More options thanks to new electronic models for BLDC motor Romotion
Complex drive tasks require intelligent control systems. To take this into account, Rotek developed the three-phase brushless DC drive Romotion with integrated control electronics as standard. Now there are new electronic models that extend the range of applications.
Update for the standard control electronics
Romotion:
- Voltage 24 V - 48 V DC
- Speed 400 - 4000 1/min
- 80 to 200 W
Integrated electronics:
- Standard electronics M52, M60/C60,
- CMS
External electronics:
- D1S
- Low-cost control electronics BLSC24-4
Optional:
- igh-resolution 14-bit rotary sensors, with which the motors can also be operated in the range below 400 rpm in a controlled manner
- Internal encoder with rotor bearing detection and A/B-I signal for maximum precision
- with drive-integrated safety function STO (safe torque cut-off)
The Romotion is a three-phase brushless DC motor with integrated control electronics as standard. It is available in two versions. The Romotion 44 is available with a maximum output power of up to 100 W. The larger Romotion 84 delivers a continuous output power of 130 W at 48 V and reaches 200 W at its peak. The variant for 24 V offers an output power of 110 to 130 W. Both variants cover a speed range of 400 to 4000 rpm in the sensorless standard version.
The standard integrated control electronics offer possibilities that go far beyond simply controlling the motor windings. The operating principle is simple: The speed controller of the electronics receives its setpoint value from a DC voltage signal of 0 to 10 V. The DC voltage is converted by the electronics into a digital signal. The DC voltage is converted into a digital signal by the electronics. The electronics receive the actual speed value via the frequency of the motor's back EMF. The current for controlling the motor coils is calculated from the comparison.
The controller sets the speed to the desired setpoint and keeps it largely independent of the required torque. This allows the drive to perform functions independently, making higher-level control systems superfluous or considerably simplifying them. This reduces the costs of the system design.
In addition to the inputs for enabling, direction of rotation and speed setting, the standard electronics offer a serial RS-485 Modbus interface and optional CAN bus. It has a modular design and can easily be expanded to include additional functions. It is used to parameterize the electronics, i.e. to adapt them to the application, and enables several motors to be networked. It can be easily set up, commissioned and its status monitored using the Windows Motor Manager program. For convenient use, it can be operated with a control panel.
The standard M51 electronics developed for the Romotion 44 in 2014 has now been replaced by the successor model M52 with optimized components, which is also cheaper to manufacture. If the plug connectors are not required, an even cheaper version with cable glands is available. This means that BLDC motors from the Romotion 44 series will cost significantly less in future. The functionality remains unchanged.
New electronic models expand possibilities
The new electronic models CMS and D1S are suitable for an input voltage of 24 V to 48 V and can be combined with both the Romotion 44 and the Romotion 84.
The integrated CMS electronics are particularly suitable for complex applications. Thanks to its integrated singleturn absolute encoder, it is ideally suited when precise positioning is required. It can support an electromechanical brake and can be extensively programmed and adapted for demanding requirements, e.g. with individually adaptable digital inputs. It can be controlled analog and digitally via Modbus RTU and CAN bus.
A Windows program is available for parameterization. The Romotion with integrated CMS electronics is used as a travel drive for large lawn mowing robots, in shuttles for warehouse automation and for conveyor belts.
In contrast, the D1S is used as external electronics. This allows more flexibility during installation, e.g. if space is limited or if higher temperature ranges need to be covered. It can be controlled via Modbus RTU and can be parameterized to a limited extent. Operation is possible without sensors and with a Hall sensor.
The digital inputs control the direction of rotation and enable, while the speed is specified via the analog input with a voltage of 0 - 10 V. Possible operating modes are either speed controller or speed regulator. With the speed controller, the speed is monitored and readjusted by the higher-level system, otherwise the drive behaves like a normal DC motor and the speed and torque are adjusted according to the load. The D1S electronics is a cost-effective solution that is easy to put into operation.
Low-cost control electronics for less complex requirements
If less complex control options are required, Rotek offers low-cost BLSC24-4 control electronics developed by partner company Ebetec from Austria. This is a motor controller for brushless DC motors that are operated without sensors using the back EMF. Due to the sensorless control method, there is a lower limit for the motor speed depending on the motor type. Setpoint specification and operation are carried out via IOs or analog voltages. Up to 100 W at 4 A power output are possible. The controller is adapted to the respective application and the drive motor used. As with the D1S, operation as a speed controller or speed regulator is possible. In speed controller mode, the BLSC24-4 adjusts the speed within the technically possible range and keeps it stable. Operation as a 4Q controller is also possible. The control electronics can both brake and accelerate. A short-circuit brake is also possible. These functions are sufficient for many applications.
- The control electronics themselves are integrated in the connection cable of the motors. This means that no additional slot, installation space, housing or control cabinet is required. The space requirement and wiring effort is therefore significantly reduced, making it flexible and cost-effective.
- The control electronics are encapsulated and sealed directly in the housing using the “hot melt” process. It is therefore also optimally protected against environmental influences.
- As no ageing components (e.g. electrolytic capacitors) are used, the control electronics are maintenance-free.
- Romotion drives with BLSC24-4 control electronics are a particularly useful solution for applications such as fans, pumps or in rotary heat exchangers.
Also with sensor if required
The Romotion can also be operated with electronics provided by the customer. It does not contain a sensor as standard, which makes it more compact and less expensive. However, many common drive solutions also require sensors built into the motor. If applications require maximum precision and accuracy, the internal rotation sensor with rotor position detection and A/B-I signal is an option. Rotek offers the installation of high-resolution 14-bit sensors for this purpose. These also allow operation at very low speeds. Romotion equipped with encoders are used in robots in agriculture, for example. The customer uses their own electronics and uses the output of the sensor.
Many possible combinations
The Romotion shows its strengths where a variable speed that is largely independent of the torque, low power consumption and a long service life are required. It regulates complex process sequences and communicates with higher-level control systems or even makes them superfluous. It starts up accurately and delivers a high torque as well as good speed control behavior. It is therefore particularly suitable for use in automated guided vehicles (AGVs), which are becoming increasingly common in warehouse and production logistics.
With the same external design as the other Rotek motors, the Romotion BLDC motors are compatible with all components from the Rotek modular system. Combinations with planetary, worm and parallel shaft gearboxes are possible. Other options include special gearboxes, mechanical modifications to the housing and special shafts, individual power connections with special cables and plugs and optional accessories such as encoders. The increased use of electronics in drive solutions has increased the need for advice. Rotek's experts find individual solutions for a wide range of customer applications in the shortest possible time.
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