Precision, efficiency, and easy integration – the future of drive technology
What are the main advantages of an integrated encoder motor with closed-loop control?
Main advantages are higher precision by eliminating step losses, improved dynamics, a more compact design through the integration of motor and encoder (often also the driver), which reduces the wiring effort by up to 30%, and often a increased energy efficiency.
How exactly does closed-loop control with an integrated encoder prevent step losses?
Der The integrated encoder continuously provides position data to the controller. If the actual position deviates from the desired position, for example due to load changes, the controller corrects this immediately. Thus, step losses that can occur in open-loop systems are effectively avoided.
For which machines are integrated encoder motors particularly suitable?
They are excellent for automation tasks, robotics (e.g., pipetting robots), machine tools (CNC milling, Z-axes), packaging machines, pick-and-place applications and specialized machine construction , wherehigh precision and reliability are required. Do integrated encoder motors represent a cost-effective alternative to servo motors?
Yes, especially in applications that
require high torque at low speeds (below 1000 RPM) , desire simple commissioning without elaborate tuning , and where servo motor hunting is problematic, they can provide a very cost-effective solution with comparable precision. What role does encoder resolution play in selection? The encoder resolution determines the mit vergleichbarer Präzision bieten.
Welche Rolle spielt die Encoder-Auflösung bei der Auswahl?
Die Encoder-Auflösung bestimmt die accuracy of position feedback and thus the achievable precision of the system. A higher resolution (e.g., more pulses per revolution) allows for finer position detection and correction, which is critical for demanding applications . How do my applications benefit from integrated brakes or battery-free absolute encoders?
An
integrated brake secures the position in the event of a power failure or at standstill, especially for vertical axes. Battery-free absolute encoders (like in the αSTEP AZ series) reduce maintenance efforts , since no battery needs to be replaced, andmaintain the position even after a power loss. What efficiency increases are possible through the use of these motors?.
Through load-dependent current control and optimized designs,
energy savings of up to 50% can be achieved. Additionally, the setup time can be reduced by up to 70% , which positively influences the overall equipment effectiveness (OEE). How does ATEK Drive Solutions assist in selection and integration? positiv beeinflusst.
ATEK Drive Solutions offers
comprehensive technical consulting , to design the optimalintegrated encoder motor for your specific closed-loop application. We assist with the system integration and provide custom adaptations for maximum performance. für maximale Performance.
Integrated encoder motors for closed-loop control offer superior precision by eliminating step losses and allow accuracies of up to ±0.05 degrees, which significantly improves product quality.
These systems significantly simplify machine construction by reducing the wiring effort by up to 30% and shorten the commissioning times by up to 70%, leading to faster market entry.
By load-dependent current control and efficient designs, savings can be realized, reducing can be achieved. Additionally, the operating costs and increasing the sustainability of applications in the industrial drive technology. Discover how integrated encoder motors can optimize your closed-loop systems, reduce costs, and increase performance. Learn all about advantages, applications, and the latest innovations.
Are you looking for a precise, efficient, and easy-to-integrate solution for your drive technology? Integrated encoder motors for closed-loop controls offer numerous benefits. Contact us at erhöht.ATEK Drive Solutions ATEK Drive Solutions, to find the perfect solution for your requirements.
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What exactly is an integrated encoder motor for closed-loop control?
Ein integrated encoder motor for closed-loop control improves precision and efficiency in drive systems. This article explains the advantages and applications of this technology for system optimization.
Compact design in the drive train
Such motors with integrated encoder combine motor, encoder, and often the driver in one unit, which can reduce wiring effort by up to 30% and save space. ATEK Drive Solutions provides efficient system solutions for customers.
Closed-loop: The principle of feedback
Die Closed-loop control with an integrated encoder motor enables continuous position monitoring. The integrated encoder continuously provides actual position data, allowing deviations – even under load with the αSTEP AZ series – to be corrected immediately. This enables accuracies of up to ±0.05 degrees.
Distinction from other systems
These drives with integrated feedback system can be a cost-effective alternative to servo systems, especially at high torques under 1000 RPM, as demonstrated by the JMC iHSS series.High-torque servo motors understand.How do you benefit from closed-loop control with integrated encoders?
High precision without step loss
Die Closed-loop control, achieved through a integrated encoder motor, prevents step losses and production rejects due to inaccurate positioning. Nanotec systems achieve repeatable positioning in the micrometer range, an advantage over open-loop stepper motors.
Enhanced dynamics and efficiency
Systems with feedback, such as those offered by integrated encoder motor for closed-loop control , allow for higher accelerations and load-dependent current control, reducing process times. Energy consumption can decrease by up to 50%, as tests with KL-5056H-like motors show.Discover precision gear boxes.
Simplified commissioning and increased robustness
Integrated systems, often designed as encoder motor units for controlled drives like JVL ServoStep motors, offer plug-and-play or automatic tuning. This reduces setup time by up to 70% and increases system robustness, which lowers the commissioning effort for precise drives.Where do integrated encoder motors reach their full potential?
Automation and robotics
For precise gripping (e.g., 0.1 mm accuracy in robotic arms), integrated encoder motors for closed-loop control are ideally suited due to their precision and compactness. Manufacturers of laboratory automation systems use NEMA 17 motors with integrated encoders for pipetting robots.
- Precision and compactness for automation and robotics (e.g., pipetting robots).
- Increase in accuracy and position stability in machine tools and CNC applications.
- Reliable solutions against creeping errors, e.g., with integrated brakes.
- High reliability and smooth operation for specialized machine construction.
- Suitability for sensitive areas such as medical technology (e.g., dialysis machines).
- Minimization of maintenance through battery-free absolute encoders in critical applications.
Machine tools and CNC applications
For increasing accuracy in CNC milling, such as for Z-axes that must hold exact positions, models like the JMC iHSSC60 with brake and encoder, a powerful integrated encoder motor, offer a reliable solution against creeping errors.Check CNC drive solutions.
Specialized machine construction and medical technology
For applications with high demands on reliability and smooth operation (e.g., dialysis machines in medical technology), motors with integrated feedback for control prove themselves. Battery-free absolute encoders, as in the αSTEP AZ series, minimize maintenance and failure risk in such closed-loop systems.What criteria do we use to select the suitable integrated encoder motor?
Definition of mechanical and electrical requirements
The selection of the right integrated encoder motor for closed-loop control must consider the load and dynamics of the application. We analyze holding torque (e.g., 2 Nm for handling axes), operating voltage (often 24/48VDC), and maximum speed to avoid oversizing.
Encoder resolution and type
When selecting a motor with integrated encoder for control tasks , the choice of encoder type (incremental or absolute) depends on the required position reliability, even after a power loss. A 1000-pulse incremental encoder is often sufficient; for critical axes, absolute encoders (e.g., JVL ServoStep with up to 819200 steps/revolution) are better.
Interfaces and additional functions
For a integrated encoder motor efficient control integration is important. We check for the need for fieldbus interfaces (EtherCAT, PROFINET) or simple pulse-direction control (RS-232 for iHSS models). Integrated brakes are often required for vertical axes to safely maintain position in the closed-loop operation. Explore fieldbus options What innovations will shape the future of integrated drive solutions?.Compactness and power density
Future
solutions will become smaller with the same or higher power. integrated encoder motors for closed-loop control werden kleiner bei gleicher oder höherer Leistung. The trend is towards higher power density through optimized motor designs and GaN power electronics in drivers, as prototypes show.
- Increased compactness with rising power density through optimized designs and GaN technology.
- Integration of sensors for predictive maintenance to prevent failures.
- Enhanced networking capabilities (Industry 4.0) via OPC UA/MQTT for cloud connectivity.
- Increased machine availability through intelligent data analysis and maintenance.
- Growing prevalence of battery-free absolute encoders to reduce maintenance effort and costs.
- Significant reduction in commissioning times through fully automatic setup systems.
- Focus on the combination of precision, efficiency, and easy system integration in drives with integrated control.
Enhanced functions and networking (Industry 4.0)
Proactive maintenance notifications prevent failures. Future motors with integrated feedback systems will have sensors for predictive maintenance and communicate via OPC UA/MQTT with clouds, which can increase machine availability by up to 15%.Understanding predictive maintenance.
Battery-free absolute encoders and simplified commissioning
Battery-free absolute encoders (e.g., Oriental Motor αSTEP AZ Series) reduce maintenance effort and costs. This technology is gaining importance in integrated drive solutions with control. Systems with fully automatic setup (e.g., from JVL) significantly shorten commissioning times.
Integrated encoder motors for closed-loop controls combine precision, efficiency, and easy integration. Such drive systems with integrated feedback are an important advancement. ATEK Drive Solutions supports you in optimizing your drive technology with customized solutions for your closed-loop applications..
