Plug & Drive Motors with Integrated Controller€¦ · nominal speed of 1000 rpm, while the BLDC model has a nominal speed of 3500 rpm and a nominal output of 135 W. Like in the PD2-C

Product Innovations 2015/2016

Plug & Drive Motors with Integrated Controller

Easy Programming with Plug & Drive Studio

Programmable stepper and BLDC motors in three sizes with

field-oriented control for precise position, speed and torque control

New software for rapid and easy setup and programming of Nanotec controllers

www.nanotec.com

TechnologyPlug & Drive Motors

Specifically for applications that require high performance and efficiency, Nanotec has developed a new generation of Plug & Drive motors with field-oriented control in which the controller and encoder have already been integrated. These motors are controllable via clock-direction, analog input or the CANopen field bus and can be programmed with NanoJ V2 (see page 5).

PD2-C

With a flange size of 42 mm, the motors of the PD2-C series are ideal for appli-cations that require less torque or have space constrictions, such as in laborato-ry automation. Like all P&D motors from Nanotec, these devices are available either as stepper or BLDC versions, con-trolled via USB or CANopen.

TECHNICAL DATA

PD2-CHigh-pole DC servo (stepper motor)Operating voltage: 12–48 VNominal torque: up to 0.5 Nm................................................................

PD2-CBLow-pole DC servo (BLDC)PD2-CB42COperating voltage: 12–48 VNominal output: 105 WPeak output: 315 WNominal torque: 0.25 NmNominal speed: 4000 rpm

Interfaces/programming:

PD6-C

The PD6-C is the largest motor of the P&D series and features very high power density in relation to its size. It is equipped with both a USB and CANopen interface, and comes in three motor versions: as a stepper motor with a nominal torque of 8.8 Nm, as a BLDC motor of size NEMA 34 with a nomi-nal output of 220 W, and as a BLDC motor with a flange size of 80 mm and a nominal output of 534 W.

TECHNICAL DATA

PD6-CHigh-pole DC servo (stepper motor)Operating voltage: 12–48 VNominal torque: up to 8.8 Nm................................................................

PD6-CB87SLow-pole DC servo (BLDC)Operating voltage: 12–48 VNominal output: 220 WPeak output: 660 WNominal torque: 0.7 NmNominal speed: 3000 rpm................................................................

PD6-CB80MLow-pole DC servo (BLDC)Flange size: 80 mmOperating voltage: 12–48 VNominal output: 534 W Peak output: 1570 W Nominal torque: 1.7 Nm Nominal speed: 3000 rpm

Stepper motors with field-oriented control are ideally suited for winding applications

nominal speed of a servo motor of the same size. In addition, this motor gets rid of the disadvantages of classical open-loop control, such as resonance or excessive heat generation.However, these advantages of field-oriented control do not justify the high-er price for the required encoder in classical stepper motor applications. The positioning accuracy of the open-loop stepper motor is often suffi-cient, and developers simply require better running behavior and less heat generation. To be able to benefit from the advantages of field-oriented control in these applications as well, Nanotec has developed a sensorless, i.e. encoder-free, control for stepper motors in which the current position and speed of the rotor are calculated by a

“virtual encoder” in the controller. An autosetup routine measures the connected motor and automatically determines the required parameters. The sensorless algorithm recognizes the accuracy with which the speed is currently being estimated. If the signal becomes too imprecise as the speed decreases, the system automaticallyswitches to open-loop control and positioning continues in this mode. When restarted from a standstill, only a few degrees are needed to return to closed-loop mode. Thus, sensorless technology makes it possible to benefit from the advantages of field-oriented control in almost all traditional stepper motor applications.

PD4-C

The motors of the PD4-C series have a flange size of 56 and 60 mm and consequently generate a higher out-put. The stepper motor version has a nominal torque of up to 3.5 Nm at a nominal speed of 1000 rpm, while the BLDC model has a nominal speed of 3500 rpm and a nominal output of 135 W. Like in the PD2-C series, the in-tegrated controller is available in a USB and CANopen version.

TECHNICAL DATA

PD4-CHigh-pole DC servo (stepper motor)Operating voltage: 12–48 VNominal torque: 1–3.5 Nm................................................................

PD4-CBLow-pole DC servo (BLDC)Operating voltage: 12–24 VNominal output: 135 WPeak output: 338 WNominal torque: 0.37 NmNominal speed: 3500 rpm

Stepper motor technology was long considered to be merely a cost-effective alternative to applications that do not demand the high performance delivered by servo motors. Especially in machine design, applications were increasingly changed over to servo motors, whose ease of integration in small spaces counters their higher procurement costs.This trend was reversed by the devel-opment of field-oriented, closed-loopcontrolled stepper motors. The core of closed-loop technology is the field-oriented control of stepper motors via encoder signals. This corresponds to the control of a servo or BLDC motor, turning a classical stepper motor into a high-pole servo motor. The resulting system continuously achieves twice or three times the torque at 20–50% of the

PD6-CPD4-C

Field-Oriented Control of Stepper Motors with and without an Encoder

TechnologyMotor Controllers

All new motor controllers from Nanotec support the sensorless control feature and are suitable for open-loop and closed-loop applications. They are quick to parameterize and easy to program using the C++ based programming language NanoJ V2.

Model series N5 C5 C5-E.................................................................................................................................................................................................................................Operating voltage 12-48 V 12-48 V 12-48 V .................................................................................................................................................................................................................................Continuous current 10 A (low current) 6 A 6 A (low current) 18 A (high current) 10 A (high current).................................................................................................................................................................................................................................Peak current 10 A (low current) 6 A 6 A (low current) 54 A (high current) 30 A (high current).................................................................................................................................................................................................................................Encoder yes no yes.................................................................................................................................................................................................................................Brake yes no yes.................................................................................................................................................................................................................................Interfaces EtherCAT, CANopen, Ethernet/IP USB USB, CANopen.................................................................................................................................................................................................................................Inputs/outputs 6 digital inputs 3 differential inputs 5 digital inputs 2 analog inputs 3 digital inputs 2 analog inputs 2 digital outputs 2 analog inputs 3 digital outputs 2 digital outputs.................................................................................................................................................................................................................................

Model series CL3-E NP5 .................................................................................................................................................................................................................................Operating voltage 12-24 V 12-48 V .................................................................................................................................................................................................................................Continuous current 3 A 6 A .................................................................................................................................................................................................................................Peak current 3 A (low current) 10 A 6 A (high current) .................................................................................................................................................................................................................................Encoder yes yes .................................................................................................................................................................................................................................Interfaces USB, CANopen, Modbus 2x SPI, 1x I2C, (RS485, RS232) CANopen (external circuitry required) .................................................................................................................................................................................................................................Inputs/outputs 5 digital inputs 2 encoder inputs 2 analog inputs 1 input for Hall sensor 2 digital outputs 7 general I/O 2 A/D converter 1 brake output 1 output for external ballast circuit.................................................................................................................................................................................................................................

Interfaces/programming:

objects, such as the reaching of a cer-tain position or the activation of a digi-tal input. Oscilloscope settings thatcontain required objects such as following errors, target positions and actual positions are predefined for a standard tuning. These settings can be adjusted at any time.To program the controller with NanoJ V2, an integrated development environment is available that consists of a source text editor with automatic code completion,

For the programming of our controllers, we developed NanoJ, a C++ based programming language in which the user program runs in a “sandbox”, which is executed in a fixed cycle of 1 ms. This method is used to read out the controller settings and status values (I/O status, actual current, speed, position, etc.) after every 1-ms cycle. As a result, users can react to changes with just a few lines of code. They can also solve complex technical requirements, such as tracking a special acceleration ramp according to a mathematical function or changing the control parameters of a motor while it is running. Because field bus communication can be operated in parallel, time-critical tasks can be processed directly in the controller.

a compiler and a debugger. The debug-ger allows programmers to set up four breakpoints in the program at which values of variables can be read out. Because all of the Plug & Drive Studio functions can be used simultaneously, controller behavior can be examined during program execution using the object directory and oscilloscope. As a result, customer-specific functions can be easily and quickly programmed.

A new software is now available for easy setup and programming of Nanotec’s motor controllers: Plug & Drive Studio. The controller can be accessed from a PC via a variety of field buses (CANopen, Ethernet, Modbus). For setup, the object directory holding the controller configu-ration can be read and written via a ta-ble. Pre-defined filters enable the user to only display the parts of CiA 402 objects that pertain to a certain task, such as set-up or a certain operating mode, i.e. the speed. Experienced users can configure the objects via an integrated command line. The entire communication can be recorded and played back later so that lengthy command sequences only need to be entered once during setup.To tune the controller parameters, an integrated oscilloscope displays up to eight objects simultaneously with a resolution of up to one millisecond. Recording can be controlled by free-ly configurable start and stop triggers that define conditions for the displayed

Model series N5 C5 C5-E

Model series CL3-E NP5 Model series CL3-E NP5

Model series N5 C5 C5-EModel series N5 C5 C5-E.................................................................................................................................................................................................................................

Plug & Drive Studio

Application-Specific Programming

NanoJ V2 development environment

Oscilloscope with target and actual positions and following errors

Object directory

Custom SolutionsBLDC Motors

Nanotec offers a variety of three-phase BLDC motors with high-energy permanent magnets that provide rapid acceleration and high speeds paired with excellent efficiency. These devices are ideal for applications that demand very smooth running and a long service life.

In addition to customized motors based on modifications of standard compo-nents through shaft processing and cable assembly, we also develop com-pletely new, customized drive solutions. As our customer, you will benefit from our many years of experience in the development of drive solutions combined with our own production center that enable us to devise optimal solutions for series production and to produce these in our own facilities. If needed, our team will support you as early as the concept phase to develop an optimal drive with motor parameters dimensioned precisely for your appli-cation. The motor will be specifically designed to meet your requirements in terms of size and performance, envi-ronmental conditions, controllers with adapted software and more.

At Nanotec, you can obtain tailored drive systems for applications demanding the highest levels of precision, reliability and functionality in a small space. Our stepper and BLDC motors, linear actuators and lin-ear positioning drives, in sizes beginning at 10 mm and featuring a wide variety of gears and encoders, are combinable into modular systems with over 4000 possible combinations.

Our online configurator at www.nanotec.com takes you through the necessary steps to obtain a motor combination that meets your needs.

Modular Motor Configuration System - over 4000 Possible Combinations Available in Stock

Solutions Developed just for You

DS16/DS28

Unlike most BLDC motors, DS16/DS28 slotless motors do not have pole shoes on the inside of the stator around which the winding wire is wound. Instead, a flat winding is applied to the ring-shaped stator. Slotless BLDC motors are ideal for high-speed applications because the absence of an iron core results in very low motor inductance, no cogging torque and no torque ripple. In addi-tion, iron losses of the motor are greatly reduced and the efficiency rating is high-er. Especially the smaller sizes of slotless motors exhibit a very high power density.

TECHNICAL DATA

DS16Diameter: 16 mmOperating voltage: 12/24 VNominal output: 3.7 –25 WPeak output: 11–75 WNominal torque: 0.16–1 NmNominal speed: 22,000–24,000 rpm................................................................

DS28

Diameter: 28 mmOperating voltage: 24 VNominal output: 17–28 WPeak output: 51–84 WNominal torque: 0.02–0.033 NmNominal speed: 8000 rpm

DB80

The DB80 has a flange size of 80 x 80 mm and is available with Hall sensors or an encoder. Powerful planetary gears can be added for high torque require-ments. Customized versions with other windings or shaft shapes are also possi-ble. Apart from applications in industrial automation, the DB80 is especially suit-able for applications in service robotics and intralogistics.

TECHNICAL DATA

DB80Flange size: 80 x 80 mmOperating voltage: 48 VNominal output: 534 WPeak output: 1570 WNominal torque: 1.7 NmNominal speed: 3000 rpm

DB41/DB43

The 10-pole BLDC motors of type DB41 are equipped with bonded magnets and feature Hall sensors that provide feedback on the rotor position. They are designed for nominal speeds of up to 3000 rpm.

The high-performance model series DB43 is a 6-pole solution with sintered magnets that offer approx. 30% more power output at the same length. Apart from the Hall sensor version, this model series can also be optionally equipped with a magnetic encoder and brake.

TECHNICAL DATA

DB41Size: NEMA 17Operating voltage: 24 VNominal output: 22–113 WPeak output: 66–339 WNominal torque: 0.07–0.36 NmNominal speed: 3000 rpm................................................................

DB43Size: NEMA 17Operating voltage: 24–48 VNominal output: 53–138 WPeak output: 159–414 WNominal torque: 0.17–0.44 NmNominal speed: 3000 rpm

just for You

Intensive Product TestingLinear Actuators and Positioning Drives

The performance curves on our website www.nanotec.com show the thrust as a function of speed. This helps in comparing different motor sizes and lead screw pitches in order to find the right combination for your needs.

Linear actuator with lead screwIn standard linear actuators, a thread nut made of thermal high-performance plastic is integrated in the hollow shaft of the motor. This thread nut converts the rotary motion of the motor to linear motion. In this version, the lead screw must be additionally secured from the outside against rotation to achieve linear motion.

Linear positioning driveUnlike linear actuators, linear positioningdrives feature an extended motorshaft with a thread. A thread nut externally mounted on this thread performs the linear movement. The nut is made of high-performance plastic and is nearly maintenance free. An additional bearing is not required due to the double ball bearings in the motor. The linear slide can be omitted in case of small loads and load capacity.

For this purpose, Nanotec has built special test benches that automatical-ly test the service life of various lead screw/load combinations under contin-uous operation and with an adjustable load. Three of these test benches are in continuous operation on 365 days of the year. The encoder on the motor ensures that the test only runs until the motor be-gins to lose steps. If testing is performed in closed-loop mode, the phase current can be monitored to identify a gradual reduction in total efficiency over the ser-vice life on account of wear.

for an initial assessment of whether the desired service life has been reached for a certain application or whether additional measures need to be taken, taken (such as electropolishing of the lead screw). Further information on service life calculations for linear actuators can be found on our website.

Linear actuator with linear slideLinear actuators with a linear slide have a flanged thrust rod unit that is linearly guided internally and locked against rotation. This gets rid of the need for an external anti-rotationlock in the connection design. Linear adjustment tasks can be easily implemented without additional mechanical systems. The achievable stroke depends on the length of the linear slide. Nanotec linear actuators with linear slides are available up to a stroke of 50 mm.

In addition to the ball bearing, linear ac-tuators from Nanotec contain another component that is subject to wear – the thread nut made of tribologically opti-mized, high-performance plastic. While ISO standards for service life calcula-tions exist for ball bearings, and service life estimates can be quickly performed using standard calculations based on the axial load, there are no standards for service life calculations of lead screw drives. The calculated assumptions therefore need to be verified by experi-mental methods.

The service life of the thread nut is sig-nificantly impacted by the contact pres-sure (p, pressure) and the sliding speed (v). Both an increase in pressure and an increase in the sliding speed mean a higher rate of wear. Normally, there-fore, the so-called pv value, which is the product of the two values, can be used as a measure of the expected wear since experience has shown that this value is roughly proportional to the wear rate at a constant temperature. For the various pv values, therefore, our test benches give us the lifetime in the form of a max-imum travel in kilometers, which we can

use to verify our calculated values. Apart from the pv value, the temperature and the form and positional tolerances of the lead screw guidance are among the main influencing factors on the service life. Especially the latter should be tested in the application. The theoretical cal-culation in combination with the results of the service life tests provide the data

Linear positioning drive

Linear Actuators on the Test Bench

High Force and Resolution

.................................................................................................................................................................................................................................Flange size 20 mm 28 mm 35 mm 42 mm 56 mm.................................................................................................................................................................................................................................Max. thrust 40 N 80 N 140 N 400 N 1000 N.................................................................................................................................................................................................................................Lead screw pitch 1, 8 mm 2, 5, 10 mm 1, 2, 5, 10 mm 1, 2, 5, 10 mm 2, 6 mm.................................................................................................................................................................................................................................Min. resolution (full step) 0.005 mm 0.001 mm 0.005 mm 0.005 mm 0.01 mm.................................................................................................................................................................................................................................Optional encoder yes yes yes yes yes.................................................................................................................................................................................................................................

Test benches for determining the service life of linear actuators

CompetitionAbout us

Nanotec Electronic GmbH & Co. KG, located in Feldkirchen near Munich, is among the world’s leading manufactur-ers of motors and motor controllers for high-quality drive solutions. The compa-ny has been developing and marketing a broad range of products since 1991. Nanotec technology is primarily used in automation systems and in medical devices.

Early on, company founder Benno Wimmer recognized that power

electronics are at the heart of efficient and effective drives and pushed the development of motor controllers. In 1996, Nanotec came out with the first Plug & Drive motor with an integrated controller, thereby setting a cornerstone that would ultimately be central to the company’s growth.

Still to this day, Nanotec focuses heavilyon research and development to createdrive solutions that closely meet the needs and requirements of our

customers. The development depart-ment in Feldkirchen, Germany, devel-ops hardware and software for motor controllers, sensors and customized applications, while innovations for our next product generation emerge from the R&D center in Pegnitz.

a sketch to [email protected]

The submitters of the first 25 project ideas that meet all of the criteria will be given a starter kit with a suitable motor and controller to implement their ideas. The idea must be an application that is suitable for production in larger numbers and not a single-use proposal.

Project ideas must be submitted before or on February 29, 2016. You then have time until October 31, 2016, to work on your application before the proposals are evaluated by a jury.

The awards ceremony will be held at the SPS IPC Drives 2016 in Nuremberg.

The Nanotec Innovation Competition is targeted toward companies and educa-tional institutes. Private persons are not included.

Nanotec will be celebrating its 25th anniversary in 2016, and in anticipation of this we are holding a competition to highlight innovative ideas for the use of our motors and controllers. The best three concepts will be presented in November 2016 in an awards ceremony.

We are looking for applications of integrated Nanotec motors or our new generation of controllers that are

sophisticated innovative economical feasible

and in which field-oriented control is applied either with or without an encoder or which use NanoJ.

If you have an idea for a new appli-cation, please send a short project description with the technical data and

Nanotec Innovation Competition

From Development to Series Production

Wheel drive of a service robot

1st prize 5,000 euros2nd prize 2,500 euros3rd prize 1,000 euros

Please check out our website at www.nanotec.com for a complete list of our sales partners.

Your Sales Contact

Nanotec Electronic GmbH & Co. KGKapellenstraße 685622 FeldkirchenGermany

Tel. +49 89 900 686-0Fax +49 89 900 686-50Email [email protected]

Harald Bär Denmark, NetherlandsTel. +49 89 900 686-55 or +49 160 7025797

Florian GeigerLiechtenstein, SwitzerlandTel. +49 89 900 686-649or +49 160 98101627