ANORAD

Anoline Series

LEA and LEB LINEAR MOTORS

User Manual

April 2004 Revision A Item Number 72075

Linear Motor Manual

LEA and LEB Linear Motors User Manual April 2004 Revision A Item Number 72075

Anorad/Rockwell Automation 100 Precision Drive Shirley, NY 11967-4710

Web site http://www.anorad.com E-mail anorad@anorad.com

Technical Support: Tel 631.344.6600 Fax 631.344.6660 email techsupport@anorad.com

Those responsible for the application and use of this equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards. The illustrations, charts, and layout examples shown in this guide are intended solely for purposes of example. Anorad does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication. Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited. 2004 Anorad Corporation. All rights reserved Anorad and Anoline are registered trademarks Patents 4560,911 4595,870 4625,132 4,733,143 4749,921 4761,573 4,834,353 4,839,545 Other patents pending

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TABLE OF CONTENTS
1. INTRODUCTION ..................................................................................................................................................... 1 1.1 PURPOSE ....................................................................................................................................................... 1 1.2 UNPACKING COMPONENTS ........................................................................................................................... 1 2. MOTOR FEATURES................................................................................................................................................ 2 3. MECHANICAL SPECIFICATIONS ...................................................................................................................... 2 4. MOTOR SPECIFICATIONS ................................................................................................................................... 5 5. CABLE WIRES ......................................................................................................................................................... 6 6. MOTOR INSTALLATION ...................................................................................................................................... 6 6.1 MOTOR MECHANICAL INSTALLATION PROCEDURE ...................................................................................... 9 7. MOTOR AND HALL EFFECT PHASING .......................................................................................................... 10 7.1 RESISTANCE VERIFICATION ........................................................................................................................ 10 7.2 MOTOR WINDINGS ..................................................................................................................................... 10 7.3 PHASE RELATION VERIFICATION ................................................................................................................ 11 7.4 LINEAR HALL EFFECT MODULE.................................................................................................................. 12 7.5 MOTOR PHASE AND HALL EFFECT SENSOR PHASING PROCEDURE ............................................................. 12 7.6 EXTRA HELP FOR MOTOR AND HALL SENSOR PHASING .............................................................................. 14 8. RECOMMENDED WIRING ................................................................................................................................. 14

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Change Page Record

Document: LEA and LEB LINEAR MOTORS User Manual

Date September 1996 April 2004 Rev 2.0 A Page All All Item All All From To Origianl Change logo and contact information

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1. Introduction This manual contains information pertaining to the installation and operation of Anorad Anoline LEA and LEB series linear motors. The manual includes specifications, installation and phasing procedures.
1.1 Purpose

The intent of this manual is to assist the user in the mechanical and electrical installation of the Anoline LEA/LEB series linear motors. Specification sections describe the physical dimensions as well as the performance levels while employing different cooling methods. Mechanical installation section outlines the proper physical installation procedure. The section on phasing ensures maximum linear motor performance. The recommended wiring diagram is a helpful guide to the user for a successful installation.
1.2 Unpacking Components

WARNING
Linear motors contain powerful permanent magnets. When handling multiple magnet channels do not allow the channels to come in contact with each other. Do not disassemble the magnet channel. The magnetic force between channels and channel plates is extremely powerful and can cause bodily injury.

WARNING
Linear motors contain powerful permanent magnets. Persons with pacemakers or A.I.C.D. should maintain a minimum distance of 12 inches between magnets and device. Identify what options your LEA or LEB linear motor is equipped with by comparing the part number on the purchase order and the Ordering Information Section located in the Anorad Linear Servo Motors Catalog. Verify that the quantity and length of the magnet channels match the purchase order and job requirements. Inspect the coil assembly and confirm, if applicable, the implementation of optional cooling, themistor, sinusoidal hall effect sensor and/or connector.

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2. Motor Features
Epoxy imbedded core Low cost non-ferrous motor Velocity above 5 m/sec (200 IPS) No magnetic attraction Optional air and water cooling Mounting from either of three sides Modular for unlimited travel Very high smoothness No eddy currents, no cogging High reliability, non-contact Sinusoidal Commutation

Anoline brushless sinusoidal linear servo motors type LEA/LEB are specifically designed for a very wide range of thrust force and velocity combinations. The compact epoxy coil assembly, reinforced by aluminum mounting, provides a unique combination of non-contact design, no preload, low inertia, no cogging, excellent heat removing capabilities and structural rigidity. Standard motors are provided without forced cooling (NC). Forced air cooling (AC) or water cooling (WC) are optional. The air cooled motors can return the air outside the mechanical stage, taking heat away from the stage. High motion smoothness is achieved by sinusoidal commutation, with or without hall effect sensors. The two motor types LEA (standard magnets) and LEB (thick magnets), vary only in the thickness of their magnet assembly. They use the same coil assembly, making it very simple to upgrade motor performance. Thermistors are provided as an option for protection against unintentional overheating. Both the coil assembly and the magnet assembly have several mounting options for easy integration into the positioning system. The LE type family of motors is ideal for most positioning applications requiring long life, high speed in combination with high force, high accuracy and high smoothness of motion. 3. Mechanical Specifications Figure 3-1 shows typical layout of LEA/LEB linear motor components. The coil assembly shows the optional cooling and hall effect. Figure 3-2 shows the dimensions for the LEA and LEB coil assemblies and magnet channels.

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Figure 3-1 - LEA/LEB linear motor components

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Figure 3-2 LEA/LEB Coil Assembly and Magnet Channel Layout

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4. Motor Specifications
Table 4-1 presents specifications using no cooling, forced air cooling and water cooling for LEA and LEB linear motors. Phase to phase specifications for; LEA are on the top, LEB are in the middle, and both are on the bottom.
LEA/LEB Specifications Parameter Cooling Continuous Force @ 25 C Continuous Force @ 25C Peak Force, 10% Duty Cycle, 1 sec on Continuous Current @ 25 C Continuous Current @ 125C Peak Current, 10% Duty Cycle, 1 sec on Force Constant Back EMF Motor Constant Km = F/P^.5 Slide Weight Parameter Cooling Continuous Force @ 25 C Continuous Force @ 25C Peak Force, 10% Duty Cycle, 1 sec on Continuous Current @ 25 C Continuous Current @ 125C Peak Current, 10% Duty Cycle, 1 sec on Force Constant Back EMF Motor Constant Km = F/P^.5 Slide Weight Units N lbs. N lbs. N lbs. amps. RMS amps. RMS amps. RMS N/amp. RMS lbs/amp. RMS volts 0 - peak/meter/seconds volts 0 peak/inch/second N/sqr rt watt lb/sqr rt watt kg lbs. Units N lbs. N lbs. N lbs. amps. RMS amps. RMS amps. RMS N/amp. RMS lbs/amp. RMS volts 0 - peak/meter/seconds volts 0 peak/inch/second N/sqr rt watt lb/sqr rt watt kg lbs. watts ohms ohms mH msec C N lbs. C/watt Air-LPM Water-LPM kPa Air-LPM Water-LPM PSIG NC 102.9 23.1 72.0 16.2 227.4 51.1 3.70 2.59 8.18 27.8 6.25 23.2 0.59 8.5 1.9 0.41 0.91 71.5 5.2 7.2 2.8 0.55 150 0 0 1.407 n/a n/a n/a n/a NC 84.7 19.0 59.2 13.3 187.0 42.0 3.70 2.59 8.18 22.9 5.14 19.1 0.48 7.0 1.6 0.41 0.91 LEA2 AC 91.9 20.7 63.8 14.3 187.0 42.0 4.02 2.79 8.18 22.9 5.14 19.1 0.48 7.0 1.6 0.42 0.92 LEB2 AC 111.7 25.1 77.6 17.4 227.4 51.1 4.02 2.79 8.18 27.8 6.25 23.2 0.59 8.5 1.9 0.41 0.91 WC 116.5 26.2 80.9 18.2 227.4 51.1 4.19 2.91 8.18 27.8 6.25 23.2 0.59 8.5 1.9 0.41 0.91 NC 185.2 41.6 129.4 29.1 410.0 92.2 3.33 2.33 7.38 55.6 12.49 46.4 1.18 12.1 2.7 0.80 1.76 WC 95.8 21.5 66.5 15.0 187.0 42.0 4.19 2.91 8.18 22.9 5.14 19.1 0.48 7.0 1.6 0.42 0.92 NC 152.5 34.3 106.6 24. 0 337.8 75.9 3.33 2.33 7.38 45.8 10.29 38.2 0.97 9.9 2.2 0.80 1.76 LEA4 AC 172.1 38.7 119.0 26.8 337.8 75.9 3.76 2.60 7.38 45.8 10.29 38.2 0.97 9.8 2.2 0.78 1.73 LEB4 AC 208.9 47.0 144.4 32.5 410.0 92.2 3.76 2.60 7.38 55.6 12.49 46.4 1.18 11.9 2.7 0.78 1.73 146.4 10.4 14.3 5.7 0.55 150 0 0 0.688 105 414 3.7 60 WC 223.1 50.2 155.0 34.8 410.0 92.2 4.02 2.79 7.38 55.6 12.49 46.4 1.18 12.0 2.7 0.78 1.73 167.0 10.4 14.3 5.7 0.55 150 0 0 0.601 3.8 276 1 40 NC 269.8 60.7 188.4 42.4 595.8 133.9 3.24 2.26 7.15 83.4 18.74 69.6 1.77 14.8 3.3 1.17 2.58 163.0 15.6 21.5 8.5 0.55 150 0 0 0.614 n/a n/a n/a n/a WC 183.8 41.3 127.7 28.7 337.8 75.9 4.02 2.79 7.38 45.8 10.29 38.2 0.97 9.9 2.2 0.78 1.73 NC 222.2 49.9 155.1 34.9 490.6 110.3 3.24 2.26 7.15 68.6 15.43 57.3 1.46 12.2 2.7 1.17 2.58 LEA6 AC 243.6 54.8 168.8 38.0 490.6 110.3 3.55 2.46 7.15 68.6 15.43 57.3 1.46 12.1 2.7 1.21 2.68 LEB6 AC 295.9 66.5 205.1 46.1 595.8 133.5 3.55 2.26 7.15 83.4 18.74 69.6 1.77 14.6 3.3 1.21 2.68 196.0 15.6 21.5 9.5 0.55 150 0 0 0.508 91 414 3.2 60 WC 311.2 70.0 217.0 48.8 595.8 133.9 3.73 2.60 7.15 83.4 18.74 69.6 1.77 14.7 3.3 1.21 2.68 216.9 15.6 21.5 8.5 0.55 150 0 0 0.462 3.8 310 1 45 NC 320.6 72.1 226.1 50.8 715.6 160.9 5.77 4.07 12.88 55.6 12.49 46.4 1.18 16.9 3.8 1.61 3.56 178.1 5.3 7.4 2.9 0.54 150 0 0 0.562 n/a n/a n/a n/a WC 256.3 57.6 178.7 40.2 490.6 110.3 3.73 2.60 7.15 68.6 15.43 57.3 1.46 12.1 2.7 1.21 2.68 NC 264.1 59.4 186.3 41.9 589.5 132.5 5.77 4.07 12.88 45.8 10.29 38.2 0.97 14.0 3.1 1.61 3.56 LEA8 AC 293.6 66.0 207.8 46.7 589.5 132.5 6.41 4.54 12.88 45.8 10.29 38.2 0.97 14.0 3.1 1.61 3.56 LEB8 AC 356.4 80.1 252.2 56.7 715.6 160.9 6.41 4.54 12.88 55.6 12.49 46.4 1.18 17.0 3.8 1.61 3.56 220.0 5.3 7.4 2.9 0.54 150 0 0 0.455 79 414 2.8 60 WC 443.0 99.6 288.9 64.9 715.6 160.9 7.97 5.20 12.88 55.6 12.49 46.4 1.18 15.7 3.5 1.61 3.56 339.9 5.3 7.4 2.9 0.54 150 0 0 0.339 3.8 345 1 50 WC 364.9 82.0 238.0 53.5 589.5 132.5 7.97 5.20 12.88 45.8 10.29 38.2 0.97 12.9 2.9 1.61 3.56

Continuous Power Loss Resistance Phase to Phase @ 25C Resistance Phase to Phase @ 125C Inductance Phase to Phase Electrical Time Constant @ 25C Maximum Coil Temperature Magnetic Attraction Thermal Resistance Cooling System Flow and Pressure Flow Pressure Drop Flow Pressure Drop

LEA/LEB Commom Specifications 84.2 91.6 115.0 5.2 5.2 10.4 7.2 7.2 14.3 2.8 2.8 5.7 0.55 0.55 0.55 150 150 150 0 0 0 0 0 0 1.192 1.091 0.875 122 414 4.3 60 3.8 193 1 28 n/a n/a n/a n/a

Table 4-1 Motor Specifications

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5. Cable Wires Table 5-1 identifies the color, function and length of the wire in the LEA/LEB motor coil assembly. All cables come standard length .3 m /1 ft
COLOR MOTOR LEADS (STANDARD) RED WHT BLK GRN SINASOIDAL HALL EFFECT MODULE (OPTIONAL) RED BLK BLU WHT ORN GRN TRAPEZOIDAL HALL EFFECT MODULE (OPTIONAL) RED BLK WHT BLU ORN THERMISTORS (OPTIONAL) BLK BLK FUNCTION A B C GND I+ IA+ AB+ BV+ RTN S1 S2 S3 o 125 C o 125 C Thermistor output 25 C 121 C 129 C 400 - 1000 2600 2600 Hall effect output; sink, 10mA max Hall sensor installed opposite cable end of motor: Hall sensor A is in phase with BC windings (S1 - BC) Hall sensor B is in phase with AB windings (S3 - AB) Hall sensor installed on cable end of motor: Hall sensor A is in phase with AB windings. (S1 - AB) Hall sensor B is in phase with BC windings. (S1 - BC) Sensor output: LEA = 320 mv / LEB = 400mv Supply Voltage 5-24 Vdc NOTES

Table 5-1 Cable Wires 6. Motor Installation

CAUTION
Linear motors contain powerful permanent magnets. When handling multiple magnet channels do not allow the channels to come in contact with each other. Do not disassemble the magnet channel. The magnetic force between channels and channel plates is extremely powerful and can cause bodily injury. There are two critical aspects that effect LEA/LEB installation and operation. Refer to Figure 6-1. 1) 2) The distance from the base of coil assembly to the base of the magnet channel must be 90mm .127mm throughout its travel. The air gap must be maintained at .76mm on both sides of the coil and parallel to the magnet channel thoughtout its travel.
COIL ASSEMBLY BASE MAGNET CHANNEL BASE

AIR GAP

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Figure 6-1 Coil Assembly and Magnet Channel Figure 6-2 shows the overall profile dimensions for the LEA/LEB motor series and Figures 6-3 through 6-5 show typical installation positions for coil assembly and the magnet channel with reference to the mounting positions of each component. The components can be mounted parallel end to end, parallel side to side and at right angles to one another.

Figure 6-2 General dimensions

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Figure 6-3 Components mounted parallel side by side

Figure 6-4 Components mounted parallel, end to end

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Figure 6-5 Components mounted at right angle

6.1 Motor Mechanical Installation Procedure

LEA/LEB linear motor components come with standard surface mounting holes but can be customized for specific mounting needs. In either case, follow the principles of the next steps to maximize motor efficiency and minimize the chance for motor damage. 1) 2) 3) Ensure the mounting surface is clean of foreign material. Verify the flatness and the straightness of the mounting surface is within .005mm (.127in) Mount the magnetic channel(s) to the mounting surface, maintain a flatness and straightness of .005mm (.127in). If the coil assembly has an optional sinusoidal hall effect sensor, direction of travel is determined by which side the hall effect sensor is located, refer to Section 7.4 to Linear Hall Effect Module. Position the axis near the end of its travel and slip the motor coil assembly into magnet channel. Attach coil assembly to the axis beam. Verify that the air gap between the magnet channel and both sides of the coil assembly is .76mm (.030in). The coil should be parallel to the magnet channel throughout the length of its travel. If needed, adjust the position of the coil assembly. Locate the motor cable in an appropriate position and verify the cables do not rub against any surfaces while the axis is in motion.

4) 5)

6)

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7. Motor and Hall Effect Phasing

CAUTION
Dangerous voltages, temperatures, forces and energy levels exist in servo controlled systems. Extreme care must be exercised when operating, maintaining or servicing this linear motor to prevent harm to personnel or equipment.
7.1 Resistance Verification

Following the installation of a motor, the phase to phase motor resistance must be verified. See Figure 7-1. The three motor leads are isolated from the motor ground and are normally measured in excess of 100M. 1) 2) 3) Make sure that the motor cable is not connected to the controller. Confirm motor model number Verify that the resistance value is equivalent to value shown on Table 4-1
RED WHT BLK GRN GRN/YEL OHM

Figure 7-1 Verifying Motor Resistance

7.2 Motor Windings

Each LEA/LEB motor consists of a group of coils connected in a "Y" configuration. The center of the "Y" is not available externally and therefore all measurements and specification are phase to phase. The back EMF phase relationship of the motor is shown in Figure 7-3.

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7.3 Phase Relation Verification

1) 2)

Make sure that the motor cable is not connected to the controller. Connect motor phases using Figure 7-2 as a guide. a) b) Connect channel 1 across any one motor phase. Connect channel 2 across another motor phase.

3)

Slide the motor by hand and observe the relationship of the sine wave produced for each phase to the relative to other phases. The relationships should appear like that shown in Figure 7-3
RED WHT BLK GRN GRN/YEL CH1 REF CH2

Figure 7-2 Motor Phase Verification Connection

C B A MAGNIETIC CYCLE LENGTH

VOLTAGE LEVELS

VBEMF PH A- B
@ MOTOR PHASE NO POWER TO MOTOR

VBEMF PH C-B

120

240

360

Figure 7-3 BEMF Phase Relationship For Motor Windings

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7.4 Linear Hall Effect Module

LEA/LEB motors can be supplied with a linear hall effect module (Anorad part number 44150 for sinusoidal and 44150-T for trapezoidal) to provide commutation feedback which many drive types require. Amplifiers are equiped with the necessary interface to the hall effect sensors. Figure 7-4 shows the relationship that constitutes a forward motion of the motor, which is defined as the motor moving away from the motor leads and hall effect module.
FORWARD
REVERSE

COIL ASSEMBLY

MOTOR LEADS

MAGNET CHANNEL

HALL EFFECT MODULE

Figure 7-4 Hall Effect Sensor and Motor Direction

7.5 Motor Phase and Hall Effect Sensor Phasing Procedure
RED WHT BLK GRN GRN/YELL SINUSOIDAL AMPLIFIER A+ HALL EFFECT B+ CH1 REF

CH2

Figure 7-5 Motor Phase and Hall Sensor Phasing Setup 1) 2) 3) 4) 5) 6) Use a dual channel storage oscilloscope and refer to Figure 7-5 Connect channel 1 to one motor lead and its reference, to another motor lead. Connect channel 2 to "A" hall gain test point and oscilloscope reference to servo board reference. While moving the motor by hand in any direction, observe the phase relationship. If the selected motor phases are not in phase with hall sensor "A", select different combination until the motor B.E.M.F. is in phase with the hall effect signal. If one combination is found to be in phase, record the direction in which the motor moved to get both signals (motor and hall), in phase.

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7) 8)

Label the motor lead connected to channel 2 as phase "A", and the motor lead connected to channel 2 reference as phase "B". Label the third phase as phase "C". Summary: Motor phase AB is in phase with hall sensor "A". (See Figure 7-6)

9) 10) 11)

Connect channel 1 to "B" hall gain and oscilloscope reference to servo board reference. Connect scope channel 2 to phase "B" and reference to phase "C". Move the motor by hand in the same direction as recorded before and verify that the motor B.E.M.F. is in phase with the hall sensor "B". Summary: Motor phase BC is in phase with hall sensor "B". (See Figure 7-6))

12)

Turn power OFF.

VOLTAGE LEVELS

VBEMF PH A-B

VBEMF PH B-C

@ MOTOR PHASE NO POWER TO MOTOR

VBEMF PH C-A

HALL A+

@ THE AMPLIFIER HALL SENSORS POWERED

HALL B+

120

240

360

Figure 7-6 BEMF vs Sinusoidal Hall Feedback

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7.6 Extra help for Motor and Hall Sensor Phasing

If the correct phase relationship between motor and hall effect sensor cannot be found verify the following: a) b) Verify that none of the motor phases are shorted to chassis or to each other. Verify that while moving the motor by hand that both hall effect signals are 120o out of phase.

If you find motor phase AB in phase with hall sensor "A" moving in a particular direction and cannot find motor phase BC in phase with hall sensor "B", re-label motor wire "A" as "B" and motor wire "B" as "A". Do not re-label wire "C". At this time, motor phase AB will be in phase with hall sensor "A", but in the opposite direction as it was found before. 8. Recommended Wiring Figure 8-1 shows the recommended wiring for motor hall sensors and encoder. Use the diagram as a guide final installation may vary.

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TWIST SENSOR WIRES INSIDE SHIELD AMPLIFIER USE TWISTED PAIR COMMAND + CONTROLLER

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A+ AB+ BI+ INote 3 Note 3 DC + PWR GND + POWER SUPPLY Ph. A Ph. B Ph. C MTR GND Ph. A Ph. B Ph. C Note 2 Note 5 Note 1 TWIST ALL WIRES TOGETHER ENCODER INTERPOLATOR LOGIC BOX (OPTIONAL) +5V Note 6 USE TWISTED PAIR USE TWISTED PAIR A+ AB+ BI+ I+5V RTN ENCODER INTERFACE NOTES: 1. IT IS RECOMMENDED THAT THE ENCODER BE LOCATED AS FAR AS POSSIBLE FROM THE MOTOR TO PREVENT ITS ELECTRO-MAGNETIC RADIATION FROM PRODUCING ELECTRICAL NOISE IN THE ENCODER SIGNALS. -METAL SHIELD SHOULD BE USED IF ENCODER SIGNALS A ARE AFFECTED BY THE MOTOR. USE DIFFERENTIAL OUTPUTS AND TWISTED PAIRS AS SHOWN HERE. 2. 3. DO NOT CONNECT POWER GND TO CHASSIS UNLESS POWER SUPPLY IS ISOLATED. SOME AMPLIFIERS HAVE OPTICAL ISOLATION BETWEEN THE ANALOG/DIGITAL SECTION AND THE POWER STAGE. IN SUCH CASES THE CONNECTION NEEDS TO BE REMOVED. ALL COMPONENT CHASSIS GROUND POINTS AND SIGNAL GROUND OR COMMON POINTS SHOULD BE TOGETHER AT A SIGLE POINT (STAR CONNECTION) THIS POINT SHOULD THEN BE TIED TO EARTH GROUND WITH A SINGLE CONDUCTOR. THIS FORM OF GROUNDING PREVENTS GROND LOOPS AND INSURES PROTECTION AGAINST SHOCK HAZARD. PASS THE ENCODER CABLE SHIELD THROUGH THE LOGIC BOX. IF THE SHIELD IS CONNECTED TO THE BOX, ISOLATE THE BOX FROM CHASSIS GROUND. 5. 6.

A+ HALL AEFFECT B+ SENSORS BI+ I-

MOTOR

Figure 8-1 Recommended Wiring Diagram

ENCODER

RECOMMENDED WIRING FOR MOTOR, HALL SENSORS & ENCODER

LEA/LEB

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Anorad/Rockwell Automation 100 Precision Drive Shirley, NY 11967-4710

Web site http://www.anorad.com E-mail anorad@anorad.com

Technical Support: Tel 631.344.6600 Fax 631.344.6660 email techsupport@anorad.com

Item Number 72075 Rev A April 2004