ELECTROMATE INDUSTRIAL SALES LTD. Precision Technology & Quality Benefits of Direct Drive Technology

Putting the Best Solution Together Operator Interface & Machine Control MotorAmp TorqueVelocityPositionPath Gen PLC-Based PC-Based 1-Axis Standalone Multi-Axis Standalone Architecture Speed Torque Matching Rotary To Linear Conversion Connecting the Load Feedbac k Motors Gearboxes Screws Bearings Couplings Motion Control

Why Direct Drive Technology? Direct coupling of the load to the motor No compliance between motor and load Inertia mismatch is irrelevant (theoretically) 1000:1 inertia mismatch applications in place (standard servo is 10:1)

DDR Direct Drive Rotary Formats DDR Product Formats Ease of Use Frameless DDR (Parts set) Significant integration, best package fit Easy to integrate, package size fixed Cartridge DDR™ Easy to integrate, package size fixed Fully housed DDR

Frameless - Brushed Permanent magnet stator (stationary) Wound armature/rotor (rotating) Self-commutating Limited peak power due to mechanical switching that results in excessive sparking in DC motors. Least torque ripple of any motor design

Frameless - Brushless Wound stator (stationary) Permanent magnet armature/rotor (rotating - reduced inertia) Commutation is done based on rotor position such that synchronism is always maintained. This is referred to as self- synchronism. The motor maintains the ability to deliver torque regardless of the velocity error. High commutation frequencies = high speeds Good heat dissipation because the windings are on the outside The ability to deliver current based on demand is a key feature of servos. If the motor is at rest and there is no load, no current is consumed, and the motor can cool. High bus voltage to force current into the windings is available; mitigates the electrical time constant of the winding

DDR: Direct Drive Rotary

GOLDLINE DDR Features Housed motor with bearings and integrated feedback Resolver or sine encoder feedback Single or double bearing version Large thru bore Typical application: Rotary indexing table To replace any mechanical transmission that is high maintenance or has short life.

To gain Benefits of Eliminating Mechanical Transmissions The Benefits of DDR Technology Zero maintenance –No Belts or gears Reliability –Reduce down time –No transmission parts to break Improved performance –Increase accuracy up to 50 times –Eliminate resonance and oscillation problems Clean mechanical assembly –Lower parts count –Reduce assembly time Smooth and quiet Hollow shaft option –Run process thru the motor

Belt/gearbox maintenance Belt/gearbox replacements Unscheduled Downtime Lower Throughput Purchase Price Purchase Price (all components) Mechanical Transmission DDR Unscheduled Downtime Lifetime Cost – DDR vs. Mechanical

Cartridge DDR

Cartridge DDR Product Line Best features of a frameless DDR and a fully housed DDR Direct drive servo performance & zero maintenance, in an easy to integrate package It has no bearings…but it has everything else Feedback is pre-mounted and pre- alignedat the factory Single part number ready to mount Eliminates significant engineering design through advanced mechanical design

Cartridge DDR: Section RINGFEDER

Small Frame Cartridge DDR

Small Frame vs Large Frame

CDDR Application Considerations Machine has existing bearings? Through-bore required? Fast, accurate motion is required? Reliability and zero motor maintenance is a must? Fast machine maintenance a requirement? Consider... –Axial shaft movement –Shaft dimensions and TIR –Perpendicularity of mounting surface –Thermal capacity of machine structure

Cartridge DDR Applications Any application where the machine has its own set of bearings, but still can benefit from the DDR performance advantages Converting: –Rollers, Coaters, Feeders, Die Cutters Other application examples –Injection molding: IM machine mold indexing –Press feed: Incremental motion

DDR Videos

GOLDLine DDR Indexer Customer Load Wheel 4 Feet Diameter 250 Pounds DH143M Goldline DDR 250 Lb-ft Continuous 989 Lb-ft Peak 96 Steel pegs 3.75 degrees per peg Total Inertia 15 lb-ft-s 2 S620 Drive Amplifier 240 or 480 Vac 20 A Continuous, 40 Peak

Single Peg Index Velocity Profile 3.75 Degree Move) Velocity Profile Total Move Time 97 ms Settling Time 13 ms

Indexing a Single Peg If the Video does not play: Right click inside Windows Media Player screen above and choose Properties Choose “SinglePeg WindowsMediaPlayer” from pull down and “Alphabetic” tab Click on button at the end of “(Custom)” row and “Browse” to file on CD-ROM File name is “DDR One Peg Index.wmv”, click Slide Show icon to view

One Revolution Index If the Video does not play: Right click inside Windows Media Player screen and choose Properties Choose “FullRevolution WindowsMediaPlayer” from pull down and “Alphabetic” tab Click on button at the end of “(Custom)” row and Browse to file location on CD-ROM File name is “DDR One Revolution Index.wmv”, click Slide Show icon to view

Bar Clamped to Table Indicator 1 Thousandth Inch / Number 1 Ten Thousandth Inch / division 0.8 Arc Seconds / division 26 inch radius from center Repeatability Test

Repeatability Test Video If the Video does not play: Right click inside Windows Media Player screen above and choose Properties Choose “Repeatability WindowsMediaPlayer” from pull down and “Alphabetic” tab Click on button at the end of “(Custom)” row and “Browse” to file on CD-ROM File name is “DDR Repeatability Test.wmv”, click Slide Show icon to view

DDR vs. Mechanical Indexer Customer identified these advantages of the DDR over the mechanical indexer they used previously –Improved Repeatability –DDR Accuracy and Repeatability do not degrade over time as with the mechanical indexer –Can immediately stop DDR motion if there is a process error –Greatly reduced audible noise –Easily change DDR index angle, speed, and dwell –DDR provides better overall value

Direct Drive Linear

Linear vs. Standard Rotary Motors Linear motor - rotary motor rolled out flat! moving coil magnetic way air gap Rotating rotor windings stator N S magnets

Mechanical Transmission AdvantagesDisadvantages Timing BeltSpeedCompliance, Accuracy Wear, Contamination Maintenance Rack and PinionSpeedBacklash, Wear Long Travel Audible Contamination Ball ScrewHigh ForceLimited Speed Settling Time Wear, Maintenance Comparative Technologies

Indicators for a Linear Motor Solution High Speeds- 200 in/sec (10 m/sec) High Acceleration- 3-5 g's are typical Fast Move and Settle High Resolution Long travel distances- 20 feet or more possible Smoothness (zero cogging) No maintenance (non-contact) Zero backlash High dynamic stiffness, no compliance

Comparison of DDL Motors Ironless –zero cogging –zero attractive force –ultra-high acceleration –very smooth motion –Up to 1600 N peak force Iron Core –high peak force –patented anti-cogging design –high force density –Up to N peak force