M I N I AT U R E D R I V E S W I T H P R E S S U R E - R E S I S TA N T C A S I N G F O R U S E I N E X - A R E A S
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Clear view for the reactor sight glass
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Parabolic trough demonstrator
University Project Award winner 2010
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New products
Powerful and multi- functional – brushless 4-pole DC-Servomotors series 32 ... BX4
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Spherical vehicle
Intelligent drive technology maintains the balance
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Nano-Shore durometer
Quality control for tiny elastomer finished parts
I S S U E 1 | 2 0 1 0
Material hardness is an important product attribute when parts are manufactured from flexible polymers. One measuring method in this area is Shore A hardness measuring. In this pro- cess, a test piece is pressed onto the material. The smaller the test needle used, the better tiny and ultra-miniature items can be measured. The most important factors here are an exact positioning and an exactly reproducible test sequence.
Only a consistently modifiable test load at the needle tip will enable a secure characterization of the material. Elec- tronically commutated miniature DC-Servomotors are the drive of choice here. With integrated motion controllers and an RS232 interface, they represent an exact mechanical link between measuring computer and test probe.
New Shore testing methods in the nano-range
B R U S H L E S S M I N I AT U R E D R I V E S A L L O W Q U A L I T Y C O N T R O L
F O R T I N Y E L A S T O M E R F I N I S H E D PA RT S
We encounter elastomers, i.e. “rubber-like”
materials, daily. Like other products, one can observe a trend here toward increas- ingly smaller items. Until now, the testing method used in accordance with DIN 53505 was carried out with a comparatively large, conical-shaped needle. Now, Q-TEC GmbH, based in Zeilarn, Germany, has been suc- cessful in geometrically scaling down the physical procedure, thus allowing the meas- urement of both ultra-miniature samples and the precise points of larger product pieces. For the exact positioning and force adjustment of the test probe, miniaturized up to factor of ten, they teamed up with the FAULHABER specialists for ultra-minia- ture drives. The collaboration resulted in a compact measuring device able to im- plement standard specification in minia- turized form.
Measuring hardness
The Shore hardness measuring method is based on purely physical procedures. In order to cover the widest hardness range possible, both the test needle’s geometry and the force progression is preset for the measurement. If the needle only penetrates superficially into the hard elastomer, the penetration force is increased. This allows I N S T R U M E N T A T I O N
soft materials to be measured accurately with a lower penetration force and longer measurement range – and also hard ma- terials with a smaller penetration depth and, simultaneously, higher force at the needle tip. This standard procedure ena- bles the hardness to be determined from a minimum test thickness of 4 to 6 mm with a bearing surface of approximately 18 mm in diameter. Specially manufactured test plates are generally used in this process.
The new measuring procedure is based on the comparative load characteristic of geometrically miniaturized bodies. So the hardness of the test specimens can now be measured with a needle reduced in size by a factor of ten, the point of which corre- sponds approximately to the diameter of a human hair, beginning with thicknesses as low as 0.5 mm. This opens up complete- ly new possibilities. For instance, a range of targeted parameters used in production, including injection velocity, vulcanization temperature or annealing rate, can be varied, in order to arrive at an optimal product result verified in the hardness test.
The standard measuring range of the new devices spans from 10 to 95 Shore A. As the small needle is not prestressed, very soft materials can also be measured with-
out having to switch to other measuring methods. To this end, the measuring range can also be extended to the range of –5 to 100 Shore A.
Precise measuring by miniature drive
In order to pinpoint the particular measur- ing position for ultra-miniature samples with the nano-Shore durometer, devel- opers use a specimen holder with a laser positioning reticle. In this way, regardless of the item’s geometry, the penetration point is defined via the reticle. Measure- ments at different positions such as wave crests or troughs are possible without any problems whatsoever on the top of the protrusion or the base surface. The pro- cedure can also be successfully used for composite materials. Starting from a crosssection of 1 mm², qualified results are assured. Once the laser allows the pre- determined position to be targeted, the vertical measuring movement of the need- le is pinpointed through a miniature servo- motor.
FAULHABER application engineers had to keep several application requirements in mind when selecting the motor: a small design to comply with the compact device measurements, the largely self-powered
operation of the motor to reduce the load on the device electronics, and naturally also a high resolution in positioning mode. For this special case, a DC-Servomotor with inte- grated motion controller proved to be ideal for measuring dimensions of 35 mm in diameter and 83 mm in length. With 50 mNm output torque on the shaft and up to a 90 W power rating, the mechanical system can be positioned without any problems whatsoever. The connected controller pro- vides speed control, precise speed profiles, stepper motor mode and positioning mode.
The latter is of key importance here. With a resolution of up to 1/3,000 revolution and the option of accounting for reference marks and limit switch positions, the drive is able to follow the precise specifications of the measuring instrument electronics.
An RS232 interface enables communica- tion with the external logic. The controller intelligence processes all drive-relevant data internally, thereby reducing the load on the actual electronic measuring equip- ment. What’s more, self-security against overloads and excess voltage as well as an error output are integrated into the drive.
The desired functions such as run programs, speed ramps etc. can be stored in the mo- tion controller.
Modern micro-drive technology is able to match the diversity of its larger technologi- cal brothers in every way. Internal sensor system and controller technology compute drive-relevant data internally within the drive. In this way, developers no longer even have to concern themselves with the actual drive technology. In many cases, this significantly reduces both overall develop- ment costs and the time to market.
www.
q-tec-gmbh.de The compact nano-Shore durometer for
direct measurements on the product
Penetration example on an O-ring
A P P L I K A T I O N X X X X
Things tend to heat up in reactor vessels in the truest sense of word. The medium is thoroughly stirred by agitators, new reagents are streamed in through conduits and the reaction often results in bursting bubbles. All of these events mean that liquids splash in every direction – natural- ly, onto the sight glass as well. In other words, window cleaning is required to maintain a clear view into the vessel.
Wipe-away effect
Spray nozzles are not always suitable for cleaning sight glasses; sometimes it is necessary for the wipers to perform manu- al work. The major disadvantage of this solution is that it requires local operation.
The Lumiglas experts took on this problem and developed a motorized wiper which can also be remote-controlled. This en- ables camera-supported monitoring solu- tions without major personnel expense.
Particularly in process engineering, special attention must frequently be given to the specific potentially explosive atmosphere surrounding the system. All mechanical and electrical components must therefore be designed with protected constructions. In case of window wipers, this necessitates a smooth-running yet gas- tight shaft feedthrough in the reactor. The drive motor must also fulfill the relevant requirements. The same applies to the necessary gearing for increasing torque. As large drives would obscure the view into the relatively small sight glasses, a further requirement is the smallest design possible.
Media which are rough or fibrous to wipe require a high torque on the part of the wiper shaft. These were all requirements which the FAULHABER drive developers needed to take into account when pro- ducing the suitable motor concept.
Pressure-resistant casing
There are several possible ways of realizing an explosion-proof device. The pressurized enclosure Ex p, the oil immersion Ex o or the encapsulation Ex m, among others, are state-of-the-art. As the motor has a colletor E X - P R O T E C T E D M I N I AT U R E D R I V E S A S W I N D O W W I P E R S
E N S U R E A C L E A R V I E W F O R T H E R E A C T O R S I G H T G L A S S
Monitoring
in extreme conditions
Many processes in chemistry, pharmacy and biotechnology are automatically controlled. Nevertheless, a glimpse into what is happening at the reactor is often desired. As many of the reactor vessels are set up in a potentially explosive area, special requirements apply here. Papenmeier GmbH & Co. KG, in its Lumiglas division, specializes in sight glass assemblies. In order to guarantee a clear view for auto- mated equipment such as camera monitoring systems, the cleaning processes for the glass also had to be automated. Window wipers with ex-protected micromotors provide the necessary transparency here.
sible continuous current of 0.5 A, the motor achieves up to 9 watts of shaft power for an ambient temperature of 40 °C. The efficiency factor is over 75%. The small rotor weight of the skew wound permits a high rate of acceleration. Specially adapt- ed attachment planetary gearheads (32 to 63.5 mm in length, 35 mm in diameter) increase the torque to up to 10 Nm. The speed reduction range, depending upon the number of stages (one to five stages) spans from 3.71: 1 to 1,526: 1. Motor and gearing are connected directly in the plant, thereby ensuring the protection class.
Protection against unauthorized heating is achieved by two integrated thermal fuses. For secure operation, only one fuse is necessary; if a disturbance has triggered and brushes, sparks are produced during
operation. Therefore only pressure-resistant casing can be used for ignition protection.
This means that all components which could ignite a spark are embedded into an enclosure that can withstand explosion pressure. The openings of the enclosure are furnished in such a way that outward trans- mission of the explosion is prevented.
The motor casing was developed for the highest possible explosion class IIC (this includes IIA and IIB) and is also authorized for zones 1 and 2. The temperature class is T5, and the highest possible class T6 is available upon request. With the excep- tion of the motor shaft feedthrough (IP 54 in accordance with EN 60529), the motor has been implemented in protection class IP 68.
In motor practice, this means that de- spite the pressure-resistant casing, the motor at a length of 80 mm and diameter of 35 mm is hardly larger than a compa- rable non-ex-protected motor. With a sup- ply voltage of 24 VDC and a maximal pos-
Pressurised motor for use in hazardous area
a fuse, continued operation is possible with the second.
Whether as a protected version for vacuum, compressed air or liquid pumps or as a specially designed drive solution for sophisticated positioning tasks – explosion-proof miniature drives open up a variety of new application fields within the explosion hazardous areas of process engineering.
www.
papenmeier.de
M E C H A T R O N I C S S T U D Y
Project studies open up future perspec- tives and can also inspire people. Nowhere is this truer than in the field of mechatron- ics, which connects three highly dynamic and growing fields offering a vast range of new developments. For this reason, GIGATRONIK Stuttgart GmbH, a medium- sized company specializing in automotive electronics and information technology, sponsored a mechatronics demonstrator as a Bachelor’s thesis. This serves for de- monstration purposes at fairs and recruit- ing days. Complex position control, in combination with fast mechanical im- plementation of the necessary commands, represented a challenge to both devel- opers and the integrated components.
Quick reflexes necessary
Like a human on two legs, a spherical vehicle has an unstable “stance”. It requires continuously active readjustment in order to maintain a position in the room. The pro- cedure must be carried out very quickly, even reflexively – for the faster the reac- tion, the more minor necessary corrections are and the better the stability of the device. In the case presented, a vehicle equipped with electronics, electric motors and rechargeable battery balances on a ball. The dimensions of the vehicle are approximately 30 cm x 30 cm x 15 cm, and it has a net weight of approximately 2.5 kg. Shifts in the center of gravity of the vehicle allow the ball to easily roll along on the surface. Like an artist, the vehicle is forced to balance out these rolling movements through corresponding counter-movements. To this end, a seam- lessly integrated inertial sensor measures acceleration, rotation rates and the force of the earth’s magnet field on the elec- tronic circuit board of the prototype con- troller “GIGABOX gate”.
The actual control is modeled with Simu- link, transferred via a Simulink target by means of autocode generation in C-code and integrated into the controller as a real- time task. From measured data, the soft- ware computes the actual status of the overall system. The system can be seen as
Acrobatic top performance
S P H E R I C A L V E H I C L E W I T H B A L A N C I N G D R I V E M O D U L E A S M E C H AT R O N I C S D E M O N S T R AT O R
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The start of a completely new develop- ment can often be a playful instinct.
In the area of technology, this means that not every feasible project can be implemented in a useful manner, but it will often create basic knowledge for later applications. An example here is the spherical vehicle created for a Bachelor’s thesis. It balances auto- nomously on a hollow mobile ball.
The project shows the possibilities of modern mechatronics, combining sensor technology, rapid data proces- sing and actuators into a functioning unit. Highly dynamic electronically commutated miniature drives also show their true potential here as an interface between electronics and mechanics.
low inertial masses, e.g. on the tip of cantilever arms or robotic arms, are ne- cessary.
Even ostensibly playful functions can contribute to the solution of problems.
Small prototypes that can complete complex tasks in real time, such as here the active balancing on a ball, are cost- effective research objects. Miniature drives with auxiliary modules, such as encoders, gearing and also integrated controllers, enable not only inexpensive implementations for experiments, but are also suitable for use in professional appli- cations. The large combination variety in connection with individual case adapta- tion enables a customized solution for every drive task.
www.
gigatronik.com a three-dimensional, inverse pendulum.
The pitch and roll angle are determined by a position scanner. Two PD controllers pro- vide the necessary pulses for the stabilizing drive. These pulses are then converted by three omnidirectional drive wheels, each offset at 120° in a circle, into mechanical motion relative to the spherical surface.
Highly dynamic and accurate
Only highly compact motor units can be used to drive the wheels. The required dynamics narrow the options to electroni- cally commutated motors. The optimal choice proved to be 20 mm-diameter brushless DC-servomotors with integrated encoder. Diameter-compliant gearing with a speed reduction of 14 : 1 supple- ments the drive package. With it, the small 20-watt drive can supply up to 0.7 Nm for short periods in order to control the position. A toothed belt re- duction further boosts the torque to the wheels. The high efficiency factor on the part of the motor (70%) and gearing (80%) enables the use of smaller re- chargeable batteries. The smaller dimen- sions here improve the vehicle’s quick reactions to position commands. The three drive units are continuously deployed independently from one another, thus converting the control commands into mechanical propulsion.
A further advantage for fast, dynamic corrections is the fact that miniature motors, especially electronically commu- tated variants, are generally able to with- stand considerable overload for short periods of time. Due to the low volume, the heat radiating to the surface is com- paratively high; the thermal capacity of the materials offers a further thermal buffer. The high efficiency of the unit, i.e.
comparatively low power dissipation, enables such a high level of energy trans- fer above the rated output. In connection with the low level of moving mass, this performance virtually predestines the use of EC drives for highly dynamic func- tions. This is particularly the case when small installation spaces and/or very
Y
A brushless motor with encoder and gear- head is the heart of the drive unit
X
T E C H N O L O G Y B X 4
Improved materials, new production methods and smaller electronic components for internal sensor technology are bringing momentum to modern DC-servomotors. Their performance characteristics can be well-adapted to the requirements at hand by varying the magnet material, winding technology or geometrical calibration. In order to use the various possibilities quickly and optimally, a modular concept for the drive confi- guration is a basic prerequisite. A new servomotor range has consistently pushed this development forward, achieving optimum values for performance, energy consump- tion and adaptation to the application requirements.
Higher, faster, further: these objectives also apply to miniature drives. The require- ments for better performance and de- pendability, and, at the same time, more rational manufacturing methods, cannot be achieved through rigorous devel- opment alone. This is the exact strategy pursued with the drive series BX4.
A new motor concept, based on four- pole technology and the use of molded thermosets instead of adhesives for com- ponent assembly, has not only brought success, but also a range of further smaller innovations. Simultaneously, an emphasis was placed on a modular structure for the new BX4 motor generation, allowing customized drives to be assembled quickly and inexpensively as standard compo- nents.
Modular variety
T H E E X T E N S I O N O F T H E 4 - P O L E D R I V E S E R I E S B X 4 O F F E R S M A N Y P O S S I B L E C O M B I N AT I O N S
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Series 22FSeries … IE3 (L) Series … IE3 (L)
Adapter
Series SC 2804 Series 32A
Motion Manager
Serie … SC Series 2232 … Series 2250 … Series 3242 … Series 3268 …
Technical characteristics
In practice, drives should not lose speed under higher loads. So from the very outset, developers placed a firm emphasis on a particularly strict characteristic curve. When applying load, a broad speed range provi- des a high torque; the motor continues to work with only minimal speed loss.
With this goal in mind, the general design of magnet material, winding technology and geometrical calibration was optimized.
Four-pole motors revolve more slowly than their two-pole counterparts. This brings advantages for both the gearhead design and life span.
In order to simplify production, the Schönaich-based specialists have dispensed with all adhesives. A form-locking joining
technology, able to equalize tolerances, was introduced using a transfer molding process with thermosetting plastic. This impregnates the winding on all sides, pro- tecting it both thermally and mechanically.
The new stator structure additionally re- duces eddy current losses in the laminated core. In order to provide the broadest pro- duct range possible, the entire motor con- cept is modular.
Modular system
Currently, motors are available in two versions of 22 and 32 mm diameters. Each has two installation lengths, for a total of four motor sizes. The thermally per- missible continuous torques range from 17 to 97 mNm with a power output of up to 60 W and an efficiency factor of
up to 80%. The permissible temperature range for all the motors lies in a wide range between –40 and +100 °C. Using finely gradated reduction gears, durable metal planetary gearheads with matching diameter allow torque increases at the output shaft and a simultaneous re- duction of speed. The continuous torque ranges from 1,500 mNm for the 22 mm gearheads to 4.5 Nm for the 32 mm version; for short periods, even 6 Nm can be attained. The maintenance-free gearing with lifetime lubrication and robust shaft bearing produce a long life- span, in line with the motor concept.
Customized adaptations of the shaft, flange, cable, etc. – a core competence of FAULHABER – are also possible for the BX4 product range.
GEARHEADSMOTORSENCODERSCONTROLLERSOfTWARE Series 22 … SC Series 32 … SC Series 32 … SCDC Series 32 … CS/CC
T E C H N O L O G Y B X 4
www.
faulhaber.com
Modular practice
In their basic versions, the motors can be integrated as pure drives and con- trolled externally. Motor versions with integrated encoder in the casing are available in four factory-preset adjust- able resolutions of 32, 64, 128 or 256 pulses per revolution plus additional index channel. A line driver version with differential output is also available.
Alternatively, for more demanding tasks, compact versions are also available with integrated motion controller (Cx) or in- tegrated speed controller (SC). The Cx version has been assembled on the basis of proven and tested FAULHABER motion control systems, and its compact design represents a major advantage for many applications. The motors feature an RS232 serial interface and can be parameter- ized with the motion manager software 4. With its dual-wire connection, the new SCDC model is very easy to operate. It can replace a conventional brushed motor, for example, should specific applications
place higher requirements in terms of lifespan. In addition, it is equipped with reverse voltage protection, and the rota- tional direction is preselected by the connector pin assignment. All products with integrated electronics feature the electronic limitation of peak and conti- nuous current, thus protecting the motor and the electronics. If necessary, both motor and electronics can also be opera- ted with separate supply voltages.
The new drives are predestined for applications which rely on a long life- span or a high torque. With integra- ted motion controller, they are also highly suitable for positioning tasks; with integrated speed control, they are perfect for pumps and ventilators. The combi- nation with gearing is ideal, as the low speed increases both gear efficiency and lifespan. The modular structure also ensures a large application variety. In this way, the optimal drive can be quick- ly and inexpensively assembled from the individual components. And the manu- facturer’s longstanding expertise guaran- tees a high-performance solution.
Reliable. Long life.
Brushless 4 Pole DC-Servomotors series 32 … BX4
A long lifespan, a high, non-slip torque and an inno- vative design without adhesive joints are characteristic of FAULHABER brushless 4 pole drive technology.
Supplementing the drives with 22 mm diameter, the BX4 series is now also available with 32 mm diameter and corresponding torque.
3242…BX4 3268…BX4
Diameter [mm] 32 32
Length [mm] 42 68
Rated voltage [V] 12 / 24 24
Continuous torque [mNm] 56 97
Stall torque [mNm] 282 718
Dynamic performance with extremely low gradient of the n/M characteristic curve
For combination with integrated three-channel encoder or speed controller, optionally available as two-wire version
Also available in a version with integrated Motion Controller
Now also with 1 024 pulses
www.
faulhaber.com/newsMagnetische Encoder Serie IE3-256 (L)
Die neuen Inkrementalencoder der Serie IE3-256 (L) mit robustem Gehäuse und einer kompakten Bauform von 22 x 18 mm wurden speziell auf die Kombination mit Motoren der CR- und CXR-Serie und Controllern der Serie SC 2804 oder MCDC 30xx ab gestimmt.
Die Encoder sind standardmäßig in vier werkseitig eingestellten Auflösungen von 32, 64, 128 oder 256 Impulsen verfügbar. Ein zusätzlicher Indexkanal sorgt insbesondere bei anspruchsvollen Positionier aufgaben für eine optimale Ansteue rung. Optional ist das Produkt in einer Linedriver-Version mit Differentialausgang verfügbar.
Modular kombinierbar
New generation of graphite commutated drives
DC-Micromotor series 26 … CXR
High dynamics, longevity and an attractive cost/per- formance ratio make the new generation of graphite commutated DC-micromotors an interesting drive solution for numerous application fields.
Magnetic incremental encoder series IE3-1024
The new encoders of the IE3 series, assembled with single chip technology according to the magnetic principle, are available with 32 up to 1 024 pre-installed pulses.
Customized solutions are available upon request.
Robust casing with compact dimensions of 22 x 18 mm
Modularly combinable with DC-motors from the series CR and CXR as well as Brushless DC-Servomotors from the series BX4
Index channel as standard for improved control in positioning mode
Also available as line driver version with differential output
IE3-1024 (L) Operating voltage [V] 4,5 … 5,5
Channels 2 + Index
Input current [mA] 16 Pulses per revolution 32 … 1024
Speed to [rpm] 28.000
N E W S
2642…CXR 2657…CXR
Diameter [mm] 26 26
Length [mm] 42 57
Rated voltage [V] 12 / 24 / 48 12 / 24 / 48
Continuous torque [mNm] 23 35
Stall torque [mNm] 150 302
Robust design with high-quality materials and employing the most modern process technology
Combinable in diameter-compliant manner with three-channel encoders (optionally with line driver) and gearing
Control either via speed controller SC 2804 or motion controller MCDC 3006
Reliability in
international trade certified
As one of a select group of medium-sized enterprises in Germany, fAULHABER has attained the highest AEO status and has thereby been internationally recognized as an Authorised Economic Operator.
As one of a select group of medium-sized enterprises in Germany, FAULHABER has attained the highest AEO sta- tus and has thereby been interna- tionally recognized as an Authorised Economic Operator.
In the context of a comprehensive audit performed by the main customs office, qual- ity and logistics processes were examined for adherence to more stringent global security regulations. In addition to proper customs procedures, correct bookkeeping and the creditworthiness of a company, the certification criteria stipulate that specific
requirements are to be met regarding incom- ing and outgoing goods, as well as the warehousing, loading and shipping of merchandise. Following a detailed exami- nation, FAULHABER was able to expand on the ISO 9001, 14001 and 13485 certifi- cations it had already received. The fact that the company’s reliability in national and international trade has now been officially recognized only confirms the longstanding philosophy of the multinational group:
high quality standards and mutual trust form the basis for providing a secure product to the end customer.
The certification, valid throughout the
European Union, is awarded for an un- limited time period. However, compliance with regulations is verified through regular monitoring procedures. Having obtained the AEO status, FAULHABER is entitled to simplified security-relevant customs inspections. The certification will have an ever-greater importance in the future, as negotiations with third countries such as China, Japan and especially the USA could lead to a global acknowledgment of the certification.
F A U L H A B E R G E R M A N Y
Trade fair calendar 2010
HMI - Hannover Messe 19.04. – 23.04.2010 Hanover DE MD&M BIOMEDevice 21.04. – 22.04.2010 Boston, MA US
MEDTEC 27.04. – 28.04.2010 Birmingham UK
fIEMA 27.04. – 30.04.2010 Bento Gonçalves BR Electrosalon 04.05. – 07.05.2010 Budapest HU
PHARMINTEC 12.05. – 14.05.2010 Bologna IT
fCE PHARMA 25.05. – 27.05.2010 São Paulo BR DRIVES & CONTROL 08.06. – 10.06.2010 Birmingham UK
EPMT 08.06. – 11.06.2010 Lausanne CH
TECHNO-fRONTIER 21.07. – 23.07.2010 Tokyo JP
fENASAN 10.08. – 12.08.2010 São Paulo BR
AUVSI's Unmanned Systems 24.08. – 27.08.2010 Denver, CO US What's new in Processing 26.08.2010 Port Elizabeth ZA
MDA RUSSIA 28.09. – 01.10.2010 Moscow RU
fenascuro 31.08. – 03.09.2010 Sertãozinho BR
Motek 13.09. – 16.09.2010 Stuttgart DE
What's new in Processing 16.09.2010 Ruslenburg ZA Industriedagene 27.09. – 30.09.2010 Lillestrøm NO MC&MT Expo 06.10. – 08.10.2010 Osaka JP
Vienna-tec 12.10. – 15.10.2010 Vienna AT
Taipei Int'l Robot Show 19.10. – 22.10.2010 Taipei TW Subcontracting fair 21.09. – 23.09.2010 Tampere FI Elektronik 10 21.09. – 23.09.2010 Odense DK
PACTEC 21.09. – 24.09.2010 Helsinki FI
SPS/IPC/DRIVES ITALIA 19.10. – 21.10.2010 Parma IT What's new in Processing 21.10.2010 Vaal ZA Mechatronik 03.11. – 04.11.2010 Winterthur CH
Instrutec 17.11. – 19.11.2010 Tallinn EE
SPS/IPC/Drives 23.11. – 25.11.2010 Nuremberg DE
www.
zoll.de » Key word: AEO
In his epic fantasy-adventure film “Avatar”, star director James Cameron leads audiences with astonishingly real spatial impressions into the fascinating world of three-di- mensional cinema entertainment. The im- pressive immediacy of the footage was achieved using a completely new pro- cedure. Björn Hedén has, with his inven- tion, changed film industry forever. For his forward-looking conceptual and develop- ment achievement, the 80+ year-old Björn Hedén was honored with the technology Oscar® by the Academy of Motion Picture Arts and Sciences on February 20, 2010.
For the development of a new type of zoom function, the Swede found at
FAULHABER a drive system able to fulfill the complete range of requirements. Integrated into the gear unit of the Heden Lens Control system, the compact two-stage friction drive with a FAULHABER DC-Micromotor ensures the steady movement of the camera lens. Hedén has been a customer to FAULHABER’s swedish agent Compotech for at least 20 years. As a fully-owned subsidiary of the listed Addtech Group, Compotech profits from both the financial and structural resources of the parent group, while at the same time retaining the flexibility and entrepre- neurial spirit of a small company. With a broad spectrum of in- dustrial components such as drive systems, switches and magnetic, isolating and inductive systems, Compotech has offered state- of-the-art quality and reliability for many years. A large network of market leaders enables efficient research on products that fulfill an application’s complete range of requirements. In addi- tion to a comprehensive product range, Compotech has primarily distinguished itself as an experienced and dialog-oriented service provider. In close collaboration with customers, experienced application engineers develop industry-compatible solutions ranging from small batch series to large-scale projects.
Digital 3-D camera technology opens up unparalleled possibilities in film production using high-precision micro- drives
Awarded with the technology Oscar ®
www.
heden-engineering.com compotech.se
oscars.org/awards/scitech
U N I V E R S I T Y P R O J E C T A W A R D
In this age of rising power shortages and dwindling raw material resources, the use of renewable energy sources is increasingly becoming the focus of economic concerns.
Solar power has taken on an enormous importance. The majority of commercially generated solar thermal power is produced from what are known as parabolic trough power stations.
In this technology for solar thermal power generation, the reflective surface of a curved parabolic mirror surface concen- trates the sunlight onto an absorber pipe.
The heat transfer medium inside is then heated up due to the concentrated solar radiation before being pumped through the pipe to a steam generator connected downstream from a steam turbine with generator. To ensure that the parabolic trough is always optimally illuminated, is it essential that it adjusts to the sun’s rays.
This regulation must be extremely precise,
Solar thermal parabolic trough demonstrator
FA U L H A B E R AWA R D W I N N E R O F T H E Y E A R 2 0 1 0
as just a tiny deviation from the desired value could mean an efficiency factor of zero. In addition to the solar position tracking system, the effect of wind, in particular, cannot be neglected. If high wind speeds occur, the mechanical load on the sail-shaped reflectors could cause an unacceptably high rotation of the mirror surface. As a consequence, the absorber would no longer be optimally illuminated.
The fAULHABER University Project Award
Each year, a fascinatingly innovative drive solution devised by junior engineers is recognized by the FAULHABER University Project Award. Students will soon be able to submit their projects for consideration for the 2011 award.
Any students interested can pre-register now at www.faulhaber.com/uni-projekt-award to be automatically notified when the application procedure begins.
www.
faulhaber.com/uni-projekt-award To ensure this control, co-directional or counter-directional electric drives are used. In this process, the co-direction or counter-direction can mean that two or more drives are running at the same speed, but also that they run in opposite rotational directions. Mechanically, the problem can be solved using a toothed belt drive or gearing, for example. How- ever, this variant is often difficult to im- plement, particularly for distributed drives.
Therefore, a mechatronic solution is fre- quently desired for many of these appli- cations that include several drives operat- ing in a network. Bremen University students confronted this challenge in the context of a project report. The task was to develop and manufacture a demon- strator that optimally fulfills the require- ments with respect to the sun position adjustment, angle difference monitoring and breakdown protection.
In its drive solution, the Bremen Univer- sity project team decided to use two DC
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FAULHABER
DR. fRITz fAULHABER GMBH & CO. KG Schönaich · Germany Phone: +49 (0)70 31/638-0 Fax: +49 (0)70 31/638-100 E-mail: info@faulhaber.de www.faulhaber.com
MINIMOTOR SA Croglio · Switzerland Phone: +41 (0)91 611 31 00 Fax: +41 (0)91 611 31 10 E-mail: info@minimotor.ch www.minimotor.ch
MICROMO
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Regelmann Kommunikation Pforzheim · Germany www.regelmann.de
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I M P R I N T
miniature gearmotors with a mounted FAULHABER encoder. When selecting the appropriate motors, two aspects were of special interest. On the one hand, the required control accuracy had to be attained; on the other, the motor’s holding torque had to be larger than the torque
caused by the demonstrator’s rotating
www.
hs-bremen.de
body. Two FAULHABER DC miniature gear- motors from the 2842 series with precision gearheads, mounted encoder and correspond- ing motion controller ideally fulfilled the desired requirements. In stepper motor mode, in high resolution and without step losses, the motion controller positions the drive one free- ly programmable step further for each pulse at the analogue input. The pulse generator enables the full dynamics of the drives to be used, even in this operation mode. In addition to stepper motor mode, defined starting and braking procedures, speed leaps and target positions can be set via the motion controllers.
Along with their high efficiency and outstand- ing positioning possibilities, the reliability of the robust drives was a further significant factor in the decision to use this FAULHABER drive system.
Hagar the Horrible
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Drive Systems catalogue 2010-2011 In its new catalog, FAULHABER presents its versatile product range for small and ultra-miniature drive systems on 420 pages. Clear perfor- mance tables and comprehensive technical information facilitate the selection, leading straight to detailed descriptions and technical data for the individual components.
Drive Systems
Catalogue 2010-2011 Brochure
1536 ... BSL 5,7 mNm Serie
Bürstenlose DC-Servomotoren sensorlos, optional mit Hall Sensoren SMARTSHELL Technologie Bürstenlose DC-Mikromotoren
Nutzen und Vorteile
■ Extrem klein und kompakt
■ Hervorragendes Leistungs-/ Volumenverhältnis
■ Bürstenlose Kommutierung:
Lange Lebensdauer Keine Funkenbildung
■ Sehr niedrige Betriebsspannung
■ Kombinierbar mit Getriebe, dadurch noch höhere Drehmomente Funktion
Dieser kleinste, bürstenlose DC-Mikromotor ist auf der selbsttragenden Spulentechnologie, System FAULHABER , aufgebaut. Der Motor besteht aus dem Gehäuse mit einer dreiphasigen Wicklung als Stator und einem zweipoligen NdFeB-Magneten auf durchgehender Welle als Rotor.
Passend zum Mikromotor wurde ebenfalls ein Mikro- planetengetriebe in herkömmlicher Bauform mit Hilfe der LIGA-Technik (Lithographie, Galvanik, Abformung) entwickelt. Verwendet werden eine spezielle Evolventen- verzahnung mit Modul 55 µm und Getriebestufe mit der Untersetzung 3,6:1. Mikroantriebe mit dreistufi gem Getriebe erzeugen ein Drehmoment von 150 µNm.
Der Antrieb wird in Serienfertigung unter Reinraum- bedingungen produziert.
Bürstenlose DC-Mikromotoren erfordern eine externe, elektronische Ansteuerung. Hierzu bietet FAULHABER verschiedene Lösungen an.
Produktkennzeichnung
0206 H 001 B Funktion Die selbsttragende Spule mit Schrägwicklung, System FAULHABER , die Platine, das laminierte Blechpaket und das vordere Lagerschild sind bei den sensorlosen bürsten- losen DC-Servomotoren der Serie SMARTSHELL eine Einheit und werden in Spritzgusstechnik mit einem, über herausragende mechanische und thermische Eigenschaften verfügenden Kunst stoff (Flüssigkristallpolymer – FKP/LCP), zusammengefügt.
Die Designkonzeption im Baukastensystem erlaubt die Kombination der SMARTSHELL Motoren mit einer großen Auswahl an Präzisiongetrieben. Das Anbringen eines Sensor-Moduls am hinteren Ende des Motors ermöglicht die Anwendung der Optionen BDS (Brushless Digital Sensors = bürstenlose Digitalsensoren) und BAS (Brushless Analog Sensors = bürstenlose Linearsensoren) mit der entsprechenden Steuerelektronik.
Nutzen und Vorteile
■ Eisenlose Spulentechnologie, System FAULHABER
■ Hohe Zuverlässigkeit, lange Lebensdauer
■ Breiter linearer Drehzahl-/Drehmoment-Bereich
■ Keine Funkenbildung
■ Kein Rastmoment
■ Dynamisch gewuchteter Rotor, ruhiger Lauf
■ Einfache Konstruktion
■ Erhältlich mit analogen oder digitalen Hall-Sensoren Produktkennzeichnung Bürstenlose DC-Servomotoren Sensorlos, SMARTSHELL Technologie
2232 S 048 BSL
Bürstenlose DC-Mikromotoren Nutzen und Vorteile
■ Extrem klein und kompakt
■ Hervorragendes Leistungs-/ Volumenverhältnis
■ Bürstenlose Kommutierung:Lange LebensdauerKeine Funkenbildung
■ Sehr niedrige Betriebsspannung
■ Kombinierbar mit Getriebe, dadurch noch höhere Drehmomente
Funktion Dieser kleinste, bürstenlose DC-Mikromotor ist auf der selbsttragenden Spulentechnologie, System FAULHABER , aufgebaut. Der Motor besteht aus dem Gehäuse mit einer dreiphasigen Wicklung als Stator und einem zweipoligen NdFeB-Magneten auf durchgehender Welle als Rotor.
Passend zum Mikromotor wurde ebenfalls ein Mikro- planetengetriebe in herkömmlicher Bauform mit Hilfe der LIGA-Technik (Lithographie, Galvanik, Abformung) entwickelt. Verwendet werden eine spezielle Evolventen- verzahnung mit Modul 55 µm und Getriebestufe mit der Untersetzung 3,6:1. Mikroantriebe mit dreistufi gem Getriebe erzeugen ein Drehmoment von 150 µNm.
Der Antrieb wird in Serienfertigung unter Reinraum- bedingungen produziert.
Bürstenlose DC-Mikromotoren erfordern eine externe, elektronische Ansteuerung. Hierzu bietet FAULHABER verschiedene Lösungen an.
Produktkennzeichnung 0206 H 001 B
Funktion Die selbsttragende Spule mit Schrägwicklung, System FAULHABER , die Platine, das laminierte Blechpaket und das vordere Lagerschild sind bei den sensorlosen bürsten- losen DC-Servomotoren der Serie SMARTSHELL eine Einheit und werden in Spritzgusstechnik mit einem, über herausragende mechanische und thermische Eigenschaften verfügenden Kunst stoff (Flüssigkristallpolymer – FKP/LCP), zusammengefügt.
Die Designkonzeption im Baukastensystem erlaubt die Kombination der SMARTSHELL Motoren mit einer großen Auswahl an Präzisiongetrieben. Das Anbringen eines Sensor-Moduls am hinteren Ende des Motors ermöglicht die Anwendung der Optionen BDS (Brushless Digital Sensors = bürstenlose Digitalsensoren) und BAS (Brushless Analog Sensors = bürstenlose Linearsensoren) mit der entsprechenden Steuerelektronik.
Nutzen und Vorteile
■ Eisenlose Spulentechnologie, System FAULHABER
■ Hohe Zuverlässigkeit, lange Lebensdauer
■ Breiter linearer Drehzahl-/Drehmoment-Bereich
■ Keine Funkenbildung
■ Kein Rastmoment
■ Dynamisch gewuchteter Rotor, ruhiger Lauf
■ Einfache Konstruktion
■ Erhältlich mit analogen oder digitalen Hall-Sensoren Produktkennzeichnung
Bürstenlose DC-Servomotoren Sensorlos, SMARTSHELL Technologie
2232 S 048 BSL
1536 ... BSL
5,7 mNm Serie
Bürstenlose DC-Servomotoren sensorlos, optional mit Hall Sensoren SMARTSHELL Technologie
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