A stepper motoris a brush-less Direct Current electric motorthat divides a full rotation into a number of equal steps. The stepper motor’s position can then be commanded to move and hold at one of these steps without any feedback sensor via an open-loop stepper motor controller as long as the stepper motor is carefully sized to the application.

Stepper Motor System Overview

Motion Control, in electronic terms, means to accurately control the movement of an object based on either speed, distance, load, inertia or a combination of all these factors. There are numerous types of motion control systems, including; Stepper Motor, Stepper Motor Controller, Linear Step Motor, DC Brush, Brush-less, Servo, Brush-less Servo and more. This post will concentrate on Step Motor technology.In Theory, a Stepper motor is a marvel in simplicity. It has no brushes, or contacts. Basically a stepper motor is a synchronous motor with the magnetic field electronically switched to rotate the armature magnet around.A stepper Motor Controller System consists of three basic elements, often combined with some type of user interface (Host Computer, PLC or Dumb Terminal).

A stepper motor controller is usually, but not exclusively, done in an open loop configuration. The rotor position of the stepper motor is assumed to follow a controlled rotating field. Because of this, precise positioning with stepper motor is simpler and less expensive than closed loop stepper motor controls.Modern stepper motor controllers drive the motor with much higher voltages than the motor nameplate rated voltage, and limit current through chopping. The usual setup is to have a positioning stepper motor controller, known as an indexer. The indexersends the step and direction pulses to a separate higher voltage drive circuit which is responsible for commutation and current limiting.

Direct Current brush motors rotate continuously when voltage is applied to their terminals. Stepper motors and stepper motor controllers, on the other hand, effectively have multiple “toothed” electromagnets arranged around a central gear-shaped piece of iron. The electromagnets are energized by an external control circuit, such as a stepper motor micro controller. To make the stepper motor shaft turn, one electromagnet is given power, which magnetically attracts the gear’s teeth. When the gear’s teeth are aligned to the first electromagnet, they are slightly offset from the next electromagnet. So when the next electromagnet is turned on and the first is turned off, the gear rotates slightly to align with the next one, and from there the process is repeated. Each of those rotations is called a “step”, with an integer number of steps making a full rotation. In that way, the motor can be turned by a precise angle.

To learn more about stepper motor controllers, please visit the reference links below. For stepper motor controller repair and replacement quotes, contactPrecision Electric.

References:

• http://en.wikipedia.org/wiki/Stepping_motor#Fundamentals_of_operation
• http://en.wikipedia.org/wiki/Stepping_motor
• http://www.stepcontrol.com/stepping101/stepping101_Overview_1.html

Industrial inverters are also known as variable speed drives, variable frequency drives, VFD’s, and adjustable speed drives. Industrial inverters are solid state motor control systems used mainly for industrial manufacturing. Variable speed drives are designed to control the speed of an electric motor. Variable speed drives can reduce energy costs up to 50% by speed reduction on applications where the full speed (RPM) of the electric motor is not required.

The energy saved on a utility bill from using an industrial inverter is often significant enough to pay for the inverter within a couple of months from installation date. Industrial inverters are commonly used on pump, fan, and air compressor applications, and are often put into production at manufacturing facilities to increase or decrease the start up time on alternating current (AC) electric motors.

Increasing and/or decreasing the start up time on an AC electric motor via an inverter can add years to the motor’s overall lifespan. Using an industrial inverter can also improve efficiency on production demands. Industrial inverters provide the ability to control the frequency of starting and stopping an AC electric motor.This motor control capability provides a means by which an AC electric motor is only operating when needed. AC electric motors have a longer lifespan if they are not continuously operating when they do not need to be.

Types of Industrial Inverters

The most common type of industrial inverter is known as a V/Hz (volts per hertz), and are applied to applications such as fans, pumps, air compressors, and other related applications wherehigh starting torque is not required; V/Hz industrial inverters are also used on applications where full torque is not required when operating an electric motor lower than the motor’s rated speed (RPM). V/Hz industrial inverters are the most inexpensive type of industrial inverters. When choosing an industrial inverter it is crucial to remember that V/Hz inverters DO NOT provide full motor torque at low motor RPM.

Open-Loop vector inverters are also known as “sensorless vector” inverters. Open loop vector inverters adapted the name “sensorless vector” because they do not use an external encoder for speed feedback to the motor for precise speed regulation. Open loop vector inverters are used in applications where high starting torque and full torque at low motor speed (RPM) is required. Open-Loop vector inverters operating a motor at zero RPM should not be used on crane or hoist applications. Most open-loop vector industrial inverters are used on CNC machines, mixers, mills, lathes, and other applications where high starting torque or full torque at low RPM is needed.Open loop vector inverters are usually more expensive than a V/Hz industrial inverters.

Closed-Loop vector industrial inverters are used in applications where precise speed regulation (0.01%) is needed, or in applications where extensive programming is needed. Closed-Loop vector inverters use an encoder on the electric motor to provide constant shaft position which sends a signal to inverter’s microprocessor. The encoder feedback allows the drive microprocessor to constantly control torque no matter how many RPM the motor is operating at. Closed-Loop vector industrial inverters are used to provide the motor to operate at full torque even at zero RPM. Closed-Loop vector inverters are commonly used on hoist and crane applications because crane and hoist motors must produce full torque prior the motor’s brake being released, otherwise the load will drop and the electric motor will not be able to stop.

Questions? Let Us Help. Call Toll Free at1-877-625-2402orE-Mail Sales and Support. Precision Electric offers free inverter repair and replacement quotes. All repair work performed by Precision Electric includes a 12 month warranty.

ABB ACS800-04 and ABB ACS800-14

ABB ACS800 industrial drive modules are meant for system integrators and/or machine builders who are making their own applications, which include the cabinet structure as well as the software features needed. ABB ACS800 industrial drive modules include everything that is required for a complete drive, and there is always a built-in harmonic filtering choke on the ABB ACS800. There is also a wide selection of built in options such as EMC filtering and different I/O andcommunication options. All the modules can be mounted side by side in the ABB ACS800.

The ABB ACS800 modules are designed for cabinet assembly and cabinet assembly documentation is included. The flexibility and programmability of the ACS800 modules make them very viable for various application needs in different areas of industry.ABB ACS800-04 drives are single drive modules that are optimized for building into customers own cabinets. They have been designed to minimize the cabinet space used, make cabinet assembly as easy as possible, and give maximum flexibility. ABB ACS800-04 power ranges are from 0.55 to 1900 kW. All the ABBACS800-04 drives, regardless of the power and voltage, have the same customer interface and I/O system design which makes training easier.

The ABB ACS800-04 units also have everything necessary built-in the; that includes, built-in chokes for harmonic filtering as standard, built-in braking chopper and built-in EMC filtering (both are optional in some frame sizes), making cabinet assembly easier. There is also a wide selection of different I/O and communications options.

The ABB ACS800-14 drives are regenerative single drive modules equipped with active supply unit. They are full performance regenerative drives in a compact package. All important features and options including LCL line filter module(s), IGBT supply module(s), inverter module(s), common mode filters are in the package. The ABB ACS800-14 power ranges are from 75 to 1700 kW. All the ABB ACS800-14 drives, regardless of the power and voltage, have the same customer interface and I/O, making system design and training easier.

To learn more about the ABB ACS800 drives or to download technical documentation for the ABB ACS800, please visit the ABB Website.

Information Source:

http://www.abb.com/product/us/9AAC100217.aspx?country=US

Yaskawa Motoman Robots are dedicated to delivering high quality, innovative automation solutions that help manufacturers to be world competitive and to providing the highest level of customer satisfaction in the automation industry.

Yaskawa Motoman Robots achieve this mission by pursuing economically sound strategies that embrace continuous improvement, innovation, and diversification in concert with perpetuating an entrepreneurial spirit throughout the organization and developing a deep and mutual trust with manufacturers, employees, vendors and shareholders.

About Yaskawa Motoman Robotics

Yaskawa Motoman Robots has been in the automation industry since 1989. Yaskawa Motoman Robots are a leading robotics company in the Americas. With over 270,000 Motoman robots, 10 million servos and 180 million inverter drives installed globally. Yaskawa Motoman Robotics provide automation products and solutions for virtually every industry and robotic application; including arc welding, assembly, coating, dispensing, material handling, material cutting, material removal, packaging, palletizing and spot welding.

The Yaskawa Motoman Robot product line includes more than 175 distinct robot models and a full-line of pre-engineered “World” solutions that are complete application specific work cells, including robot, process and safety equipment.Combined with the Yaskawa sister and partner companies, Yaskawa supports robotic solutions throughout the world. Yaskawa Motoman Robots has a proven track record of delivering industry leading quality, innovation and customer satisfaction to help manufacturers exceed in robotic automation goals.

Yaskawa Motoman Robots are backed by a powerful parent,Yaskawa Electric Corporationof Japan. Since 1915, Yaskawa Electric has demonstrated a passion for automation by developing specialized solutions to help customers increase efficiency, improve quality, boost productivity, and deliver outstanding ROI. As one of the world’s largest manufacturers of industrial robots, Yaskawa Electric has offices in 28 countries and approximately 14,000 employees worldwide.

To learn more about the Yaskawa Motoman Robot products, download technical information, or to learn more about Yaskawa Variable Speed Frequency Drive Products, please visit the Yaskawa Website.

Information Sources:

http://www.motoman.com/index.php

http://www.yaskawa.com/site/home.nsf/home/home.html

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Extended Reach For Larger Parts

The MA 1900 Yaskawa is Ideally suited for use in work cells with larger work pieces, as well as forapplications that require access to parts in tight spots or those with potentialinterference from fixtures. The YaskawaDX100 Controlleris Patented for multiple robot control and supportsup to 8 robots/72 axes, WindowsCE programming pendant with color touch screen and USB interface. The Yaskawa MA 1900 usesDX100 welding full function arc weldingsoftware including graphics-based weld file settings.

With the MA 1900 Yaskawa, you’ll get faster processing speeds for smoother interpolation, quicker I/O response, accelerated Ethernet communication,and the extensive I/O suite includes integral PLC and touch screen HMI, 2,048 I/O andgraphical ladder editor. MA 1900 Yaskawa supports all major fieldbus networks, including EtherNet/IP, DeviceNet, Profibus-DPand many others. MA 1900 Yaskawa is alsocompliant to ANSI/RIA R15.06-1999 andother relevant ISO and CSA safety standards.

To learn more about the Yaskawa MA 1900, visit the Yaskawa Website.