Phase TK Series Installation And Application Manual

TK Series frameless motors installation and application

manual

Rel 2.6 doc MA0012.6 ENG

Phase Motion Control

Via Adamoli 461, 16141 Genova Italy

Ph: [phone]

Fax: [phone]

e-mail:

[e-mail]

http://www.phase.eu

2 Phase Motion Control

TABLE OF CONTENTS

TABLE OF CONTENTS ............................................................................................................ 2

Introduction ......................................................................................................................... 3

Safety ................................................................................................................................. 3

General safety instructions .................................................................................................. 3

Electrical risk ..................................................................................................................... 4

Transport and storage conditions............................................................................................. 5

Transport and packaging ..................................................................................................... 5

Unpacking and mounting ..................................................................................................... 5

Storage ............................................................................................................................ 5

Transportation ................................................................................................................... 6

General technical information on TK frameless motors ................................................................ 7

Thin ring, large diameter motors for high torque, low speed (torque motors) ............................ 8

Spindle motors for mills and lathes .................................................................................... 9

Tube motors, small diameter, for multiple spindle units ......................................................... 9

Selection guidelines ............................................................................................................. 10

How to choose the optimal TK motor? ................................................................................. 10

Motor morphology and protections......................................................................................... 13

TKST Stator..................................................................................................................... 13

Type and manufacture of TK motors ................................................................................... 16

Insulation voltage .......................................................................................................... 17

Over temperature protection ........................................................................................... 17

Ground connection......................................................................................................... 18

Standard type and size of output power leads .................................................................... 19

Anti-resonance filter (snubber) ........................................................................................ 19

Motor integration ................................................................................................................ 21

Stator ............................................................................................................................. 21

Rotor .............................................................................................................................. 22

Mounting of the rotor inside the stator ................................................................................. 22

Radial force vs. mounting eccentricity ................................................................................. 24

Check list after integration ................................................................................................. 24

3 Phase Motion Control

Introduction

The present document detail the installation, integration and initial mechanical set-up of PHASE

MOTION CONTROL series TK frameless torque motors (henceforth named TK motors). It provides the

customer with the necessary information on how to integrate and operate with TK in his application.

Remark: The liability of PHASE MOTION CONTROL is in all events limited to the functionality of the

motor alone and is limited to its repair or replacement according to the rules agreed in the documente

Condizioni Generali di vendita Phase Motion Control ,

www.phase.eu, which are implicitly accepted

when the motor is purchased.

Frameless motors are just components, however important, of complex systems of which Phase

Motion Control is not aware and not responsible. The Customer or whoever owns or operates the

system must take the responsibility to assess all safety or economical concerns relevant to the

complete system, over and beyond motor replacement, which may stem from any type of motor

failure, and of which Phase Motion Control is unaware and is not and cannot be responsible.

Safety

The user must have read and understood this documentation before carrying out any activity. In case

of unclear information, please contact PHASE MOTION CONTROL.

Handling, installation and maintenance must be done by competent and trained technical personnell

according to IEC 364. Non-compliance with the safety instructions, statutory and technical regulations

may lead to injuries to persons, damage to property and the environment.

General safety instructions

Anyone having active implants (pacemakers) or having any other ferromagnetic

prosthesis is not qualified to work with these kinds of devices, or to approach them.

Keep at safe distance from the motor!

Electronic devices and measuring equipment may be affected or destroyed by strong

magnetic fields. Avoid placing devices with magnetic parts close to computers,

monitors and all magnetic data carriers (e.g. disk, credit cards, audio and videotape,

etc). Because of strong attraction forces, special caution is required in the direct

proximity of the rotor (i.e. under 100 mm). Therefore heavy or wide objects made of

steel of iron must never be brought close to the rotor by free hand. As magnetic forces

are invisible, their effects are generally overlooked close to the rotor.

To cope with any event of an accident while handling the motor, always have at

hand at least two wedges of solid, non-magnetic material (i.e. aluminium) as well as a

non-magnetic hammer (approx. 2-3 Kg). In emergency cases, these tools are for

separating parts magnetically attached to the rotor in order to free caught limbs

(finger, hand, foot).

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Electrical risk

Before installation verify the motor about any damage due transportation and handling, that may

impair electrical safety.

Drive start-up may produce sudden uncontrolled movement. Keep away from all moving parts to

avoid injury!

Do not connect motor to power supply other that specified by PHASE MOTION CONTROL.

A defective power supply may damage the TK assembly.

It is dangerous to interrupt earth or grounding connections. In no way must an earth wire be

disconnected!

Before servicing, make sure that the TK is not powered.

TK motors may have hot surfaces also when the motor is not powered. Normal operating temperature

could be over 100°C.

Slow turning motors have high back-EMF. For example, a TK-xxx-xxx-100 would develop 300 Vac at

its terminals when manually rotated at 5 rpm. Beware of manual or gravitational rotation, dangerous

voltage can be present at the motor terminals even if the machine is not connected.

WARNING: Deep deflux motors (constant power range > 1:2) may deploy higher than mains voltage

between motor and series inductor. Verify maximum interconnection voltage while siziong the plant.

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Transport and storage conditions

Transport and packaging

The PHASE MOTION CONTROL standard package is designed to avoid transport damage.

If any transport damage is observed upon reception of the goods, please inform immediately Phase

Motion Control so that transport damages can be timely claimed or corrected.

Unpacking and mounting

To unpack the TK, please adopt all general safety instructions, reported on the paragraph 3.1.

After opening the package, never pull the motor cable, nor lift the motor by its cables.

Check for cable damage during transport or unpacking

For handling of heavy motors (i.e. >15Kg) the use of lifting tools is recommended, using threaded

lifting bolts, when possible, or using a lift belt.

When storing the motor outside the original packaging put a non-magnetic spacer (i.e. wood) with

40-mm minimum thickness between stator and rotor.

After unpacking the rotor, keep the original rotor wrapping or wrap the magnetic part of the rotor

with paper tape, to keep the magnetic surface clean. The tape must be removed just before mounting

the rotor into the stator.

Take care with the rotors banded with carbon fibre ring: an accidental contact with metallic parts

attracted by the magnetic field can cause damages to the carbon ring, if this happens please contact

PHASE MOTION CONTROL.

Do not leave the rotor outside of its package longer than necessary for assembly to prevent pollution

of the magnet surface and accidents

After mounting verify that the rotation of the rotor inside the stator is free, without contact for the

whole revolution.

Storage

The storage area of TK motors must be strictly restricted and indicated with “Caution, powerful

magnets”.

Motors and motors parts, whenever possible, should be stored in the original packaging.

The storage air humidity should be between 5 and 80% and the temperature between 5 and 45°C.

Should components be stored outside their original packaging, wrapping with oiled paper to prevent

corrosion is recommended.

Magnetic parts should be separated and wrapped in non-magnetic protection. These protections

should be at least 40 mm thick.

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Transportation

By land

The motor must be shipped with original packaging; if it is not possible use IP54 protection

packaging. The parts must be packaged firmly to avoid any movement in case of shocks.

By sea

Use only sea standard packaging (IP55).

By air

CAUTION: if the rotor must be shipped unassembled, i.e. not inside the stator, airline authorisation is

required because of the stray field of the rotor. The use of the original iron box in which the rotor was

supplied is recommended. As required, enquire with Phase Motion Control for the supply of a shielding

box.

7 Phase Motion Control

General technical information on TK frameless motors

The TK series of frameless brushless motors provide the

highest torque density available today for direct drive,

high performance applications. Unlike traditional torque

motors, TK units have both high torque and high speed

capability and thus operate seamlessly both as spindle

and table motors.

TK motors consist of separately supplied stator and rotor

units suitable for direct assembly inside the structure of

the machine. TK motors are three phase, rare earth (Iron

Neodymium Boron) permanent magnet units and reach

the highest continuous and peak torque density available

today, together with high speed and flux control ability

over a constant power range up to 10:1.

The rotors use special manufactured magnets with

minimized loss factor allowing high speed operation with

a thin isotropic rotor. All rotors are rigid units with

mechanical, glue free magnet retention, preloaded carbon

fiber sleeve for safe operation even at very high speed.

Rotor are often semi custom units to allow direct coupling

to bearings, encoders, brakes.

All TK motors are designed for fluid (water) cooling on the outside of the stator for maximum

performance. Conduction/convection cooling is also possible. Constant power operation (flux control)

always requires water cooling.

Customized frames with integral cooling or even partial machine subassemblies with bearings and

encoders are manufactured on request based on the standard frameless magnetic designs available.

The torque range spans from 10 to 40,000 Nm with maximum diameter 1150mm; above that size,

segmented semi custom units are available, currently up to 18 m diameter.

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Typical applications:

Metal cutting DD rotary tables with both contouring and turning ability;

DD spindles for mills and lathes;

Tubular spindle motors for multi spindle machines;

Rotary table indexing for transfer machines;

Metal forming DD flywheels for press;

Cold rolling machines;

DD Capstans for hot and cold rolling/drawing;

Plastic DD extruders;

Injection and mixing stages for plastic injection molding machines;

Gearbox suppression in mixer, grinders, shredders;

Energy PM generators for small steam or gas turbine, cogeneration;

Micro Hydro-generators;

Wind turbines;

Depending on their geometry and magnetic circuit, TK motors can be divided into three main

branches:

Thin ring, large diameter motors for high torque, low speed

(torque motors)

Typical applications:

• Rotary tables for NC machine tools, often with turning capacity

• Indexers for transfer machines

• NC machine head orientation

• Large rotary tables (glass, packaging, assembly)

•

Carbon fiber deposition machinery

•

Direct drive of mills (concrete, ceramics, rubber

•

Large low speed generators (mini hydro, wind power)

•

Metal forming: electric press and bending

•

Direct drive plastic injection machines

In all these applications, direct drive eliminates play and removes the

need of an accurate mechanical gearbox, which in turn would limit the accuracy and the dynamic

performance of the system. Mechanical brakes-dividers are unnecessary. The table accuracy is the

accuracy of the encoder system. The system is thus extremely simple, flexible and reprogrammable.

The removal of the transmission system and of its backlash and elasticity results in control bandwidth

up to 250 Hz, so that a positioning cycle can be completed with great accuracy within a few msec with

advantage on the machine cycle time.

To ensure adequate servo performance in direct drive high accuracy, high stiffness applications such

as indexing and rotary tables in NC machine tools, the sensor must be sinusoidal so that the drive