Linear Motor Technology PDF

Linear Motor Technology
Motor & Drive Systems Conference 2008

Jrgen Khnle
TD-PE/Jrgen Khnle Linear Motor Technology 25 January 2008 modified: 25 January 2008, JKHL
A small linear motor history
Who discovered the basics of the linear motor technology?
When was the first linear motor designed?
When was the first patent applied for?
TD-PE/Jrgen Khnle Linear Motor Technology 25 January 2008 modified: 25 January 2008, JKHL 2
1821 Mi h l F d (UK) 1821 Michael Faraday (UK)
Builds the first experimental
electrical motor
1831 Michael Faraday (UK)
Explain the electrical induction
1834 M it H J bi (G ) 1834 Moritz H. von Jacobi (Germany)
First usable electrical motor
1864 J Cl k M ll (UK) 1864 James Clerk Maxwell (UK)
Theory of electrodynamics
and their mathematical
formulas.
1882 M l D (F ) 1882 Marcel Deprez (France)
Electric hammer with linear
motor
1885 D Th B (G ) 1885 Dr. Th. Bruger (Germany)
Patent for the first linear motor
We discussing about a very old technology
First linear motor application 1882
125 years ago y g
First patent 1885
122 years ago 122 years ago
Linear Motor Technology
Linear motor technologies (application view)
SWOT analysis of these linear motor technologies
Linear Motor Technologies (Application View)
Customers are interested in the solution of their application and not the specific linear motor
t h l Th i it i f th l ti f li t technology. The main criteria for the selection of linear motors are:
Dynamics for short positioning times
Or Accuracy
Customers are looking mainly on the difficulties in the application. The technology based main
disadvantages are:
th t t t ti fi ld ith hi h tt ti f t i t the magnets generate a strong magnetic field with high attraction force to iron parts.
Due the used materials (iron, copper, steal) are the linear motors very heavy.
Linear Motor Flat Bed
Every rotary motor
i i l b d
Theoretical the rotary And formed to a flat
principle can be used
to build linear motors
motor can be cut bed linear motor
Flat Bed Linear Motor Technologies (Application View)
Linear motors with permanent magnets Linear motors without permanent magnets
Bed with permanent magnets
Main advantage
High power density
Bed with sheeted metal
Main advantage
No magnetic fields
Main disadvantage
Permanent magnets attract iron parts with
high force.
Very high attraction force between slider and
Main disadvantage
Power density is poor.
Very high attraction force between slider and
bed. A good linear guide system is necessary.
Tubular Linear Motor
Flat bed linear motor
Can be rolled up from Can be rolled up from
the side
To get a tubular linear
motor
motor
Tubular Linear Motor Technologies (Application View)
Short Coil System Long Coil System
Rod with permanent magnets Permanent magnets always inside coil Rod with permanent magnets
Main advantage
High power density
Main disadvantage
Permanent magnets always inside coil
system
Main advantage
No external magnetic fields
Main disadvantage
Permanent magnets attract iron parts with
high force.
o t a ag t s
Main disadvantage
Reduced power density
SWOT Analysis Linear Motors with Permanent Magnets
Strength Weakness
High power density
High load capacity
High attraction force between slider and bed
Heavy duty linear guide system necessary
Difficult assembly due high attraction force
Magnets get more and more expensive
Opportunity
Highest load carrying capacity
Threats
Permanent magnets can loose
characteristics if magnet temperature
Machining centers
characteristics, if magnet temperature
exceeds 8090C
SWOT Analysis Linear Motors without Permanent Magnets
Strength Weakness
No external magnetic field
High load capacity
Air bearing easy possible
Poor power density
Machining of the bed is very expensive
With air bearing smooth operation possible
Opportunity
Due the smooth operation ideal for
measuring machines and high accuracy
Threats
Very heavy
measuring machines and high accuracy
SWOT Analysis Linear Motors Short Coil System
Strength Weakness
High power density
Simple production
High attraction force between slider and
magnetic rod
Difficult assembly due high attraction force
M d i Magnets get more and more expensive
Opportunity
Compact design
Threats
Permanent magnets can loose
characteristics if magnet temperature
Handling
characteristics, if magnet temperature
exceeds 8090C
SWOT Analysis Linear Motors without Permanent Magnets
Strength Weakness
No external magnetic field
High load capacity
Drive similar to pneumatic cylinders
Poor power density
Opportunity
Change of pneumatic cylinder designs to
linear motors
Threats
Very heavy
linear motors
Comparison Between the Different Linear Motor Technologies
Drive Flat bed with Flat bed Short coil Long coil
technology permanent
magnets
without
magnets
system system
Load
200 kg 200 kg 200 kg .200 kg
Stroke
10 m 10 m 3 m 0.5 m
Velocity
10 m/s 4 m/s 10 m/s 3 m/s
Acceleration
250 m/s 80 m/s >250 m/s >250 m/s
P i i
0 1 m 0 1 m 10 m 10 m
Precision
0.1 m 0.1 m 10 m 10 m
External
magnetic
fields
Yes No Yes No
fields
Guide system
Circulating ball
linear guide
Air bearing;
Linear guides
Slider bearing;
Linear guides
Slider bearing;
Linear guides
Hybrid Linear Motor Technology
Combination of linear motor and pneumatic in one axis
SWOT analysis of the hybrid linear motor technology
Comparison Servo-Pneumatic Drive with Linear Direct Drive
Servo-Pneumatic Drive Linear Direct Drive
High speed (3 m/s)
Medium acceleration (30 m/s)
Slow force generation (30 ms)
High speed (>3 m/s)
High acceleration (150 m/s)
Quick force generation (1 ms)
Medium accuracy (0,1 mm)
Complex control loop
High power density
High accuracy (1 m)
Simple control loop
Low power density
Cost efficient
No heat generation
High purchasing costs
Strong heat generation
21
Comparison Dynamic Force Generation: Linear Direct Drives
Linear Direct Drive
peak force
Quick force generation
After 1 ms > max force reached
force reduction 1
controller amplifier: overheat
After 1 ms -> max. force reached
Force must be reduced. Reasons:
Force reduction 2
linear motor: overheat
Nominal force 20-30%
after 1 s: overheating of the
controller amplifier
ti
Depends on the cooling
Nominal force 20-30%
after 110 min: overheating of
the linear motor
time 1 ms
1 - 10 min
1 s
Comparison Dynamic Force Generation: Pneumatic Cylinder
pneumatic cylinder
peak force = continuous force
Slow force generation
Between 10 and 100 ms Between 10 and 100 ms
No temperature depending force
reduction necessary
(depending on the
piston position)
reduction necessary
p p )
ti
time 10 ms
100 ms
Comparison Dynamic Force Generation: Hybrid Axis
peak force linear motor + pneumatic
Ideal force generation
Peak force after 1 millisecond Peak force after 1 millisecond
No force reduction necessary
1,5 times peak force
2,5 times continuous force
1 ms 1 min 1 s time
,
time
Force distribution in the frequency domain
High frequency components of the reference force are the inputs of the current controller
Low frequency components of the reference force are the inputs of the pressure controller
In this way automatic compensation of static force like gravity
In this way: automatic compensation of static force like gravity
Measurement data of a positioning experiment
Total Force
El t i l F Electrical Force
Pneumatic Force
e

F
o
r
c
e
[
N
]
Mass load 5 kg
Positioning time 0.35 sec
Stroke 200 mm
Stroke 200 mm Time
[sec]
System Concept
FCT Software
FCT Software
reference
Hybrid Axis + Internal Interface
motor +
temperature
ext. Controller
FCT Software
i
t
i
o
n
g
r
a
m
m
i
n
g
internal
wiring
reference
switch
measuring
system
48V
firmware
for interface
pressure
sensors
s
P
o
s
i
p
r
o
g
pneumatic
for interface
c
o
n
t
r
o
l

s
i
g
n
a
l
s
firmware
for controller
connections
Platform:
HME + HMP cylinder
+ pressure sensors
compressed air
max. 500 mm
servo valve
6 bar
220V
power supply
supply
(volume / filter)
Technical Data HME-P
Project Hybrid Axis: Linear direct drive with pneumatic support
Mechanical dimension HME
More dynamic than the single linear motor
Linear direct drive
By redundant system higher security
Both drive systems work active controlled and parallel
Plug & Work
Guide
Low self-heating
Higher duty cycle
Size 16 25
Internal
i t f
Size 16 25
Stroke [mm] 100, 200, 320 100, 200, 320,
400
Thrust
force
Continuous [N] 140 260
P k [N] 240 375
Measuring system
Pneumatic cylinder
interface
Peak [N] 240 375
Repeatability [mm] 0.03 0.03
Measuring system
Comparison: Servo-Pneumatic, Linear Direct Drive and Hybrid Drive
Servo Pneumatic Linear Direct Drive Hybrid Drive Servo-Pneumatic Linear Direct Drive Hybrid Drive
Peak force 120 N 200 N 250 N
Continuous force 120 N 60 N 150 N Continuous force 120 N 60 N 150 N
Absolute accuracy 0.2 mm 0.03 mm
(temparture extenstion)
0.01 mm
Max. speed 3 m/s 3 m/s 3 m/s p
Cycles/sec cont.
operation
1 1.2 2.0
Max. payload vertical 5 kg 2 kg 7 kg
Duty cycle at Fmax 100 % 5 % 50 %
Costs complete system 70 % 100 % 120 %
SWOT Analysis Hybrid Linear Motor Axis
Strength
Hi h l ti
Weakness
Hi h d i l ith l ti l ll High acceleration
High accuracy
Double continuous force
Three times peak force
High dynamics only with relatively small
loads
Expensive technology
Stiff mounting surface necessary p
Very compact design
Low heat generation of the drive
Higher security (redundant system)
F ti f h ldi b k i t t d
g y
Play in the assembly must be small
Compressed air necessary
Failure rate higher (more components)
M diffi lt i t ll ti Function of a holding brake integrated
With same performance cheaper than a
comparable linear motor
More difficult installation
Opportunity
Offers highest possible dynamics
Combination of dynamics and accuracy
i f f li
Threats
Belt driven systems can reach similar
dynamics, but the not the accuracy
Costs saving of 2535% of a linear motor
with similar performance
Why are linear motors necessary?
Where is the place of linear motors in the drive technologies?
SWOT analysis of the drive technologies and selection support
Standard Pneumatic
1. Elements
2. General Data
3. Applications
4. SWOT Analysis
Elements Pneumatic Axis
Fixing holes g
for load
Piston
General Technical Data Standard Pneumatic
Load 100 kg
Velocity 3 m/s
Symbol
Velocity 3 m/s
Acceleration 30 m/s
Precision 100 m
Noise level very noise Noise level very noise
Stiffness medium
Stroke 10 m
Costs 1 * pneumatics Costs 1 * pneumatics
Flexibility not programmable
Power Density high
Maintenance maintenance free Maintenance maintenance-free
Applications Standard Pneumatic
1 axis application (example)
Assembly by force fitting
Ideal application range
y y g
Load Medium 30 kg 100 kg 200 kg
Dynamics Medium 0,5 m/s 3 m/s >5 m/s
Assembly of bulb socket
Stroke Medium 2 m 5 m 10 m
Accuracy Low 100 m 50 m <20m
Activity Rate Cont. 1/d 1/s Cont.
Following combinations are difficult:
Loading / unloading of machines
High load + high dynamics
High dynamics
High accuracy
Slow speeds
Change over between machines
Slow speeds
Movements with constant speed
SWOT Analysis Standard Pneumatic
Strength Weakness
Low costs
High power density
Simple technology
Expensive energy
No low speeds possible
Constants speed difficult
overload possible
Long time holding force without additional
energy
Noisy
leakage
Opportunity
Simple applications with 2 positions
( )
Threats
Large number of competitors
(Servopneumatic)
General Technical Data Servo Pneumatic
Load 2300 kg
Velocity 5 m/s
Symbol
Velocity 5 m/s
Acceleration 50 m/s
Precision 200 m
Noise level very noise (with air Noise level very noise (with air
outlet quite)
Stiffness medium
Stroke 0 2 2 m Stroke 0.2 2 m
Flexibility programmable
Power Density high
Maintenance maintenance-free Maintenance maintenance-free
SWOT Analysis Servo Pneumatic
Strength Weakness
Low costs
High power density
Simple technology
Expensive energy
No low speeds possible
Constants speed difficult
overload possible
Long time holding force without additional
energy
Noisy
Leakage
Strokes 202000 mm
Opportunity
Unique selling position of Festo (no
competitor)
Threats
Technology unknown
competitor)
Future: hybrid technology (combination of
pneumatics and electrical drives)
Energy costs
Price reduction of electrical drives
Belt Driven Axis
1. Elements
2. General Data
3. Applications
4. SWOT Analysis
Picture shows DGEL-_-ZR
Elements Belt Driven Axis
B lt Slid
Fixing holes
f l d
Pulley (inside
Belt Slider for load
Pulley (inside
Axis)
Pulley (inside
Axis)
Motor adaptor
General Technical Data Belt Driven Axis
Load up to 200 kg
Velocity 5 10 m/s
Symbol
Velocity 510 m/s
Acceleration 100 m/s
Precision 100 m
Noise level noisy
230VAC
Noise level noisy
Stiffness medium
Stroke up to 10 m
Costs 2 * pneumatics
Motor Controller
Flexibility high
Power Density medium
Maintenance maintenance free
Motor Controller
Maintenance maintenance-free
Belt axis
with
motor
The symbol of the mechanics is not included in a standard. We will use it in future for ProPneu
Applications Belt Driven Axis
Transport of parts in a machine
p p
Unloading parts from a machine
Load High 30 kg 100 kg 200 kg
Stroke Short 2 m 5 m 10 m
Accuracy Low 100 m 50 m <20m
Dispenser Positioning
High load + high activity rate
High dynamics + high activity rate
High dynamics + accuracy
Closing of bottles
High dynamics + accuracy
SWOT Analysis Belt Driven Axis
Strength Weakness
Cost optimized electrical axis
Long strokes
Light weight
Medium stiffness
Belt sensitive against lubricants and solvents
Wear
X-lengths possible
Belt is exchangeable (cheap spare part)
High dynamics
Tension at long strokes
Damages due mechanical block possible
Opportunity
Dynamic applications
Threats
Large number of competitors
Lead Screw Axis
1. Elements
2. General Data
3. Applications
4. SWOT Analysis
Picture shows DGEL-_-SP-KF
Elements Lead Screw Axis
Slider Slider
Motor
Bearing
Adaptor
Bearing Spindle Nut
General Technical Data Lead Screw Axis
Load up to 200 kg
Velocity 0 5 m/s
Symbol
Velocity 0.5 m/s
Acceleration 30 m/s
Precision 50 m
Noise level low
230VAC
Noise level low
Stiffness very high
Stroke up to 2 m
Costs 2 5 * pneumatics
Motor Controller
Costs 2.5 * pneumatics
Flexibility high
Maintenance lubrication
Motor Controller
Screw Axis
with
motor
Applications Lead Screw Axis
Adjustment of positions (rare movements)
j p ( )
Load Medium 30 kg 100 kg 200 kg
Dynamics Low 0,5 m/s 3 m/s >5 m/s
Accuracy Medium 100 m 50 m <20m
Positioning of screwing head (rare movements)
Activity Rate Low 1/d 1/s Cont.
3 axis application
not recommended
4 axis application
Not recommended
High load + higher activity rates
Not recommended
SWOT Analysis Lead Screw Axis
Strength Weakness
High forces
Medium accuracy
Interesting costs
Low speed
Medium acceleration
Lubrication very important
Self locking Friction (low efficiency)
Opportunity
Cost sensitive applications
Threats
Lifetime of the screw
Ball Screw Axis
1. Elements
2. General Data
3. Applications
4. SWOT Analysis
Picture shows DGEL-_-SP-KF
Elements Ball Screw Axis
Slider Slider
Motor
Bearing
Adaptor
Bearing Spindle Nut
General Technical Data Ball Screw Axis
Load up to 200 kg
Velocity 3 5 m/s
Symbol
Velocity 35 m/s
Acceleration 50 m/s
Precision 20 m
Noise level low
230VAC
Noise level low
Stiffness high
Stroke up to 2 m
Motor Controller
Flexibility high
Motor Controller
Screw Axis
with
motor
Applications Ball Screw Axis
Loading of machines (adjustable)
g ( j )
Load High 30 kg 100 kg 200 kg
Testing of printed circuit boards (PCB)
Accuracy High 100 m 50 m <20m
Testing of
High dynamics + high accuracy
Palletizing and rotating
High dynamics + high accuracy
SWOT Analysis Ball Screw Axis
Strength Weakness
High forces
High accuracy
Medium speed
Medium acceleration
Limited strokes
Not repairable
Only standard strokes
For longer strokes only limited speed
Opportunity
High loads with higher dynamics and
accuracy
Threats
Costs for linear motors will fall
accuracy
Belt systems can move similar loads, but not
with the accuracy
Linear Motor Axis
1. Elements
2. General Data
3. Applications
4. SWOT Analysis
Elements Linear Motor Axis
Magnets Magnets
Slider with coils
Linear guide
Measuring system
General Technical Data Linear Motor Axis
Load up to 30 kg
Symbol
Velocity 510 m/s
Acceleration 150 m/s
Precision 3 m
230VAC
Noise level low
Stiffness high (depends on motor
controller)
Motorcontroller
Stroke up to 10 m
Flexibility high (free programmable)
Power Density low
Maintenance lubrication of guides
M
3 ~
Linear Motor
Applications Linear Motor Axis
Loading of machines (precise)
g (p )
Positioning for optical quality test
Load Low 30 kg 100 kg 200 kg
Dynamics High 0,5 m/s 3 m/s >5 m/s
Filling of micro arrays
Stroke Long 2 m 5 m 10 m
Accuracy High 100 m 50 m <20m
Palletizing and rotating
Activity Rate Medium 1/d 1/s Cont.
Linear motors are oversized for (but possible)
Linear motors are oversized for (but possible)
Low accuracy
Low activity rate
SWOT Analysis Linear Motor Axis
Strength Weakness
High acceleration
High speeds
High accuracy
High dynamics only with relatively small
loads
Expensive technology
Of i li k l d
Long strokes
Often specialist knowledge necessary
Stiff mounting surface necessary
Play in the assembly must be small
Opportunity
Offers highest possible dynamics
Threats
Belt driven systems can reach similar
dynamics but the not the accuracy
Combination of dynamics and accuracy
dynamics, but the not the accuracy
Comparisons Electrical Axis
Content
Comparison Between the Different Axis Technologies (Technical Data)
Comparison Between the Different Axis Technologies (Recommendation)
Selection of Axis Technologies Based on the Needs of the Application
Comparison Between the Different Axis Technologies (Technical Data)
Drive Standard Belt Driven Screw Driven Ball Screw Linear Motor
technology Pneumatics Axis Axis Driven Axis Axis
Load
Up to 100 kg Up to 200 kg Up to 100 kg Up to 200 kg Up to 30 kg
Stroke
Up to 8.5 m Up to 10 m Up to 2 m Up to 2 m Up to 10 m
Velocity
3 m/s 510 m/s 0,5 m/s 35 m/s 510 m/s
Velocity
3 m/s 510 m/s 0,5 m/s 35 m/s 510 m/s
Acceleration
30 m/s 100 m/s 30 m/s 50 m/s 150 m/s
Precision
100 m 100 m 50 m 20 m 3 m
Noise
Very noisy Noisy Low Medium Low
Stiffness
Medium Medium Very high High High
Costs
1 2*pneumatics 2,5*pneumatics 3*pneumatics 4*pneumatics
p p p p
Flexibility
Not
programmable
Programmable Programmable Programmable Programmable
Comparison Between the Different Axis Technologies (Recommendation)
Load
++ +++ ++ +++ +
Stroke
+++ +++ ++ ++ +++
Velocity
++ +++ + ++ +++
Velocity
++ +++ + ++ +++
Acceleration
+ +++ + ++ +++
Precision
++ ++ ++ +++ +++
Noise
+ ++ ++ +++ +++
Stiffness
++ ++ +++ +++ +++
Costs
+++ ++ ++ + +
Flexibility
+ +++ +++ +++ +++
Selection of Axis Technologies Based on the Needs of the Application
High Load + +
Long Stroke + + +
High Velocity + + g y
High Accel. + +
High Precision + +
Low Noise + + Low Noise + +
High Stiffness + + +
Low Costs + +
High Flexibility + + + +
Future Outlook
What are the main future trends in the field of linear motors and other direct drives.
Reasons for Automatization
Others
High level of process standardization
Environmental conditions
Others
High quantities
Unburden employees
Required accuracy
Process capability
Reproducibility
Control of large
number of variants in
a production
Productivity
Labor cost reduction
Required accuracy
0% 10% 20% 30% 40% 50% 60% 70%
User's View Manufacturer's View
Source: WZL, RWTH Aachen and Institute Production Technology of Fraunhofer Institute
Control of Large Number of Variants in a Production
P tf li f ti li d t Portfolio of pneumatic cylinders at
Festo in 1954:
50 catalogue products g p
P tf li f ti li d t Portfolio of pneumatic cylinders at
Festo today
>25000 catalogue products g p
P d ti hi d Production machines need
Higher flexibility to produce Higher flexibility to produce
several variants / products on
one machine
Leads to the use of free
programmable electrical axis
Higher througput to improve
the return on investment
Higher needs on accuracy to
i th d ibilit
Leads to the use of high dynamic
linear motors
improve the reproducibility
67
Reasons for Automatization
Others
High level of process standardization
Environmental conditions
Others
High quantities
Unburden employees
Required accuracy
Process capability
Reproducibility
Productivity
Labor cost reduction
Required accuracy
Control of the cost
factor production
0% 10% 20% 30% 40% 50% 60% 70%
User's View Manufacturer's View
Source: WZL, RWTH Aachen and Institute Production Technology of Fraunhofer Institute
Control of the cost factor production
P d ti hi d Production machines need
Higher throughput to improve Higher throughput to improve
the labor costs
Leads to the use of high dynamic
linear motors
Higher needs on accuracy to
improve the reproducibility
linear motors
Labor Costs in Selected Countries
Annual crowing rate g
Indonesia China India Russia Poland Tsch. R. Korea
Japan
USA Germany
Source: BCG
Price Trends Machines and Components for Machines
For the most machine types are higher
s
For the most machine types are higher
increases for quantities than for turnover
forecasted.
The average price for most machines will
C
u
s
t
o
m
e
r
s
p
decrease in the next years by 35%.
A quantity rise of 24% is forecasted.
O
u
r

C
F
e
s
t
o
Source: European Machinery Production Yearbook 2007, IMS Research
Technology Trends
Markets requests less products in the
medium technology area and go more to low
and high technology areas.
High Tech
For low technology area
costs factor is the leading reason
F hi h t h l l l
Medium Tech
Market Market
For high technology level
increase of productivity is the leading
reason
L T h Low Tech
END END

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Motor & Drive Systems Conference 2008

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