High-torque direct drive rotary servomotor

Transcription

1 High-torque direct drive rotary servomotor advanced Direct DRive technology in a compact, customized package for high-power applications What moves your world

2 Moog s new line-up of customized High-Torque Direct Drive Rotary Servomotors provides exceptional power and control without increasing machine size. With peak torque up to 50,000 Nm, they are ideal for highspeed applications such as press work, injection molding, laser cutting, and sheet metal punching. An extraordinary response pattern, customized motor characteristics, and original control solutions provide a significant performance edge, with implementation costs able to be recovered in just one to two years. Read on to find out more about this exciting technology

3 Fitting motors to the mechanism, not the mechanism to motors Machine builders are increasingly being forced to adapt their designs to fit a number of globally uniform motion control components such as ballscrews, controllers, and servomotors. A performance edge is a strong appeal point for end users. However, increased use of standard components makes this difficult to achieve. Moog has tackled this issue head on with a new line-up of High-Torque Permanent Magnet Rotary Servomotors incorporating advanced direct drive technology in a customized package. With peak torque up to 50,000 Nm and a very compact design, these motors deliver the power and control required for large, high-speed applications without proportionate increases in machine size.

4 Investment in Performance Moog s Direct Drive Servomotors are an investment in performance-enhancing technology that simplifies drive systems, improves control, and reduces assembly time to provide greater value for machine builders and end users alike. Advantages over conventional servomotors Conventional rotary servomotors are connected to loads via mechanical transmissions such as gearboxes and belt drives. However, mechanical transmissions cannot provide optimal performance due to inherent backlash and compliance which affects repeat and position accuracy. A larger moment of inertia also affects motor response and velocity control. Eliminating these wear-prone, redundant components with a Moog Direct Drive Servomotor allows machine length to be reduced, renders the motion control system maintenance free, improves reliability, cuts operating noise and frictional heat losses, and reduces machine assembly time. Advantages over servo-hydraulic systems Servo-hydraulic systems are more demanding than electric. Oil must be kept clean and there is an inherent fire risk. They also consume large amounts of electricity because pumps are operated continuously. Accuracy is a challenge due to changes in hydraulic fluid viscosity as machine temperature rises, and the large number of components involved impacts machine assembly time. A leading injection molding machine builder found operational problems reduced by 90 percent when it switched to direct drive servo-electric technology because problems such as filter blockages, valve seizures, and oil leaks were eliminated. Machine builders in other application areas have found trouble disappeared altogether. Maintenance free Improved reliability Faster response Increased accuracy Direct drive servomotor benefits Reduced machine length Reduced assembly time Higher efficiency Less operating noise Stepless movement

5

6 more torque without increasing machine size Moog knows that a motor s performance is not determined by its kilowatt output, but by how much torque it has. Focusing on this important yet often neglected fact in motor design enables us to extract more torque from a given kilowatt size. Moog Servomotors are up to 40 percent smaller than equivalent direct drive offerings and permit exact torque requirements to be matched with any motor speed between 300 and 1000 rpm Frame Size (mm) This line-up of direct drive motors also provides more peak torque at a higher range to enable electrification of larger tonnage machines. The top model is one of the world s largest synchronous servomotors with 50,000 Nm peak torque. Rated torque ranges from 185 Nm to 17,000 Nm. Motor performance is enhanced via water- and fan-cooling. Peak Torque (Nm) Short Medium Long (Motor length) Motor Line-up Motor Line-up Application 1: Press work The superior control characteristics of Moog s direct drive technology make it the ideal development platform for advanced techniques such as net shaping and intelligent pressing. Gearboxes can be eliminated from crank-type presses up to 50 tons. Gears ratios such as 10:1, or less, can be used on crank-type machines from 50 to 3,000 tons for significant space reduction and cost savings compared with conventional servomotors which use expensive torque gears to reduce backlash.

7 7 Solutions designed around you Faster response Moog Servomotors have an extraordinary response pattern that matches the requirements of the most dynamic applications. They combine high peak torque with a low moment of inertia for faster response, improved accuracy, and stepless movement during high-speed operation. Response time is up to half that of conventional servomotors with gearboxes. Speed (rpm) 300 Design flexibility Moog Direct Drive Motor Response Time Conventional Servomotor with Gearbox Time (s) Moog customizes the characteristics and packaging of these motors to provide higher performance and machine design flexibility than previously possible. Stator design can be customized to maximize peak or rated torque for a motor with the optimal performance characteristics for each given application. Every kind of shaft and hollow shaft configuration can be accommodated to enable greater originality in machine design. For example, flange, spline, key, and thread configurations are available and hollow shafts can be freely enlarged to pass cables or house mechanical components to reduce machine length. The motor can provide the bearing unit for the machine or alternatively the machine can provide the bearing unit for the motor for cost reduction and ease of installation. Taper roller bearings can be accommodated for high radial and axial loads, and thrust bearings when ballscrews are used. Electromagnetic brakes in sizes not supplied by brake manufacturers are available for the largest applications. Drive solutions Moog provides customized drive solutions for easier operation, faster set up, optimal performance, and size advantage, especially on medium to large capacities. Solutions include original programs for control of machine axes and customization of drive shape and configuration. Drives can be separated into heat producing and nonheat producing stages to enable more efficient cooling processes, and multiple circuit configurations provided for optimal control of larger motors. Water-cooling and customized mounting are also available. Application 2: Injection molding These high-torque servomotors are ideal for both crank and ballscrew type injection molding systems. They can be applied to the injection axis of 500 to 3,000 ton machines and the plasticizing axis of even the largest hybrid machines. Either way, they greatly reduce machine envelopes. Their low-speed, hightorque characteristics enable use of long lead ballscrews on the injection axis for longer ballscrew life. Hollow pancake designs on the plasticizing axis reduce overall machine length.

8 8 Reducing Total Cost of ownership for end users Coming from servo-hydraulic systems The greatest advantage for machine users in switching from hydraulic to electric systems is savings on power charges. High-speed applications which run hydraulic pumps continuously can recover the cost of direct drive motors in one to two years through savings on electricity costs. Servo-electric presses only consume 10 to 20 percent of the electricity required by their hydraulic counterparts, while all-electric injection molding machines only consume 20 to 30 percent of hydraulic machines. Consumables such as hydraulic fluid and filters are no longer required and maintenance burden is greatly reduced. Servo-electric machines are also inherently safer than hydraulic-based processes because they eliminate the need to handle and manage large quantities of hydraulic fluids. In some cases, removal of servovalves, accumulators, manifolds, pumps, and hoses even reduces overall machine cost. The elimination of these components in a servoelectric system also simplifies machine assembly. Coming from conventional servo-electric systems Servomotors are intended to be maintenance-free. However, use of conventional servomotor systems on applications requiring different torques or motor speeds complicates power transmission design through the addition of mechanical couplings using gearboxes or belt drives. The use of such mechanical transmissions initiates a series of inefficiencies that snowball into higher operating costs for end users. Gearboxes and belt drives also introduce problems with tuning and position inaccuracy. The increased number of components involved tax design and integration resources, while part failures increase maintenance burden and reduce output. Removing backlash or compliance from mechanical transmissions is very expensive and prone to further problems with thermal expansion and performance. Application 3: Laser cutting This technology provides higher traverse speeds on laser cutting machines. A compact, high-torque hollow motor directly drives the nut, and not the ballscrew. This minimizes inertia and eliminates skipping that occurs when motors drive long screws. Combined with a long lead ballscrew, this enables laser heads to be rapidly and accurately positioned for clear performance advantage.

9 9 It all starts with a Yes : moog total support Yes, we can help you. Whether you are considering switching from hydraulic to servo-electric systems, from conventional electric systems to direct drive motion control, looking to refit a machine or design a completely new one, Moog is here to support you. Our trained engineers, based in 24 countries around the world, bring a dynamic and collaborative approach to helping you solve your engineering problems. That s because, instead of starting with a particular motor, we start with a thorough understanding of your application. By addressing your unique needs, we can customize the ideal motor specifications for your largest applications with no artificial barriers to originality or performance. Contact your nearest Moog representative today for an introduction to this unique direct drive servo-electric technology. Application 4: Sheet metal punching These direct drive servomotors can be used to improve the performance of turret punch presses with punching capacities from 20 to 50 tons. Converting the ram drive from servo-hydraulic to direct drive improves accuracy, reduces operating noise, and increases hit rates. Energy savings associated with servomotor implementation are further increased by Moog s drive regeneration technology.

10 10 specifications and mounting These servomotors come in five frame sizes, with three different stack lengths per frame. Different voltage ratings are available including 3-phase 220V and 400V for maximum flexibility and robust operation. The standard feedback device provided with the motors is an absolute encoder. However, incremental encoder and resolver are also available. Servomotor specifications Frame size mm 290x x x x x825 Motor length* (short, medium, long) S M L S M L S M L S M L S M L Motor length mm Nominal power Rated torque Fancooled Watercooled Fancooled Watercooled kw kw Nm Nm Peak torque Nm Rated speed rpm Max. speed rpm *See chart on page 6. Mounting diagram Water-cooling: 4 x 25mm 75 Motor Length Frame Size Fan-cooling: 2 x 71mm (for 290, 375 and 450 Frame) 2 x 75mm (for 550 and 825 Frame)

11 Whenever the highest levels of motion control performance and design flexibility are required, you ll find Moog expertise at work. Through collaboration, creativity, and world-class technological solutions, we help you overcome your toughest engineering obstacles. Enhance your products performance. And help take your thinking further than you ever thought possible.

12 moog.com/industrial For the Moog location nearest you, visit moog.com/industrial/globallocator. Argentina +54 (0) Australia +61 (0) info.australia@moog.com Austria +43 (0) info.austria@moog.com Brazil +55 (0) info.brazil@moog.com China +86 (0) info.china@moog.com Finland +358 (0) info.finland@moog.com France +33 (0) info.france@moog.com Germany +49 (0) info.germany@moog.com Hong Kong info.hongkong@moog.com India +91 (0) info.india@moog.com Ireland +353 (0) info.ireland@moog.com Italy info.italy@moog.com Japan +81 (0) info.japan@moog.com Korea +82 (0) info.korea@moog.com Luxembourg info.luxembourg@moog.com Netherlands +31 (0) info.netherlands@moog.com Norway info.norway@moog.com Russia +7 (8) info.russia@moog.com Singapore info.singapore@moog.com South Africa +27 (0) info.southafrica@moog.com Spain info.spain@moog.com Sweden +46 (0) info.sweden@moog.com Switzerland +41 (0) info.switzerland@moog.com United Kingdom +44 (0) info.unitedkingdom@moog.com USA info.usa@moog.com 2006 Moog Inc. Moog is a registered trademark of Moog, Inc. and its subsidiaries. All trademarks as indicated herein are the property of Moog, Inc. and its subsidiaries. All rights reserved. Specifications may be revised without notice. Comparisons based on internal Moog data. DDR Servomotor CDL Mobium/PDF What moves your world