BRUSH DC motors. Brush DC 8mm. Motor Coil Cross Section. Brush DC 16mm. Brush DC 35mm

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1 BRUSH DC motors Brush DC 8mm Motor Coil Cross Section Brush DC 16mm Brush DC 35mm Your miniature motion challenges are unique and your ideas for meeting those challenges are equally unique. From medical to aerospace or security and access, Portescap s brush DC motion solutions are moving life forward worldwide in critical applications. The following Brush DC section features our high efficiency and high power density with low inertia coreless brush DC motor technology. Why a Brush DC motor 50 Brush DC Spotlight on Innovation 51 Brush DC Motor Basics 52 Brush DC Working Principles 55 How to select your Brush DC motor 57 Brush DC Specifications 58 Where to apply Brush DC motors 59 Brush DC motors at Work 60

2 Why a Brush DC motor Models Available from 8mm to 35mm Diameter Long life Patented Commutation Sysyem Virtually Eliminates Brush Maintenance Select Either Sleeve or Ball Bearings Ironless Rotor Coil Enables High Acceleration Optional Gearboxes and Magnetic or Optical Encoders Are Easily Added Innovation & Performance Portescap s brush DC coreless motors incorporate salient features like low moment of inertia, no cogging, low friction, very compact commutation which in turn results in high acceleration, high efficiency, very low joule losses and higher continuous torque. High Efficiency Design - Ideal for Battery-Fed Applications Brush DC commutation design Longer commutator life because of the design. REE system Stands for Reduction of Electro Erosion. The electro erosion, caused by arcing during commutation, is greatly reduced in low inertia coreless DC motors because of the low inductivity of their rotors. Ideal for portable and small devices, Portescap s coreless motor technologies reduce size, weight, and heat in such applications. This results in improved motor performance in smaller physical envelopes thus offering greater comfort and convenience for endusers. In addition, the coreless design enables long-life and higher energy efficiency in battery-powered applications. NEO magnet The powerful Neodymium magnets along with enhanced air gap design thus giving higher electro-magnetic flux and a lower motor regulation factor. Coreless rotor design Optimized coil and rotor reduces the weight and makes it compact. Portescap continues innovating coreless technology by seeking design optimizations in magnetic circuit, self supporting coreless coil along with commutator and collector configurations. Get your products to market faster through Portescap s rapid prototyping and collaborative engineering. Our R&D and application engineering teams can adapt brush DC coreless motors with encoders and gearboxes to perform in different configuration, environment, or envelope. Standard Features Max continuous torque ranging from 0.66 to mnm Speed ranging from 11,000 RPM (8mm) to 5,500 RPM (35mm) Motor regulation factor(r/k 2 ) ranging from 1,900 to /Nms Your Custom Motor Shaft extension and double shaft options Custom coil design (different voltages) Mounting plates Gear pulleys and pinion Shock absorbing damper and laser welding Special lubrication for Civil aviation and medical applications EMI filtering Cables and connectors Gearboxes

3 SPOTLIGHT ON INNOVATION Innovation is a passion at Portescap. It defines your success, and defines our future. We help you get the right products to market faster, through rapid prototyping and collaborative engineering. With experienced R&D and application engineering teams in North America, Europe, and Asia, Portescap is prepared to create high-quality precision motors, in a variety of configurations and frame sizes for use in diverse environments. Demanding application? Portescap is up for the challenge. Take our latest innovation Athlonix in high power density motors. Ultra-compact, and designed for lower joule heating for sustainable performance over the life of your product, Portescap s Athlonix motors deliver unparalleled speed-to-torque performance. And better energy efficiency brings you savings while helping you achieve your green goals. Athlonix motors are available in 12, 16, and 22mm. More Endurance. Higher Power Density. Smaller Package Looking for a lighter motor with more torque? 35GLT brush dc coreless motor from Portescap might be the solution for your needs. The 35GLT provides a 40% increase in torque-to-volume ratio over most average iron core motors. A featured multi-layer coil improves performance and offers insulating reinforcement, resulting in improved heat dissipation. Weighing in at only 360 grams and providing an energy efficiency of 85%, the 35GLT offers less power draw and excellent space savings. The quest for high-resolution feedback with accuracy in speed is the essence of Portescap s innovative MR2 magneto resistive encoder. These miniature encoders accommodate motors from frame sizes of 8mm to 35mm with superior integration schemes to facilitate a compact assembly with motors. And, with a resolution of 2 to 1024 lines, Portescap s MR2 encoders meet your application requirements today - while flexibly adapting to your evolving needs.

4 Brush DC Motor Basics Construction of Portescap motors with iron less rotor DC motors All DC motors, including the ironless rotor motors, are composed of three principle sub assemblies: 1. Stator 2. Brush Holder Endcap 3. Rotor Stator Tube Self Supporting High Packing Density Rotor Coil Sleeve or Ball Bearing Collector High Efficiency High Strength Rare Earth Magnet Cable Clamp Metallic Alloy Brush Commutation System 1. The stator The stator consists of the central, cylindrical permanent magnet, the core which supports the bearings, and the steel tube which completes the magnetic circuit. All three of these parts are held together by the motor front plate, or the mounting plate. The magnetic core is magnetized diametrically after it has been mounted in the magnetic system 2. The Brush Holder Endcap The Brush Holder Endcap is made of a plastic material. Depending on the intended use of the motor, the brush could be of two different types: Carbon type, using copper grahite or silver graphite, such as those found in conventional motors with iron rotors. Multiwire type, using precious metals. 3. The Rotor Of the three sub-assemblies, the one that is most characteristic of this type of motor is the ironless, bell-shaped rotor. There are primarily four different methods of fabricating these ironless armatures utilized in present-day technology. A In the conventional way, the various sections of the armature are wound separately, then shaped and assembled to form a cylindrical shell which is glass yarn reinforced, epoxy resin coated, and cured. It is of interest to note the relatively large coil heads which do not participate in the creation of any torque.

5 B A method which avoids these coil heads uses an armature wire that is covered with an outer layer of plastic for adhesion, and is wound on a mobile lozenge-shaped support. Later, the support is removed, and a flat armature package is obtained, which is then formed into a cylindrical shape (Figure 1). The difficulty with this method lies in achieving a completely uniform cylinder. This is necessary for minimum ripple of the created torque, and for a minimum imbalance of the rotor. Figure 1 - Continuous winding on mobile support 3 1 2a 1a 2 5 a) support arrangement b) armature as flat package c) forming of armature in cylindrical shape C A procedure which avoids having to form a perfect cylinder from a flat package consists of winding the wire directly and continuously onto a cylindrical support. This support then remains inside the rotor. Coil heads are reduced to a minimum. Although a large air gap is necessary to accommodate the armature support; this method is, however, easily automated. D The Skew-Wound armature method utilizes the same two-layer plastic coated wire described in Method B. This Wire is directly and continuously wound onto a cylindrical support which is later removed, thus eliminating an excessive air gap and minimizing rotor inertia. In this type of winding, inactive coil heads are non-existent. (Figure 2). This kind of armature winding does require relatively complex coil winding machines. Portescap thru its proprietary know how has developed multiple automated winding machines for different frame sizes and continues to innovate in the space so that dense coil windings can be spun in these automated machines. Figure 2

6 Features of Ironless Rotor DC Motors The rotor of a conventional iron core DC motor is made of copper wire which is wound around the poles of its iron core. Designing the rotor in this manner has the following results: A large inertia due to the iron mass which impedes rapid starts and stops A cogging effect and rotor preferential positions caused by the attraction of the iron poles to the permanent magnet. A considerable coil inductance producing arcing during commutation. This arcing is responsible on the one hand for an electrical noise, and on the other hand for the severe electro erosion of the brushes. It is for the latter reason that carbon type brushes are used in the conventional motors. A self supporting ironless DC motor from Portescap has many advantages over conventional iron core motors: high torque to inertia ratio absence of preferred rotor positions very low torque and back EMF variation with armature positions essentially zero hysteresis and eddy current losses negligible electrical time constant almost no risk of demagnetization, thus fast acceleration negligible voltage drop at the brushes (with multiwire type brushes) lower viscous damping linear characteristics REE System proven to increase motor life up to 1000 percent The two biggest contributors to the commutator life in a brush DC motor are the mechanical brush wear from sliding contacts and the erosion of the electrodes due to electrical arcing. The superior surface finish, commutator precision along with material upgrades such as precious metal commutators with appropriate alloys has helped in reducing the mechanical wear of the brushes. To effectively reduce electro erosion in while extending commutator life Portescap innovated its proprietary REE (Reduced Electro Erosion) system of coils. The REE system reduces the effective inductivity of the brush commutation by optimization of the mutual induction of the coil segments. In order to compare and contrast the benefits of an REE system Portescap conducted tests on motors with and with out REE coil optimization. The commutator surface wear showed improvements ranging from percent as shown in Figure 5. Coils 4, 5 and 6 are REE reinforced while 1, 2 & 3 are without REE reinforcement.

7 Brush DC Working Principles The electromechanical properties of motors with ironless rotors can be described by means of the following equations: 1. The power supply voltage U 0 is equal to the sum of the voltage drop produced by the current I in the ohmic resistance R M of the rotor winding, and the voltage U i induced in the rotor : U 0 = I x R M + U i (1) RM I U0 with an ironless rotor : U 0 = M x R M + k E x ω (4) By calculating the constant k E and k T from the dimensions of the motor, the number of turns per winding, the number of windings, the diameter of the rotor and the magnetic field in the air gap, we find for the direct-current micromotor with an ironless rotor: M = U i = k (5) I ω Which means that k = k E = k T The identity k E = k T is also apparent from the following energetic considerations: Graphic express speed-torque characteristic: n n 0 0 M L U 0 To overcome the friction torque M f due to the friction of the brushes and bearings, the motor consumes a no-load current I 0. This gives M f = k x I 0 I M L I M L M UI 2. The voltage U i induced in the rotor is proportional to the angular velocity ω of the rotor : U i = k E x ω (2) It should be noted that the following relationship exists between the angular velocity ω express in radians per second and the speed of rotation n express in revolutions per minute: ω = 2π n The rotor torque M is proportional to the rotor current I: M = k T x I (3) It may be mentioned here that the rotor torque M is equal to the sum of the load torque M L supplied by the motor and the friction torque M f of the motor : M = M L + M f By substituting the fundamental equations (2) and (3) into (1), we obtain the characteristics of torque/angular velocity for the dc motor The electric power P e = U 0 x I which is supplied to the motor must be equal to the sum of the mechanical power P m = M x ω produced by the rotor and the dissipated power (according to Joule s law) P v = I 2 x R M : P e = U 0 x I = M x ω + I 2 x R M = P m + P v Moreover, by multiplying equation (1) by I, we also obtain a formula for the electric power P e : P e = U 0 x I = I 2 x R M + U i x I The equivalence of the two equations gives M x ω = U i x I or U i = M and k E = k T = k ω I Quod erat demonstrandum. Using the above relationships, we may write the fundamental equations (1) and (2) as follows: U 0 = I x R M + k x ω (6) and : U 0 = M x R M + k x ω (7) k and: U 0 = I 0 x R M + k x ω 0 where ω 0 = 2π x n 0 60 hence: k = U 0 - I 0 x R M (8) ω 0 Is it therefore perfectly possible to calculate the motor constant k with the no-load speed n 0, the no-load current I 0 and the rotor resistance R M. The starting-current I d is calculated as follows: I d = U 0 R M It must be remembered that the R M depends to a great extent on the temperature; in other words, the resistance of the rotor increases with the heating of the motor due to the dissipated power (Joule s law): R M = R M0 (1 + γ x T) Where γ is the temperature coefficient of copper (γ = 0.004/ C). As the copper mass of the coils is comparatively small, it heats very quickly

8 Brush DC Working Principles through the effect of the rotor current, particularly in the event of slow or repeated starting. The torque M d produced by the starting-current I d is obtained as follows: M d = I d x k - M f = (I d - I 0 )k (9) By applying equation (1), we can calculate the angular velocity ω produced under a voltage U 0 with a load torque M i. We first determine the current required for obtaining the torque M = M L + M f : I = M L + M f k Since M f = I 0 k we may also write (10) I = M L + I 0 k required for obtaining a speed of rotation n for a given load torque M L (angular velocity ω = n x 2π/60). By introducing equation (10) into (6) we obtain: U 0 = ( M L + I ) 0 R M + k x ω (13) k Practical examples of calculations Please note that the International System of Units (S.I.) is used throughout. 1. Let us suppose that, for a Portescap motor 23D21-216E, we wish to calculate the motor constant k, the starting current I d and the starting torque M d at a rotor temperature of 40 C. With a power supply voltage of 12V, the no-load speed is n 0 is 4900 rpm (ω 0 = 513 rad/s), the no-load current I 0 = 12 ma and the resistance R M0 = 9.5 Ω at 22 C. Using equation (10) we first calculate the current which is supplied to the motor under these conditions: I = M L + I 0 = k = 0.357A Equation (11) gives the angular velocity ω: ω = U 0 I x R M = x 10.2 k = 231 rad/s and the speed of rotation n: n = 60 ω = 2200 rpm 2π Thus the motor reaches a speed of 2200 rpm and draws a current of 357 ma. For the angular velocity ω, we obtain the relationship ω = U 0 I x R M (11) k = U 0 R M (M L + M f ) k k 2 In which the temperature dependence of the rotor resistance R M must again be considered; in other words, the value of R M at the working temperature of the rotor must be calculated. On the other hand, with the eqation (6), we can calculate the current I and the load torque M L for a given angular velocity ω and a given voltage U 0 : I = U 0 k x ω = I d k ω (12) R M R M And with equation (10) M L = (I I 0 )k We get the value of M L : M L = (I I 0 )k k 2 ω R M The problem which most often arises is that of determining the power supply voltage U 0 By introducing the values ω 0, I 0, R M0 and U 0 into the equation (8), we obtain the motor constant k for the motor 23D21-216E: k = x 9.5 = Vs 15 Before calculating the starting-current, we must calculate the rotor resistance at 40 C. With T = 18 C and R M0 = 9.5Ω, we obtain R M = ( x 18) = 9.5 x 1.07 = 10.2Ω The starting-current I d at a rotor temperature of 40 C becomes I d = U 0 = 12 = 1.18A R M 10.2 and the starting-torque M d, according to equation (9), is M d = k(i d I 0 ) = ( ) = Nm 2. Let us ask the following question: what is the speed of rotation n attained by the motor with a load torque of Nm and a power supply voltage of 9V at a rotor temperature of 40 C? 3. Let us now calculate the torque M at a given speed of rotation n of 3000 rpm (ω = 314 rad/s) and a power supply voltage U 0 of 15V; equation (12) gives the value of the current: I = U 0 k x ω = I d k x ω R M R M = x 314 = 0.466A 10.2 and the torque load M L : M L = k(i I 0 ) = ( ) = Nm (M L = 10.5 mnm) 4. Lastly, let us determine the power supply voltage U 0 required for obtaining a speed rotation n of 4000 rpm (ω = 419 rad/s) with a load torque of M L of Nm, the rotor temperature again being 40 C (R M = 10.2Ω).. As we have already calculated, the current I necessary for a torque of Nm is A U 0 = I x R M + k x ω = x x 419 = 13.4 volt

9 How to select your Coreless motor PRODUCT RANGE CHART FRAME SIZE 08GS 08G 13N 16C 16N28 16G Max Continuous Torque mnm (Oz-in) 0.66 (0.093) 0.87 (0.102) 3.33 (0.47) 1.0 (0.14) 2.4 (0.34) 5.4 (0.76) Motor Regulation R/K /Nms Rotor Inertia Kgm S 17N 22S 22N28 22V 23L Max Continuous Torque mnm (Oz-in) 2.6 (0.37) 4.85 (0.69) 9.5 (1.34) 7.3 (1.04) 8.13 (1.15) 6.2 (1.16) Motor Regulation R/K /Nms Rotor Inertia Kgm FRAME SIZE 23V 23GST 25GST 25GT 26N 28L 28LT Max Continuous Torque mnm (Oz-in) 13 (1.8) 22 (3.1) 27 (3.8) 41 (5.8) 17.3 (2.4) 21.0 (2.97) Motor Regulation R/K /Nms (0.4) Rotor Inertia Kgm D 28DT 30GT 35NT2R32 35NT2R82 35GLT Max Continuous Torque mnm (Oz-in) 33.6 (4.8) 41 (5.8) 93 (13.2) 58.3 (8.3) 115 (16.3) Motor Regulation R/K /Nms Rotor Inertia Kgm (3.23) Motor Designation 22 N 2R 2B - 210E 286 Motor diameter (in mm) Bearing type: blank = with sleeve bearings 2R = with front and rear ball bearings Coil type: nb of layer wire size type connexion Execution coding Motor generation/ length: L, C = old generation (C: short, L: long), Alnico Magnet S, N, V = middle generation (S: short, N: normal, V: very long) G, GS = new generation (high power magnet), S: short version Commutation size & type/ magnet type: Alnico/ Precious Metal = 18, 28, 48, 58 NdFeB/ Precious Metal = 78, 88, 98 Alnico/ Graphite & Copper = 12 NdFeB/ Graphite Copper = 82, 83

10 Explanation of Specifications MOTOR PART NUMBER 16N28 205E Explanation MEASURING VOLTAGE V 18 Is the DC voltage on the motor terminals and is the reference at which all the data is measured NO LOAD SPEED rpm 9600 This is the the speed at which motor turns when the measuring voltage is applied with out any load STALL TORQUE mnm (oz-in) 2.9 (0.41) Minimum torque required to stall the motor or stop the motor shaft from rotating at measuring voltage AVERAGE NO LOAD CURRENT ma 4.9 The current drawn by the motor at no load while operating at the measured voltage TYPICAL STARTING VOLTAGE V 0.45 The minimum voltage at which the motor shaft would start rotating at no load MAX RECOMMENDED VALUES MAX CONT CURRENT A 0.15 The maximum current that can be passed through the motor with out overheating the coil MAX CONT TORQUE mnm (oz-in) 2.5 (0.35) The maximum torque that can be applied without overheating the coil MAX ANGULAR ACCELERATION 10 3 rad/s The maximum feasible rotor acceleration to achieve a desired speed INTRINSIC PARAMETERS BACK-EMF CONSTANT V/1000 rpm 1.8 Voltage induced at a motor speed of 1000 rpm TORQUE CONSTANT mnm/a (oz-in/a) 17.3 (2.45) Torque developed at a current of 1 A TERMINAL RESISTANCE ohm 109 Resistance of the coil at a temperature of 22 o C MOTOR REGULARION 10 3 /Nms 360 It is the slope of speed torque curve ROTOR INDUCTANCE mh 3 Measured at a frequency of 1 khz ROTOR INERTIA kgm Order of magnitude mostly dependent on mass of copper rotating MECHANICAL TIME CONSTANT ms 20 Product of motor regulation and rotor inertia Speed vs Torque curve 16N28 at 18V N (RPM) Continuous Working range Temporary Working range M (mnm)

11 Markets & Applications MEDICAL Powered surgical instruments Dental hand tools Infusion, Volumetric & Insulin Pumps Diagnostic & scanning equipment Benefits: Reduced footprint analyzers with high efficiency & precision sample positioning SECURITY & ACCESS Security cameras Locks Bar code readers Paging systems Benefits: Low Noise & Vibration, High Power & Superior Efficiency AEROSPACE & DEFENSE Cockpit gauge Indicators Satellites Optical scanners Benefits: Low Inertia, Compactness and Weight, High Efficiency ROBOTICS & FACTORY AUTOMATION Conveyors Remote controlled vehicles Benefits: High Power & Low Weight Industrial robots POWER HAND TOOLS Shears Pruning hand tools Nail guns Benefits: High Efficiency, Compactness and Weight, Low Noise OTHER Office equipment Semiconductors Model railways Document handling Optics Automotive Transportation Audio & video Benefits: Low Noise, High Power, Better Motor Regulation

12 Brush DC Motors at Work MEDICAL ANALYZERS Portescap solves multiple application needs in analyzers, from sample draw on assays to rapid scanning and detection of molecular mechanisms in liquids and gases, with its coreless brush dc motors. For high throughput applications those where over 1,000 assays are analyzed in an hour high efficiency and higher speed motors such as brush DC coreless motors are a suitable choice. Their low rotor inertia along with short mechanical time constant makes them ideally suited for such applications. As an example, a Portescap 22-mm motor brush coreless DC motor offers no-load speed of 8,000 rpm and a mechanical time constant of 6.8 milliseconds. Another analyzer function that plays a vital role in their output is collecting samples from the vials or assays, and serving them up to measurement systems based on photometry, chromatography, or other appropriate schemes. Here again, a brush DC coreless motor is highly applicable due to the power density it packs in a small frame size. You can maximize your application s productivity with a 16 or 22mm workhorse from Portescap. INFUSION PUMPS Coreless brush DC motors offer significant advantages over their iron core brush counterparts for some of the critical care pump applications where, the benefits range from improved efficiency to higher power density, in a smaller frame size. One of the factors that deteriorates motor performance over long term usage is the heating of the motor with associated Joule loss. In motor terminology this is governed by the motor regulation factor determined by the coil resistance, R, and the torque constant, k. The lower the motor regulation factor (R/k 2 ) the better would the motor perform over its life while sustaining higher efficiencies. With some of the lowest motor regulation factors Portescap s latest innovation in Athlonix motors is already benefiting applications in the infusion pump space by offering a choice of a higher performance motor with less heat loss, higher efficiency and power density in compact packages. ELECTRONICS ASSEMBLY SURFACE MOUNT EQUIPMENT Portescap s versatile 35mm coreless motors with carbon brush commutation excel in electronic assembly, robotics and automated machinery equipment and have been a work horse in some of the pick and place machinery used in surface mount technology. Our 35mm low inertia motors can provide high acceleration, low electro magnetic interference, and frequent start stops that the machines need while maintaining smaller and light weight envelopes.

13 BRUSHLESS DC motors BLDC Gearmotor Size 9 BLDC 22mm nuvodisc 32BF BLDC Gearmotor Size 5 Portescap Brushless DC motors are extremely reliable and built to deliver the best performances. Their high power density allows a reduction in the overall size of most of the applications. They feature silent running even at high speed. The autoclavable option is ideal for medical applications. Why a Brushless Motor 12 How to select your Brushless Motor 13 Brushless Terminology 14 Where to apply your Brushless Motor 15 Specifications 16

14 Why a Brushless motor Housing Lamination Stack Flange Winding Shaft Print with Hall sensors Permanent magnet Bearing Brushless technology Conventional DC motors use a stationary magnet with a rotating armature combining the commutation segments and brushes to provide automatic commutation. In comparison, the brushless DC motor is a reversed design: the permanent magnet is rotating whereas the windings are part of the stator and can be energized without requiring a commutator-and-brush system. Therefore this motor type achieves very long, trouble-free life even while operating at very high speeds. Slotted & Slotless technologies One technology uses a stator that consists of stacked steel lamination with winding placed in the slots that are axially cut along the inner periphery. This is called the BLDC motor, slotted iron structure. The other technology uses a self-supporting cylindrical ironless coil made in the same winding technique as for our ironless rotor DC motors. This is called the BLDC motor, slotless iron structure. Standard Features Max Continuous stall torque up to 39 oz-in (276 mnm) Peak torque up to oz-in (2 278 mnm) No mechanical commutation Long life (limited only by wear on ball bearings) Mainly linear motor characteristic Excellent speed and position control Static winding attached to motor housing Improved heat dissipation and overload capability High efficiency Autoclavable Option Available Your Custom motor Various stack lengths available in each frame size Autoclavable option Custom winding Shaft modification including hollow shaft Special material, coating and plating Lead length, type, color and connector Gearhead Encoder Speed up to rpm Standard diameter from 0.5 to 2.3 in (12.7 to 58 mm)

15 How to select your Brushless motor Hall Sensors In general, BLDC motors have three phase windings. The easiest way is to power two of them at a time, using Hall sensors to know the rotor position. A simple logic allows for optimal energizing of the phases as a function of rotor position, just like the commutator and brushes are doing in the conventional DC motor. Possible applications: high variation of speed and/or load, positioning Sensorless With this solution the motor includes no sensors or electronic components and it is therefore highly insensitive to hostile environments. In all motors, the relation of back-emf and torque versus rotor position is the same. Zero crossing of the voltage induced in the non-energized winding corresponds to the position of maximum torque generated by the two energized phases. This point of zero crossing therefore allows to determine the moment when the following commutation should take place depending on motor speed. This time interval is in fact equivalent to the time the motor takes to move from the position of the preceding commutation to the back-emf zero crossing position. Electronic circuits designed for this commutation function allow for easy operation of sensorless motors. As the back- EMF information is necessary to know the rotor position, sensorless commutation doesn t work with the motor at stall or extremely low speed. For applications: constant speed and load (spindle), cable diameter limitation motor Designation Slotted B A - R R Motor Type B = BLDC Motor Diameter 05 = 0.5 in 06 = 0.6 in 09 = 0.9 in 11 = 1.1 in 15 = 1.5 in Stack Length 04 = 0.4 in 05 = 0.5 in 06 = 0.6 in 08 = 0.8 in 09 = 0.9 in 12 = 1.2 in 18 = 1.8 in 25 = 2.5 in Winding Shaft Option R = Round F = Flat D = 2 fiats spaced 180 Type O = Motor only G = Gearhead Gear Ratio 04 = 4:1, 05 = 5:1, 07 = 7:1, 12 = 12:1, 15 = 15:1, 16 = 16:1 20 = 20:1. 25 = 25:1. 28 = 28:1, 35 = 35:1, 49 = 49:1 (*) not used if motor only Gearhead Shaft Option R = Round F = Flat D = 2 fiats spaced 180 Slotless 22 BH m 8B P 01 Diameter (in mm) Brushless Body Length S = Short M = Medium L = Long C = Short F = Flat 8B: Hall Sensor (8 wires) 3C: sensorless (3 wires) 6A: On board electronic (6 wires) 2A: On board electronic (2 wires) Winding C-E-H-K... Execution 01, 05...

16 Explanation of Specifications MOTOR PART SPECIFICATION BACK-EMF CONSTANT K e [V/krpm] +/-8% ELECTRICAL TIME CONSTANT t e [ms] INDUCTANCE L [mh] MAX CONTINUOUS POWER AT 10krpm [W] MAX CONTINUOUS POWER DISSIPATION [W] MAX CONTINUOUS STALL CURRENT OR MAX CONTINUOUS CURRENT I cs [A] MAX CONTINUOUS STALL TORQUE T cs [mnm OR oz-in] MAX CONTINUOUS TORQUE AT 10krpm [mnm OR oz-in] MOTOR CONSTANT 10krpm [mnm/watt 1/2 OR oz-in/watt 1/2 ] NO-LOAD CURRENT I 0 [ma] +/-50% NO-LOAD SPEED W nl or n 0 [rpm] +/-10% MEASURING OR RATED VOLTAGE U OR V r [V] MECHANICAL TIME CONSTANT t m [ms] PEAK CURRENT I pk [A] PEAK TORQUE [mnm OR oz-in] ExpLanation Voltage induced at a motor speed of rpm The time required for current to reach 63% of its nal value for a xed voltage level Measured with a frequency of 1 khz between 2 phases of the stalled motor. The value gives an order of magnitude Power developed at 10krpm so the motor doesn t exceed its thermal rating The maximum power the motor can dissipate without exceeding its thermal rating Current drawn by the motor at zero speed (locked condition) so the motor doesn t exceed its thermal rating. The amount of torque at zero speed, which a motor can continuously deliver without exceeding its thermal rating Torque developed at 10krpm so the motor temperature doesn t exceed its thermal rating Figure of merit to evaluate motor Current of the unloaded motor at no-load speed. It represents the friction losses of the standard motor at that speed. Speed of the unloaded motor, it is proportional to the supply voltage. Supply voltage at which the characteristics have been measured (at 20/25 C). It is the product of motor regulation (R/k 2 ) and rotor inertia J. It describes the motor physically taking into account electrical (R), magnetic (K t ) and mechanical (J m ) parameters. It is the time needed by the motor to reach 63% of its no-load speed or of its nal speed in view of the voltage and load conditions. The current drawn by the motor when delivering peak torque The maximum torque a brushless motor can deliver for short periods of time. RESISTANCE R [Ohm] +/-10% Terminal resistance phase to phase at 25 C ROTOR INERTIA J m [kg-m 2 or oz-in-sec 2 ] STATIC FRICTION TORQUE T f [mnm OR oz-in] Rotor (magnet and shaft) inertia Torque required to turn the motor shaft with out powering the motor THERMAL RESISTANCE [ C/Watt] Gives the motor temperature rise for a power dissipation of 1 W. For slotted motor the value is measured with motor mounted on a 6.0 x 6.0 x 0.25 aluminum heat sink For slotless motor the value is measured under unfavorable conditions (motor alone). With measuring methods refiecting more common operating conditions, values which are 10 to 50% lower may be obtained. TORQUE CONSTANT K t [mnm/a OR oz-in/a] +/-10% VISCOUS TORQUE (LOSSES) [mnm/krpm OR oz-in/krpm] WEIGHT W [g OR oz] Indicates the torque developed for a current of 1 Amp Inherent losses such as friction in the ball bearings and Foucault current. Those are proportional to speed. Average weight of the standard motor

17 Where to apply your Portescap Brushless motor SURGICAL HAND tool When you re an orthopedic surgeon performing multiple operations in a day, hand tools that are powerful and precise are a must. However, a smaller, more lightweight version of the tool would be a welcome relief. Portescap supplies customized solutions that are exceptionally lightweight but do not compromise performance. Its lightweight feel and low-heat feature reduce hand fatigue in surgeons. Suitable sealing and optimized design assure adequate autoclaving and prevent contamination. So surgeons, and their patients, have a lot to feel comfortable about. medical High speed surgical hand tools Small bone surgical hand tools Large bone surgical hand tools Dental hand tools Respirators & ventilators Infusion & insulin pumps Dental imaging Analyzers INDUStRIAL AUtomAtIoN Industrial nut runners Industrial screwdrivers Air pumps Conveyors Electronic assembly AERoSPACE & DEFENSE Aircraft on board instrumentation Gyroscope Satellites Valves SECURItY & ACCESS Barcode readers Camera Fuel metering system Electric actuator Locks Ticket printer & dispenser other Robotic Precision instrumentation Engraving

18 Timing Relationship B0504, B0508, B0512, 13BC, 16BHS, 16BHL, 22BHS, 22BHM, 22BHL Timing relationships between the motor phases and the hall sensors that support cummutation (four pole motor). CW rotation from shaft end. Motor is supplied with connector AMP # which may be removed. 16

19 Miniature Motors B0610, B0614, B906, B909, B912, B1106, B1112, B1118, B1505, B1515, B1525, nuvodisc series Timing Relationship Slotted BLDC Timing relationships between the motor phases and the hall sensors that support cummutation (four pole motor). CW rotation from shaft end. Motor is supplied with connector AMP # which may be removed. 17

20 turbodisc StEPPER motors P430 P532 P310 P110 P010 The TurboDisc provides exceptional dynamic performance unparalleled by any other stepper on the market. The unique thin disc magnet enables finer step resolutions in the same diameter, significantly higher acceleration and greater top end speed than conventional steppers. TurboDisc excels in applications that require the precision of a stepper and the speed/acceleration of a DC motor. Why a TurboDisc motor 98 TurboDisc Motor Basics 99 How to select your TurboDisc motor 100 TurboDisc Specifications 101 Where to apply TurboDisc motors 103

21 Why a turbodisc motor Stator w/windings Bearings Disc magnet End Bells Innovation & Performance A technology providing unique results. At its heart there is the rotor, a thin disc or rare earth magnet material. Portescap s unique design allows for axial magnetizing with a high number of poles, and for optimizing the magnetic circuit with a corresponding reduction of losses. The quantum leap of this state-of-the-art technology developed by Portescap is extremely high dynamic performance comparable to DC servo motors but obtained from a simple stepper motor. The TurboDisc is well suited to be tailored to your application requirements. Our design engineers can integrate our motor into your assembly. Our TurboDisc design assistance can range from providing additional components to a fully customized motion solution that optimizes the space and performance of your machine. TurboDisc advantages include: Precise - Well suited for microstepping Fast - Disc Magnet enables fastest acceleration and highest top speed of any step motor while maintaining accurate positioning Unique - Low detent torque and highly customizable Your custom motion solution Sintered or ball bearings Various windings Shaft modiflcations increase/decrease length, knurling Longer leads, connectors Gearheads for increased torque Encoders for position veriflcation Standard Features Frame sizes ranging from: Outer diameter - 10 mm to 52 mm Output speed - up to 10,000 rpm Step angle 3.6º, 6, 9º & 15º Output torque - up to 350 mnm Adaptable - Higher steps per revolution than CanStack products; can be increased through tooling Miniature - Down to 10 mm diameter with 24 steps per revolution

22 turbodisc motor Basics the High Performance Disc magnet technology The exceptional possibilities offered by the Turbo Disc line of disc magnet stepper motors are unequalled by any other kind of stepper motor. The advanced technology, developed and patented by Portescap, allows for truly exceptional dynamic performance. The rotor of these motors consists of a rare earth magnet having the shape of a thin disc which is axially magnetized. A particular magnetization method allows for a high number of magnetic poles, giving much smaller step angles than conventional twophase permanent magnet stepper motors. Short magnetic circuit using high quality laminations Such a rotor design has a very low moment of inertia, resulting in outstanding acceleration and dynamic behavior. These features, together with high peak speeds, mean that any incremental movement is carried out in the shortest possible time. Low inertia also means high start/stop frequencies allowing to save time during the first step and to solve certain motion problems without applying a ramp. Those motors, specially designed for microstepping, feature a sinusoidal torque function with very low harmonic distortion and low detent torque. Excellent static and dynamic accuracy is obtained for any position and under any load or speed conditions. No magnetic coupling Rotor with very low inertia Concept Detail Motor Characteristics Advantages for the application Thin multipolar rare earth disc magnet Very low motor inertia Very high acceleration, high start/stop frequencies Very short iron circuit made of SiFe / NdFeB laminations, Coils placed near to the airgap No coupling between phases Sinusoidal torque function Low detent torque Superior angular resolution in microstep mode Optimally dimensioned iron circuit Torque constant is linear up to 2 to 3 times nominal current High peak torques High energy magnet High power to weight ratio For motors in mobile applications For size limitations

23 How to select your turbodisc stepper turbodisc motor torque Range P010 P110 P310 P430 Continuous torque Peak torque PP520 P520 P530 P532 Torque in mnm Torque in oz-in turbodisc motor Designation P X V TurboDisc Internal Code Code of length Number of rotor pole pairs Resistance per winding Motor execution code Particular option Code of diameter Motor version of full/ half-step = 2 Motor version of microstep = 0 Number of connections or terminal wires

24 Explanation of Specifications MOTOR PART NUMBER P /12 ExpLanatIon RATED VOLTAGE vdc Voltage rating of motor - motor can be run continuously at this voltage RESISTANCE PER PHASE, ± 10% ohms Winding resistance dictated by magnet wire diameter and # of turns INDUCTANCE PER PHASE, TYP mh Winding inductance dictated by magnet wire diameter and # of turns RATED CURRENT PER PHASE * amps 0.12 Current rating of motor - motor can be run continuously at this current BACK-EMP AMPLITUDE V/kst/s The torque constant of the motor - the back EMF generated by the motor when externally spun at 1000 steps per second HOLDING TORQUE, TYPICAL * oz-in / mnm DETENT TORQUE, TYPICAL oz-in / mnm 1.0 / 7 When energized, the amount of torque to move from one mechanical step to the next 0.1 / 1 When un-energized, the amount of torque to move from one mechanical step to the next STEP ANGLE, ± 10% * degrees deg / number of mechanical steps of the motor STEPS PER REVOLUTION * Number of mechanical steps of the motor NATURAL RESONANCE FREQUENCY (NOMINAL CURRENT) Hz The frequency at which the motor vibrates at maximum amplitude ELECTRICAL TIME CONSTANT ms 0.80 Represents the time it takes for the input current to the motor coil to reach approximately 63% of its final value ANGULAR ACCELERATION (NOMINAL CURRENT) THERMAL RESISTANCE ºC/watt ROTOR MOMENT OF INERTIA rad/s The rotational acceleration of the motor when supplied with nominal current oz-in-s2/ g-cm x 10E-4 / 0.4 Inertia of the rotor AMBIENT TEMPERATURE RANGE OPERATING ºC -20 ~ +50 Temperature range which the motor will operate STORAGE ºC -40 ~ +85 Storage temperature where the motor will operate BEARING TYPE - SINTERED BRONZE SLEEVE (Optional Ball Bearing on request) INSULATION RESISITANCE AT 500VDC Mohms 100 MEGOHMS Bearings on front and rear of the motor DIELECTRIC WITHSTANDING VOLTAGE vac 300 FOR 5 SECONDS WEIGHT lbs / g 0.05 / 23 Weight of the motor SHAFT LOAD RATINGS, MAX AT 1500 RPM RADIAL lbs / N 0.12 / 0.5 (AT SHAFT CENTER) Maximum load that can be applied against the shaft AXIAL lbs / N 0.12 / 0.5 (BOTH DIRECTIONS) Maximum load that can be applied directly down the shaft LEADWIRES - Insulated Cable, AWG 26 Rating of the lead wires TEMPERATURE CLASS, MAX - B (130 C) Maximum temperature of the winding insulation RoHS - COMPLIANT

25 P /P Pull-Out Torque vs Speed Full step, bipolar voltage Pull-Out Torque oz-in 0.4 Pull-In Torque 3.0 mnm Torque Speed pps rpm P Pull-Out 24V, 47 ohms Series Resistor P Pull-Out 0.9A, 24V P Pull-In 24V, 47 ohms Series Resistor P Pull-In 0.9A, 24V Definitions Pull-Out Torque The amount of torque that the motor can produce at speed without stalling Pull-In Torque The amount of torque that the motor can produce from zero speed without stalling Speed # of pulses per second provided to the motor, also stated in revolutions per minute Voltage Voltage applied to the drive Current Current applied to the drive Drive Chopper type drive - current controlled to the motor winding

26 Where to apply your turbodisc stepper the turbodisc stepper provides the highest torque to inertia ratio and is ideal for applications requiring, fast and precise positioning. Focus On: medical Analyzer Portescap s challenge for the application was to provide maximum torque in a small diameter package. The higher speed capability of the TurboDisc allowed a higher gear ratio to be utilized, yielding an increase in output torque at the desired speed. The disc magnet design creates quick response time for the motor, increasing the throughput of the machine. textile Yarn monitoring system Electronic wire winding Factory Automation Pick & place machines Head positioning Die bonding Wafer handling Feeders medical & Lab Automation Analyzers Syringe pumps Pipettes Milling machines Prosthetics Other Industries & Applications Engraving Laser cutting Bar code scanning Aircraft instrumentation Fiber optic splicers Mail sorting

27 ENCoDeRS Feedback mechanisms for gauging motor position and speed are highly essential for a wide range of applications in medical, industrial automation, security and access. Portescap s encoder technologies spanning from the simplest tachogenerators to highly sophisticated MR encoders provide a bundle of solutions for positioning and speed related feedback to facilitate the needs of motion in a variety of applications. Why an Encoder 250 Spotlight on MR2 Encoder 251 Encoder Specifications 254

28 Why an Encoder Asic LED Codewheel Feedback & Positioning D.C. tachogenerators magnetic ENCODERS The combination of an ironless rotor, a high grade permanent The integrated Portescap type D magnetic encoder consists of magnet, and a commutation system made of precious metals, a multipolar magnet mounted directly on the motor shaft. As results in Portescap DC tachogenerators having a truly linear the motor shaft turns, magnetic flux variations are detected by relationship between angular velocity and induced voltage, a Hall sensors which generate two TTL-CMOS compatible output very low moment of inertia and negligible friction. signals having a 90 phase shift between both channels. The OPtICAL ENCODERS simple and robust design of this sensor makes it ideally suited to applications with severe operating conditions, such as high The incremental optical encoders from Portescap have three temperature, dust, humidity, and vibration. Integrated into output channels. It uses a dedicated ASIC having a matrix of Portescap motors, these units are intended for applications optoelectronic sensors which receives infrared light from an requiring compact and reliable high performance systems for LED after its passage through a metal codewheel. The mask speed and position control. determining the phase angle and index position is directly integrated onto the circuit, ensuring very high precision. The differential measure of the light modulated by the codewheel generates digital output signals insensitive to temperature drift with an electrical phase shift of 90 between channels A and B. The standard version of the encoder provides CMOS compatible complementary signals for improved signal transmission and noise rejection. Besides the detection of the direction of rotation and signal transitions in channel A and B for direct control of a counter or a microprocessor, the integration of this particular circuit offers additional functions such as a stand-by mode for reduced current consumption in battery powered equipment.

29 Spotlight on mr2 encoder Magnetoresistance effect which was first discovered in 1857 can be seen in three different configurations:- 1.R(M(T)) Resistance changes due to indirect manipulation of magnetization through thermal changes 2.R(M) Resistance changes due to direct manipulation of the magnetization. 3.R(ω M,I ) Resistance changes due to the angle between the magnetization and current The third effect, also referred to as anisotropic magnetoresistance is exploited in Portescap s high resolution MR encoders. This resistance variation responds to the following equation: γ(ω M,I ) = γ 0 + γ fi cos 2 (ω M,I ) where γ 0 is the zero-field resistivity, γ fi is the minimal resistivity and ω M,I is the angle between the magnetic field and the current. The relation between resistivity and magnetic angle governs the design of the MR encoder and as such the encoder signals have negligible effect on variation in magnetic field strength. Using interpolation techniques, several output lines per revolution are generated with only one period of analog signal coming out from the sensor magnet system, in incremental magnet encoders. The pulse signal from MR encoder as shown below is proportional to speed and distance traveled by the shaft and can be used for effective feedback. A B State: Permanent magnet As the MR technology is not needed to have physically all the output lines (poles in case of a magnetic encoder) on the encoder disc, the MR encoder can be made very compact, even for high resolution. The magnetic field inside the encoder can be maximized by having a low number of relatively big magnetic poles. The strong field so obtained makes this encoder very resistant against any unwanted external field. Also, with this compact design the encoder disc magnet remains very small thus sustaining the motor s high dynamic performances. Finally, as this encoder is made around a magnetic angle sensor, it is not sensitive to vertical position changes and, hence, ball bearings in a motor are not a prerequisite to achieve high resolution.

30 Motor End cap Encoder Chip Encoder Chip Concept Detail Encoder Characteristics Advantages for the Application Interpolated lines Field angle sensor Low thickness high field density magnet Physical line count on the encoder disc is much lower than encoder resolution High magnet field obtained with simple bipolar magnet No sensitivity to axial movement of the encoder magnet Ultra low encoder inertia Ultra compact design for high resolution Very low sensitivity to unwanted external field Ball bearing motor not required even for high resolution High dynamic performance of the motor stays intact

31 GEARHEADS R16 R40 R32 M22 Portescap manufactures some of the highest performance miniature gearheads in the industry that are subjected to rigorous quality tests during manufacturing. With a range of planetary and spur gearheads from 8 mm to 40 mm in diameter, Portescap can offer an entire drive train based on its motor gearbox solutions. Resident experts in gear technology can assemble the gears at Portescap with metal or plastic gears based on an application need. Why a Gearhead 224 Basic Gearhead Operation 225 How to select your Gearhead 226 Gearhead Specifications 228

32 Why a Gearhead Efficient Performance Every application has power requirements in terms of speciflc values of speed and torque. With a load demanding high torque at low speed, use of a large motor capable of developing the torque would be uneconomic, and system efflciency would be very low. In such cases, a better solution is to introduce some gearing between the motor and the load. Gearing adapts the motor to the load, be it for speed, torque, or inertia. The motor-and-gearbox assembly will provide greater efflciency and will be an economic solution. Reduction Gearboxes using Spur Gears This gear technology offers advantages in current-limited applications where lowest input friction and high efflciency are essential. The broad range of Portescap spur gearboxes is well adapted to our motor lines, and includes integrated gearmotors. Planetary Gearboxes The main advantages of Portescap planetary gearboxes are their high rated torque and a high reduction ratio per gear train. Both types use high quality composite materials. The all-metal planetary gearboxes, have a very compact design with excellent performance and lifetime. Gearhead Designation R Gearbox Type Gearbox diameter in mm Gearbox execution code Reduction ratio High Speed Planetary Gearboxes This high performance product line was designed for use on BLDC motors with iron core windings. The gearboxes tolerate input speeds in the range of 10,000 to 70,000 rpm and output speeds of several 1,000 rpm. This facilitates a motor-gearbox unit of very small dimensions that can provide extremely high values of speed and torque.