllers (speed and current controllers) are usually designed for analog specification of set values. Alternatively, PWM signals or fixed set values are also possible. In the case of position controllers (motion controllers), the set values are usually specified by means of digital commands that are transmitted to the controller using a field bus telegram (e.g. RS485, CANopen). 伺服控制器 ( 速度或电流控制器 ) 通常用模拟量信号来给定设定值 除此之外, 也可用 PWM 信号或固定的设定值 在位置控制器 ( 运动控制器 ) 中, 设定值通常是利用现场总线 ( 比如 RS485,CANopen) 以数字指令的形式发送到控制器 24

25 Notes of DC motor 关于直流电机的说明 The motor as an energy converter 电机中的能量转换 The electrical motor converts electrical power P el (current I mot and voltage U mot ) into mechanical power P mech (speed n and torque M). The losses that arise are divided into frictional losses, attributable to P mech and in Joule power losses P J of the winding (resistance R). Iron losses do not occur in the coreless DC motors. In EC motors, they are treated formally like an additional friction torque. The power balance can therefore be formulated as: 电机将电能 P el ( 电流 I mot 与电压 U mot ) 转化为机械能 P mech ( 转速 n 和转矩 M) 其中损耗可分为摩擦损耗 机械功耗 P mech 和绕组中的焦耳热损耗 P J ( 由电机绕组中的电阻 R 引起 ) 对于有刷直流电机来说, 是没有铁耗的 而对于无刷直流电机来说, 铁耗可以看成是一种附加摩擦转矩引起的损耗 因此, 根据能量守恒定律, 可得出 : P el = P mech + P J The detailed result is as follows 更详细地, 也可描述为 : U mot I mot = P mech = M n 9550 π n M + R I 2 mot Electromechanical motor constants 电机的电机常数 The geometric arrangement of the magnetic circuit and winding defines in detail how the motor converts the electrical input power (current, voltage) into mechanical output power (speed, torque). Two important characteristic values of this energy conversion are the speed constant k n and the torque constant k M. 电机中磁路和绕组的几何分布决定了电机如何将电能 ( 电流 电压 ) 转换为机械能 ( 转速 转矩 ) 在这 个能量转换过程中, 有两个参数是至关重要的, 它们是速度常数 k n 和转矩常数 k M The speed constant combines the speed n with the voltage induced in the winding U ind (= EMF). Uind is proportional to the speed; the following applies: 速度常数 k n 是指电机转速和绕组反电动势 U ind (EMF) 之间的关系,U ind 和转速 n 成正比关系 : n = k n U ind Similarly, the torque constant links the mechanical torque M with the electrical current I mot. 类似地, 转矩常数把机械转矩 M 和电流 I mot 联系起来 : M = k M I mot The main point of this proportionality is that torque and current are equivalent for the DC motor. The current axis in the motor diagrams is therefore shown as parallel to the torque axis as well. 这个比例关系的要点 : 对于直流电机来说, 转矩和电流是等同的 因此, 在电机的工作图表中, 电流坐 标轴和转矩坐标轴是平行的 Speed constant k n and torque constant k M are not independent of one another. The following applies: 速度常数和转矩常数并非不相关, 它们之间有如下关系 : k n k M = π 25

26 Motor diagrams 电机的特性曲线 A diagram can be drawn for every DC and EC motor, from which key motor data can be taken. Although tolerances and temperature influences are not taken into consideration, the values are sufficient for a first estimation in most applications. 所有的 DC 电机和 EC 电机而言, 都可以给出它们的特性曲线图, 通过该曲线可以得到电机的关键数据 尽管在曲线图中没有考虑公差和温度等因素的影响, 但是对于大多数应用中电机的初步选型来说, 这些数据已是足够的 In the diagram, speed n, current I mot, power output P 2 and efficiency η are applied as a function of torque M at constant voltage U mot. 在特性曲线中,n 为转速,I mot 为电流,P 2 为输出功率,η 为效率,M 为转矩 在恒定的电压 U mot 下, 以上数据可以看成是转矩 M 的函数 Speed-torque line 速度 - 转矩曲线 This curve describes the mechanical behavior of the motor at a constant voltage U mot : 这一曲线描述了在一个恒定电压下电机的机械特性 : Speed decreases linearly with increasing torque. 转速随着转矩的增大而线性降低 The faster the motor turns the less torque it can provide. 电机的转速越高, 所能提供的转矩就越小 The curve can be described with the help of the two end points, no-load speed n 0 and stall torque M H. DC motors can be operated at any voltage. No-load speed and stall torque change proportionally to the applied voltage. This is equivalent to a parallel shift of the speed-torque line in the diagram. Between the no-load speed and voltage, the following proportionality applies in good approximation: 该曲线可以由两点给出 : 空载转速 n 0 和堵转转矩 M H DC 电机可以运行在允许范围内的任何电压下, 空 载转速与堵转转矩随着给定电压的变化而线性改变 这就相当于转速 - 转矩曲线在特性曲线图上平移 空 载转速和电压有如下关系 : n 0 k n U mot where k n is the speed constant. 式中 k n 为速度常数 Independent of the voltage, the speed-torque line is described most practically by the slope or gradient of the curve. 实际上, 转速 - 转矩曲线是用斜率来描述的, 它与施加到电机上的电压无关 The speed-torque gradient is one of the most informative pieces of data and allows direct comparison between different motors. The smaller the speed-torque gradient, the less sensitive the speed reacts to torque (load) changes and the stronger the motor. 转速 - 转矩曲线斜率是反映电机性能的最重要参数 之一, 可以用来直接比较不同的电机 转速 - 转矩曲 线斜率越小, 转矩变化对转速的影响就越小, 电机 的出力就越大 n M = n 0 M H 26

27 Derivation of the speed-torque line 转速 - 转矩曲线的推导 The following occurs if one replaces current I mot with torque M using the torque constant k M in the detailed power balance: 如果用转矩 M 和转矩常数 k M 来表示电流 I mot, 可得出如下关系式 : U mot M k M = π n M + R ( M 2 ) k M Transformed and taking account of the close relationship of k M and k n, an equation is produced of a straight line between speed n and torque M. 考虑到 k M 和 k n 之间的关系, 上式可转换成一个反映转速 n 和转矩 M 之间的一个线性方程 : R n = k n U mot π 2 k M M or with the gradient and the no-load speed n 0 或者可以用转速 - 转矩曲线斜率和空载转速来表示 n = n 0 n M M Current gradient 电流曲线 The equivalence of current to torque is shown by an axis parallel to the torque: more current flowing through the motor produces more torque. The current scale is determined by the two points no-load current I 0 and starting current I A. 电流和转矩是等效的, 电流轴平行于转矩轴 电机电流越大, 电机的输出转矩就越大 电流曲线可通过两点来确定 : 空载电流 I 0 和堵转电流 I A The no-load current is equivalent to the friction torque M R, which describes the internal friction in the bearings and commutation system. 空载电流可等效为摩擦转矩, 反映了电机内部轴承和换向器上的摩擦力 M R = k M I 0 In the EC motor, there are strong, speed dependent iron losses in the stator iron stack instead of friction losses in the commutation system. 对于 EC 电机, 和有刷电机存在换向器摩擦转矩的情形不同, 在定子铁芯中存在着和转速有关的铁耗 The motors develop the highest torque when starting. It is many times greater than the normal operating torque, so the current uptake is the greatest as well. The following applies for the stall torque M H and starting current I A. 电机起动时的转矩最大, 是额定工作转矩的好多倍, 此时的电流也是最大的 下式说明了堵转转矩 M H 和起动电流 I A 之间的关系 : M H = k M I A 27

28 Efficiency curve 效率曲线 The efficiency η describes the relationship of mechanical power delivered to electrical power consumed. 效率 η 说明了在电能 - 机械能转换过程中的能量损耗 η = One can see that at constant applied voltage U and due to the proportionality of torque and current, the efficiency increases with increasing speed (decreasing torque). At low torques, friction losses become increasingly significant and efficiency rapidly approaches zero. 可以看出, 在给定的电压下, 因为电流和转矩之间 的比例关系, 当转速增加 ( 相应地, 转矩在降低 ) 时效率也在增加 但是在低转矩区域, 摩擦转矩所 占的地位愈加显著, 效率急剧下降到零 π n (M M R ) U mot I mot Maximum efficiency η max is calculated using the starting current and no-load current and is dependent on voltage. 最大效率可以用起动电流和空载电流计算出来 当然, 效率还与施加到电机上大电压有关 2 η max = (1 I 0 R ) 100 U mot Maximum efficiency and maximum output power do not occur at the same torque. 电机的最大效率点和最大输出功率点不会发生在同一个转矩点上 Rated working point 额定工作点 The rated working point is an ideal working point for the motor and derives from operation at nominal voltage U N and nominal current I N. The nominal torque M N produced in this working point follows from the equivalence of torque and current. 额定工作点是指电机工作在额定电压 U N 和额定电流 I N 下的理想工作点 工作点上的额定转矩 M N 可以从电流和转矩的对应关系得到 : M N k M (I N I 0 ) Nominal speed n N is reached in line with the speed gradient. The choice of nominal voltage follows from considerations of where the maximum no-load speed should be. The nominal current derives from the motor s thermally maximum permissible continuous current. 额定转速可由转速 - 转矩曲线的斜率得到 额定电压的选择应考虑到电机的最大空载转速 额定电流是电机发热限制规定所允许的最大连续电流 28

29 Motor diagrams, operating ranges 电机工作图表, 允许范围 The catalogue contains a diagram of every DC and EC motor type that shows the operating ranges of the different winding types using a typical motor. 在样本中, 对于每一种 DC 和 EC 电机, 提供了一个电机工作图, 以一典型的电机型号为例, 说明了同一型号不同绕组电机的运行范围 Permanent operating range 连续运行范围 The two criteria maximum continuous torque and maximum permissible speed limit the continuous operating range. Operating points within this range are not critical thermally and do not generally cause increased wear of the commutation system. 最大连续转矩 和 最大允许转速 限定了电机可连续运行的范围 电机运行在此范围内的任一工作点上, 不会产生过热, 并且通常也不会加剧换向器的磨损 Short-term operating range 短时工作范围 The motor may only be loaded with the maximum continuous current for thermal reasons. However, temporary higher currents (torques) are allowed. As long as the winding temperature is below the critical value, the winding will not be damaged. Phases with increased currents are time limited. A measure of how long the temporary overload can last is provided by the thermal time constant of the winding. The calculation of the exact overload time is heavily dependent on the motor current and the rotor s starting temperature. 因为发热的原因, 电机只能在最大连续电流下带负载运行 然而, 短时的过流 ( 过载 ) 也是允许的 只要绕组的温度低于危险温度值, 绕组就不会被烧毁 要对短时电流的时间加以限制, 短时电流的持续时间是由绕组的热时间常数决定的 精确的过载时间计算主要取决于电机电流以及开始运行前转子的温度 Maximum continuous current (torque) 最大连续电流 ( 转矩 ) The Jule power losses heat up the winding. The heat produced must be able to dissipate and the maximum rotor temperature should not be exceeded. This results in a maximum continuous current, at which the maximum winding temperature is attained under standard conditions (25 C ambient temperature, no heat dissipation via the flange, free air circulation). Higher motor currents cause excessive winding temperatures. 焦耳功耗会引起绕组温度的升高, 产生的热量必须能够耗散掉, 而且绕组温度也不能超过其最高允许温度 在标准环境 ( 环境温度 25 C, 电机法兰上无散热器, 自然对流 ) 下, 最大连续电流将使绕组温度到达最高允许温度 更大的电流将导致绕组温度过高 29

30 The nominal current is selected so that it corresponds to this maximum permissible constant current. It depends heavily on the winding. These thin wire windings have lower nominal current levels than thick ones. With very low resistive windings, the brush system s capacity can further limit the permissible constant current. 额定电流对应于最大允许电流, 它和绕组有很大关系 细漆包线绕组比粗漆包线绕组的额定电流要小 对于阻值很低的绕组, 电刷系统的电流承受能力进一步限定了最大连续电流 With graphite brush motors, friction losses increase sharply at higher speeds. With EC motors, eddy current losses increase in the return as speed increases and produce additional heat. The maximum permissible continuous current decreases at faster speeds accordingly. 对于石墨刷电机, 高转速时摩擦损耗增加很快 ; 对于 EC 电机, 随着转速的增加, 定子铁芯中的涡轮损耗将增大, 可引起额外的电机发热 因此, 在更高的转速下, 最大允许连续电流会下降 Maximum permissible speed 最高允许转速 The maximum permissible speed for DC motors is primarily limited by the commutation system. The commutator and brushes wear more rapidly at very high speeds. The reasons are: 对于 DC 电机, 电机最大转速主要受到换向器系统的限制 在非常高的转速下, 换向器和电刷的磨损会更大 原因有 : Increased mechanical wear because of the large traveled path of the commutator within a certain period of time 转速高意味着换向器在单位时间内的行程更大, 加剧了机械磨损 Increased electro-erosion because of brush vibration and spark formation 电刷振动和电火花将加快其电腐蚀 A further reason for limiting the speed is the rotor s residual mechanical imbalance which shortens the service life of the bearings. Higher speeds than the limit speed n max are possible. However, they are paid for by a reduced service life expectancy. 电机转速受到限制的另外一个更深层次的原因就是转子的剩余机械不平衡量, 在高速运行下会缩短轴承的寿命 超过极限转速 n max 是允许的, 但是, 这是以牺牲电机的工作寿命为代价的 The maximum permissible speed for the EC motor is calculated based on service life considerations of the ball bearings (at least 20,000 hours) at the maximum residual imbalance and bearing load. EC 电机的最高允许转速是在转子最大剩余机械不平衡量和轴承负荷情况下, 考虑到滚珠轴承的工作寿命 ( 至少 20,000 小时 ) 后经计算得出的 Maximum winding temperature 绕组最高温度 The motor current causes the winding to heat up due to the winding s resistance. To prevent the motor from overheating, this heat must dissipate to the environment via the stator. The coreless winding is the thermally critical point. The maximum rotor temperature must not be exceeded, even temporarily. With graphite brush motors and EC motors which tend to have higher current loads, the maximum rotor temperature is 125 C (in individual cases up to 155 C). Favorable mounting conditions, such as good air circulation or cooling plates, can significantly lower temperatures. 30

31 由于绕组的电阻, 电机电流将引起绕组的发热 为了避免电机过热, 绕组所产生的热量必须通过电子耗散到外部环境中去 空心杯绕组的过热是很危险的, 不允许超过绕组最高允许温度, 甚至是短时过流 EC 电机和石墨刷电机可承受相对高一点的电流, 转子最高温度为 125 C( 个别型号电机可达到 155 C) 如果安装条件良好, 如良好的通风手段或散热器可显著降低绕组的温度 Acceleration 加速过程 In accordance with the electrical boundary conditions (power supply, control, battery), a distinction is principally made between two different starting processes: 按照不同的电气边界条件 ( 电源 控制和电池供电 ), 主要有两种不同的起动过程 : Start at constant voltage (without current limitation) 恒电压起动 ( 不限制电流 ) Start at constant current (with current limitation) 恒电流起动 ( 限制电流 ) Start at constant current 恒电流起动 A current limit always means that the motor can only deliver a limited torque. In the speed-torque diagram, the speed increases on a vertical line with a constant torque. Acceleration is also constant, thus simplifying the calculation. Start at constant current is usually found in applications with servo amplifiers, where acceleration torques are limited by the amplifier s peak current. 限制电流意味着电机只能输出一个有限的转矩 在转速 - 转矩曲线上, 转速的上升是沿着一条垂直于某一恒定转矩的直线, 并且角加速度也是恒定的, 起动过程比较简单 在使用伺服放大器的场合会经常看到这种恒电流的起动方式, 电机的加速转矩会受到放大器峰值电流的限制 Angular acceleration α (in rad/s2) at constant current I or constant torque M with an additional load of inertia J L : / 负载转动惯量为 J L, 恒电流 I( 也即恒转矩 M) 下的角加速度 α( 弧度 / 秒 2) 为 : α = 10 4 k M I mot = 10 4 M J R + J L J R + J L Run-up time Δt (in ms) at a speed change Δn with an additional load inertia J L : / 负载转动惯量为 J L, 电机转速改变 Δn 时的上升时间 Δt( 毫秒 ) 为 : t = π 300 n J R + J L k M I mot Start with constant terminal voltage 恒电压起动 Here, the speed increases from the stall torque along the speed-torque line. The greatest torque and thus the greatest acceleration are effective at the start. The faster the motor turns, the lower the acceleration. The speed increases more slowly. This exponentially flattening increase is described by the mechanical time constant τ m. After this time, the rotor at the free shaft end has attained 63% of the no-load speed. After roughly three mechanical time constants, the rotor has almost reached the no-load speed. 31

32 在此情形下, 从堵转转矩点开始, 转速沿着转速 - 转矩曲线上升 在起始阶段, 电机提供最大的转矩, 角加速度也是最大的 但随着电机转速的上升, 角加速度开始减小, 转速上升也越来越慢 这种指数形式的单调上升可以用机械时间常数 τ m 来表示 到这个时间时, 电机转速将上述到空载转速的 63%, 大约经过三倍的机械时间常数后, 电机几乎到达空载转速 Mechanical time constant τ m (in ms) of the unloaded motor: / 空载电机的机械时间常数 τ m ( 毫秒 ) 为 : τ m = 100 J R R k M 2 Mechanical time constants τ m (in ms) with an additional load inertia J L : / 负载转动惯量为 J L 时的机械 时间常数 τ m ( 毫秒 ) 为 : τ m = 100 J R R 2 (1 + J L ) k M J R Maximum angular acceleration α max (in rad/s 2 ) of the unloaded motor: / 电机空载时的最大角加速度 α max ( 弧度 / 秒 2) 为 : α max = 10 4 M H J R Maximum angular acceleration αmax (in rad/s 2 ) with an additional load inertia JL: / 负载转动惯量为 J L 时的最大角加速度 α max ( 弧度 / 秒 2) 为 : M H α max = 10 4 J R + J L Run-up time (in ms) at constant voltage up to the operating point (M L, n L ): / 恒电压下, 到达工作点 (M L, n L ) 时的上升时间 Δt( 毫秒 ) 为 : (1 M L + M R ) n M 0 t = τ m In { H (1 M } L + M R ) n M 0 n L H Thermal behavior 热特性 The Joule power losses P J in the winding determine heating of the motor. This heat energy must be dissipated via the surfaces of the winding and motor. The increase ΔT W of the winding temperature T W with regard to the ambient temperature arises from heat losses P J and thermal resistances R th1 and R th2. 绕组中的焦耳功耗 P J 引起了电机的发热 这些热量必须通过绕组和定子的表面扩散到环境中去 相对于 环境温度, 绕组温度的温 ΔT W 可以用热损耗 T W 和热阻 R th1 及 R th2 来表示 : T W T U = T W = (R th1 + R th2 ) P J Here, thermal resistance R th1 relates to the heat transfer between the winding and the stator (magnetic return and magnet), whereas R th2 describes the heat transfer from the housing to the environment. Mounting the motor on a heat dissipating chassis noticeably lowers thermal resistance R th2. The values 32

33 specified in the data sheets for thermal resistances and the maximum continuous current was determined in a series of tests, in which the motor was end-mounted onto a vertical plastic plate. The modified thermal resistance R th2 that occurs in a particular application must be determined using original installation and ambient conditions. Thermal resistance R th2 on motors with metal flanges decreases by up to 80% if the motor is coupled to a good heat-conducting (e.g. metallic) retainer. 其中, 热阻 R th1 描述了绕组和定子 ( 指磁钢和磁回路 ) 之间的热交换, 而 R th2 描述了电机外壳和环境之间的热交换 把电机安装到一个散热器上将显著降低热阻 R th2 电机数据表中的热阻和最大连续电流数值是经过一系列的测试后得出的, 电机是安装在一个垂直的塑料盘上 在特定的应用场合, 热阻 R th2 的改变必须通过实际的安装及环境状态来确定 具有金属法兰的电机, 如果安装在良好的导热体上 ( 比如金属 ), 热阻 R th2 可以下降 80% The heating runs at different rates for the winding and stator due to the different masses. After switching on the current, the winding heats up first (with time constants from several seconds to half a minute). The stator reacts much slower, with time constants ranging from 1 to 30 minutes depending on motor size. A thermal balance is gradually established. The temperature difference of the winding compared to the ambient temperature can be determined with the value of the current I (or in intermittent operation with the effective value of the current I = I RMS ). 由于质量的不同, 绕组和定子的温升速率是不同的 通电后, 首先是绕组升温 ( 热时间常数从几秒到半 分钟不等 ), 定子的温升要慢一些, 其热时间常数从 1~30 分钟不等, 取决于电机的尺寸大小 最终, 将达到热平衡状态 绕组和环境之间的温度差值可以用电流 I 来计算 ( 在间歇工作模式下, 可用电流的 有效值 I RMS 来计算 ) T W = (R th1 + R th2 ) 2 R I mot 1 α Cu (R th1 + R th2 ) 2 R I mot Here, electrical resistance R must be applied at the actual ambient temperature. 注意 : 此处 R 的数值必须是实际环境温度下的电阻值 Influence of temperature 温度的影响 An increased motor temperature affects winding resistance and magnetic characteristic values. Winding resistance increases linearly according to the thermal resistance coefficient for copper (α Cu = ): 电机温度的升高将影响绕组的电阻和磁钢的性能 依据铜材料的电阻温度系数 (α Cu = ), 绕组电 阻随着温度的升高而线性增大 : R T = R 25 (1 + α Cu (T 25)) The most important consequence of increased motor temperature is that the speed curve becomes steeper which reduces the stall torque. The changed stall torque can be calculated in first approximation from the voltage and increased winding resistance: 温度升高对电机最重要的影响是转速 - 转矩曲线变得更陡, 堵转转矩变小 变化后的堵转转矩可以通过电 压和绕组的实际电阻大概地估算出来 : M HT = k M I AT = k M U mot R T 33

34 Operation mode 电机工作制 S1: Continuous duty at constant load 恒定负载连 续运行 Starting and electrical brake process does not affect the stator winding temperature rise: 在起动和电气制动不影响定子绕组温升的情况下 : S2: Short-time duty 短时运行对 S2 工作制, 应在代号 S2 后加工作时限, 例如 : S2-60min S3: Intermittent duty 间歇运行 S3 工作制, 应在代号后加负载持续率 例如 : S3-25% S6: continuous duty with intermittent loading 间歇负载连续运行 S6 工作制, 应在代号后加负载持续率 例如 : S6-40% S10: duty with discrete constant loads 带离散恒定负载运行对 S10 工作制, 应在代号后标以相应负载及其持续时间的标称值 Starting and electrical brake process affects the winding temperature rise: 在起动和电气制动影响绕组温升的情况下 : S4: Intermittent duty (starting affects winding temperature) 起动会影响绕组温度的间歇运行对 S4 工作制应在代号后加负载持续率 电动机的转动惯量 Jm 和负载的转动惯量 Jext, 转动惯量均为归算至电动机轴上的数值 34

35 S5: Intermittent duty (starting and brake affects winding temperature) 起动和制动会影响绕组温度的间歇运行对 S5 工作制应在代号后加负载持续率 电动机的转动惯量 Jm 和负载的转动惯量 Jext, 转动惯量均为归算至电动机轴上的数值 S7: Continuous duty with starting and brake process 带起动和制动的连续运行对 S7 工作制, 应在代号后加电动机的转动惯量 Jm 和负载的转动惯量均为归算到电动机轴上的数值 S8: Continuous duty with non-periodic load and speed variations 具有非周期负载和转速变化的 连续运行 S9: Continuous duty with non-periodic load and speed variations 具有非周期负载和转速 变化的连续运行 35

36 Enginesound gears 擎声齿轮箱 Technical specifications 技术概述 Gears 齿轮箱 If mechanical power is required at a high torque and correspondingly reduced speed, an enginesound precision gearbox is recommended. According to the gear ratio the output speed is reduced while the output torque is amplified. For a more precise determination of the torque, efficiency must be taken into consideration for calculation. 如果要获得更大的转矩和相对较低的转速, 推荐使用擎声精密齿轮箱 根据减速比, 输出速度会降低而输出扭矩会变大 为了更精确地确定转矩的大小, 必须考虑效率问题 Conversion 换算 The conversion of speed and torque of the gear output (n L, M L ) to the motor shaft (n mot, M mot ) follows the following equations: 齿轮箱输出轴上的转速和转矩 (n L, M L ) 与电机轴上的转速和转矩 (n mot, M mot ) 的换算遵循以下的公式 : n mot = i. n L where 其中 : i: reduction 减速比 η: Gear efficiency 齿轮箱效率 M mot = M L i. η Gears efficiency 齿轮箱效率 Efficiency of the gears is decided by the gear, lubrication, bearing friction, shaft seals and other factors. 齿轮箱的效率由齿轮 润滑状况 轴承摩擦力以及轴密封件等因素决定 The efficiency of the reducer shown in the catalogue is obtained when the gears are working under rated conditions. 样本上的效率是齿轮箱在满负荷运动情况下, 减速机的传输效率 Service factor f B 服务系数 f B The operation condition is very critical to choose service factor and gear motor type. f Btot is decided according to load classification, start frequency and operation period per day. 运行条件对于服务系数的确定和减速电机的选型来说至关重要 服务系数 f Btot 由负载分级 起动次数以及每天的运行时间来确定的 In the standard operation (i.e. even load, smaller inertia, less starting times), service factor fbtot=1. 在标准运行中 ( 即被带动的负载均匀, 要加速的质量较小, 起动次数较少 ), 可选择服务系数 f Btot =1 For the various operating conditions, service factor can be selected from the table. 36

37 对于各种不同的运行条件, 可从表中选择服务系数 Load classification 负载分级 Acc. coefficient of inertia 惯性加速系数 Driven load 工作负载 I (Mild impact) 0.3 发电机 传送带 起重机 阀门 挡板 轻度冲击负载 II (Moderate impact) 3 机床主传动装置 重型升降机 回转机构 中等冲击负载 III (Heavy impact) 重度冲击负载 10 冲床 离心机 Acceleration coefficient of inertia m AF is calculation according the following formula: 惯性加速系数可用下式来计算 : J mot : J B : J Z : J x : J 2 : n 1 : n 2 : i mot : inertia of motor 电机的转动惯量 inertia of brake 制动器的转动惯量 J x m AF = J mot + J B + J z J x = J 2 ( n 2 2 ) n 1 = J2 2 i mot additional inertia of fan 大惯量的风扇的附加转动惯量 inertia of load (relative to motor shaft) 相对于电机轴的负载传动惯量 inertia of load (relative to output shaft of reducer) 相对于齿轮箱输出轴的转动惯量 input speed of reducer 齿轮箱输入转速 output speed of reducer 齿轮箱输出转速 reducer ratio 速比 Service life 寿命 The gears usually achieve 1,000 to 3,000 (for spur gears) or 20,000 (for planetary gears) operating hours in continuous operation at the maximum permissible load and recommended input speed. The service life is significantly extended if these limits are not pushed. 37

38 在最大允许载荷和推荐的输入转速范围内, 直齿轮箱可连续工作 1,000 到 3,000 小时, 而行星齿轮箱可连续工作高达 20,000 小时 如果不超出这些限制, 齿轮箱的工作寿命将会显著的延长 If the speed drops below this threshold, the gearbox may be loaded with higher torques without compromising the life span. On the other hand, higher speeds and thus higher reduction ratios can be chosen if the torque limits are not fully exploited. We can provide special gears if the standard products can t fulfill the application request. 如果转速低于最高转速, 齿轮箱可以输出更高的转矩, 而对于寿命没有多大影响 另一方面, 如果没有超出转矩极限, 可以选择更高的转速和更大的速比 当标准产品不能满足要求时, 我们也可提供定制齿轮箱 Factors affecting life span include: 影响工作寿命的因数有 : Exceeding maximum torque can lead to excessive wear. 超过最大输出转矩, 加剧机械磨损 Massively exceeding the gear input speed reduces the service life. 大大超出齿轮箱额定输入转速会减少工作寿命 Local temperature peaks in the area of tooth contact can destroy the lubricant. 齿轮啮合接触部位局部温度过高会破坏润滑剂的性能 Radial and axial force on the bearing. 轴承所承受的径向和轴向力 Radial force F r on output shaft refers to the force which is applied to the shaft vertically with axial distance of (x). This force point is as a lever with a bending moment form a lateral force. It can be obtained from the following aspects: 输出轴上的径向力 F r 指垂直作用于轴向的一个力 它的作用点与轴端有一定的轴向距离 (x), 这个 点成一个杠杆点, 横向力形成一个弯挠力矩 可通过以下方式获得 : Output torque T 2 of gear motor 所需减速电机的输出扭矩 T 2 Nominal diameter d 0 of transmission component 所安装的传动部件的平均直径 d 0 Type of transmission component which decides additional coefficient C 传动部件的类型, 决定 了附加系数 C F R = 2000 T 2 d 0 C Generally additional coefficient C value is between 附加系数 C 一般取值 Permissible radial force F r2 is mainly decided by the bearing service time L h10 and intensity. The permissible radial force F r2 in the catalog is determined when the force point is in the middle of the output shaft. Otherwise, the following formulas can be used to calculate actual permissible force. 许用轴向力 F r2 由轴承运行寿命和强度决定的 样本中列出的许用轴向力 F r2 是当力施加在轴伸的中 部, 否则, 实际运行中应根据下式计算许用轴向力 38

39 y F xperm1 = F r2 z + x F xperm2 = a b + x The smaller value between F xperm1 (bearing service time) and F xperm2 (intensity) is the permissible radial force. This calculation is suitable when there is no axial force on the shaft. F xperm1 ( 轴承运行寿命 ) 和 F xperm2 ( 强度 ) 中的较小值就是许用轴向力 这种计算适用于没有轴向 力的情况 The axial force F as is a force parallel to the axis of output shaft. There is an axial offset (I ) between the force point and output shaft end which will form an extra bending moment. When axial force is more than the rated value, a coupling must be used to counteract the bending force. 轴向力 F as 是指平行于轴心的一个力, 它平行于输出轴, 它的作用点与输出轴端有一定的轴向偏 (I ) 时, 会形成一个额外的弯挠力矩 轴向力超过样本所示的额定值时, 须用联轴节来抵消这种弯挠力 Selection of gears 齿轮箱选型 For the selection of the gears, the maximum transmittable power the product of speed and torque is decisive. It should be noted that the transmittable torque depends on the number of gear stages. The load torque should be below the nominal torque (max. continuous torque) of the gears M N,G. 在齿轮箱选型中, 最大传输功率, 也即输出转速和输出转矩的乘积, 是至关重要的 需要指出的是输出 转矩取决于齿轮箱的级数 负载转矩应小于齿轮箱的额定输出转矩 M N,G ( 也即最大连续输出转矩 ) M N,G M L For short-term loading, the short-term torque of the gears must also be considered. Where possible, the input speed of the gear n max,g should not be exceeded. This limits the maximum possible reduction i max at a given operating speed. The following applies to the selection of the reduction i: 对于瞬时负载工况, 还要考虑齿轮箱的瞬时输出转矩 在可能的情况下, 齿轮箱的输入转速都不应超过 最大输入转速 n max,g 对于给定的工作转速, 这限制了最大的减速比 i max 可用下面的公式来选择合适的 减速比 i: i i max = n max,g n L If the gear is selected, the data conversed to the motor axis (n mot, M mot ) are used to select the motor. 齿轮箱选择好后, 利用折算到电机轴上的数据 (n mot, M mot ) 来确定合适的电机 齿轮箱定位精确度 The key to achieve high-speed reciprocating motion precise mechanical positioning is possible to reduce the angular deviation produced by the movement. The positioning accuracy depends on two values, one is a deflection angle of the loading involves the backlash and torsional rigidity, and the other is the deflection angle for motion control, related to the synchronization deviation. 在高速机械往复运动中做到精确定位的关键在于尽量减小通过运动产生的角偏差, 定位精确度取决于两个值, 一个是与加载有关的偏转角, 涉及到回程间隙与扭转刚度, 另一个是与运动控制有关偏转角, 涉及到同步偏差问题 39

40 Backlash j t refers to the maximum deviation angle gearbox output shaft and input. To measuring, fix the input gear first, load a certain torque on the output shaft with a torque meter, in order to overcome the friction reducer inside. 回程间隙 j t 指减速机输出轴与输入端的最大偏差角 测量时先将齿轮输入端固定住, 然后在输出轴用力矩仪加载一定力矩, 以克服减速机内的摩擦力 The torsional stiffness is defined by the ratio of load torque and the torsion angle generated. It shows how much torque needed to rotate the output shaft of an arcmin. Torsional rigidity is derived from the hysteresis curve. C t21 = T φ 扭转刚度由加载力矩和所产生的扭转角之间的比率来定义 它说明需要用多大的力矩才能把输出轴转动 一弧分 扭转刚度是从迟滞曲线得出的 The synchronization deviation refers to the difference between the measured input speed and output speed within one output shaft revolution. This deviation is caused by the gear manufacturing tolerances, resulting in the angle difference and a slight ratio difference. 同步偏差指在输出轴转一圈时所测得的输入转速与输出转速两值的偏差 这种偏差是由齿轮加工容差引起的, 从而导致及微小的角差以及速比差 Hysteresis curve: Hysteresis detection is to draw torsional stiffness reducer, and hysteresis curves obtained by testing. When detection, first fix gear input, and continue to load in both directions of rotation, respectively, to the output of the maximum acceleration torque T 2B, then gradually unloaded, with the instrument recorded imitation of torque angle, the resulting curve is a closed curve, which can calculate the gear backlash (j t ) and torsional stiffness (C t21 ) 迟滞曲线 : 迟滞检测是为了得出减速机的扭转刚度, 通过检测得到迟滞曲线 检测时, 先将减速机输入端固定住, 然后在输出端的两个旋转方向分别持续地加载到 T 2B 最大加速力矩, 继而逐步卸载, 用仪器记录下力矩的仿差角, 得到的曲线是一条闭合曲线, 从中可以计算出减速机的回程间隙 (j t ) 和扭转刚度 (C t21 ) 40

41 Type of gears 齿轮箱类型 Technical specifications 技术概述 Spur gears GS 直齿轮箱 GS Open design spur gears 开放式齿轮设计 Spur gears in an aluminum alloy enclosure 带铝合金壳体的直齿轮 41

42 Other spur gears reducer Spur gear components Spur gear with powder metallurgical techniques 直齿轮采用粉末冶金技术制造 Or spur gears with case-hardened grinding techniques 直齿轮采用硬齿面磨齿制造 Fixed shaft with turning gears internally 内部采用轴固定 齿轮组旋转设计 Or shaft with interference fit fixed gears internally 内部采用轴与齿轮组过盈配合设计 42

43 Sleeve bearing 滑动轴承 Or ball bearing 滚珠轴承 High torque up to 30N.m with low noise lower than 65dB 高扭矩 ( 高达 30N.m), 低噪声 ( 低于 65dB) Ultra-high cost performance 极高性价比 Module based flat design 模块化扁平设计 Parallel input and output shaft 输入 / 输出轴平行设计 Robust structure with closed aluminum enclosure 带封闭铝合金壳体, 结构坚固 Optimized for positioning control system 对定位控制系统进行了优化 Various reduced ratio 速比范围从 39 到 2450 Suitable for mass production 适合大批量生产 Maintenance-free 免维护 1. Planetary gears GP 行星齿轮 GP Planetary gears are very precise and particularly suitable for the transfer of high torques and high speed. The gearbox is normally fitted with ball bearings at gearhead output. 行星齿轮非常精密, 特别适合于传动高扭矩 高转速的场合 此类齿轮箱输出轴一般都配有滚珠轴承 Input flange 输入法兰 Collet locking mechanism 筒夹式锁紧机构 3 Input side ball bearing 输入端滚珠轴承 4 Housing 外壳 5 Planet gears 行星轮 6 Integrated arm and output shaft 一体化臂架与输出轴 7 Output side ball bearing 输出端滚动轴承 8 Output flange 输出法兰 Structure of planetary gear 行星齿轮结构 43

44 External diameter mm 外部直接 30 80mm Reduction ratios of 5:1 to 512:1 速比从 5:1 到 512:1 High torques up to 100 Nm 转矩高达 100Nm High performance in a small space 高性能, 空间占用小 High reduction ratio in a small space 高速比, 空间占用小 Concentric gear input and output 输入轴与输出轴同心 Standard service time 20,000 hours under rated conditions 在额定工况下标准寿命 20,000 小时 High precision with low backlash 高精度, 低背隙 High overload capacity due helical gear design 斜齿轮设计, 高过载能力 Maintenance free 免维护 44

45 Enginesound Positioning Controller 擎声定位控制器 Technical specifications 技术概述 Based on her experience of motors, gears and electronics, enginesound develops, and sales the precise positioning controller which is an integration of motor, gears, sensor and electronic controller. It can be used to control the positioning and auxiliary axes (such as the angle, speed, or linear position of valve, flapper, roller, robotics and any other positioning object). The input signal can be set by analog/ digital or bus system. 基于电机 齿轮及电子器件的经验, 擎声研发 销售精密定位控制器, 它集电机 齿轮箱 传感器以及电子控制部件于一体, 可用来控制阀门 挡板 转辊 机械手以及其他定位对象的角度 速度或线性位置 输入信号可通过数字 / 模拟量或总线系统给定 poscon 10 AC synchronous motor 内置交流同步电机 Spur gears with aluminum enclosure 直齿轮, 带铝合金外壳 Max. output 10Nm 最大输出 10Nm Different positioning angle available 不同定位角度可选 Integrated absolute position sensors 内置绝对位置传感器 Positioning precision: better than ±1.0 定位精度 : 优于 ±1.0 Set value via analog signal 通过模拟量给定设定值 Hysteresis integrated 集成迟滞设计 Output shaft with adjustable collets locking mechanism available 带筒夹式锁紧轴输出可选 Highly robust 高可靠性 IP 54 / IP 64 protection IP 54 / IP 64 防护等级 Easy wiring which reduces labor effort on site 接线简单, 现场安装方便 Low cost 低成本 45

46 poscon 20 DC/EC motor 内置直流电机 Spur gears with aluminum enclosure 直齿轮, 带铝合金外壳 Max. output 30Nm 最大输出 30Nm Different positioning angle available 不同定位角度可选 Integrated absolute position sensors 内置绝对位置传感器 Positioning precision better than ±1.0 定位精度优于 ±1.0 Set value via analog signal or bus system (CANopen, RS-485) 通过模拟量给定设定值或总线 (CANopen, RS-485) 给定设定值 Hysteresis integrated for analog control 集成迟滞设计 Output shaft with adjustable collets locking mechanism available 带筒夹式锁紧轴输出可选 Highly robust 高可靠性 Overload protection 过载保护 IP 54 / IP 64 protection IP 54 / IP 64 防护等级 Easy wiring which reduces labor effort on site 接线简单, 现场安装方便 High cost performance 高性价比 46

47 maxpos 10 EC motor 内置直流无刷电机 High precise planetary gears 高精度行星齿轮 Max. output 100Nm depends on size 根据尺寸不同最大输出 100Nm Suitable for continuous speed or precise positioning control 适用于连续速度调节或精密定位控制 Integrated absolute encoder 内置绝对值编码器 Positioning precision better than ±0.3 定位精度优于 ±0.3 Set value via analog signal or bus system (CANopen, RS-485) 通过模拟量给定设定值或总线 (CANopen, RS-485) 给定设定值 Hysteresis integrated for analog control 集成迟滞设计 Output shaft with lead/ball screw for linear positioning 线性定位输出轴带梯形 / 滚珠丝杆 Highly robust 高可靠性 Overload protection 过载保护 IP 64 protection IP 64 防护等级 Easy wiring which reduces labor effort on site 接线简单, 现场安装方便 High performance 高性能 47