Motion Control of Lead Screw Linear Actuators - Webinar

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today's webinar integrated approach to motor and lead smooth technology now I'd
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like to introduce our presenters Jamie Stockton is global product manager for PBC linear he has been in the industrial
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automation market for a decade offering engineering support for both mechanical and electrical solutions he has deep
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background in diverse applications including packaging medical aerospace defense and various food-grade
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situations and applications and the score nkow is the Sales Director from
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lunes industry of america inc and he has worked in the industrial automation market for more than 14 years focusing
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on electromechanical products and working with customers on applications across many industries his goal is to
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bring value to his customers to his engineering and customer service background and finally mike maloney is
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the application engineering manager at applied motion products previously he worked as a design engineer at AMC where
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he contributed to the design of several motor drives and played a central role in the development of can open
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compatible drives and integrated motors more recently he has worked in the medical and industrial device market and
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now I'm going to turn the presentation over to the speakers all right thank you
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very much hi this is Jamie Stockton thanks for joining us today what we're going to do
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is go over PBC's integrated approach to motor and leadscrew technology first of
Agenda
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all on the agenda we're going to go over the foundational elements of load leadscrew motor including the control
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motor screw and the nut and then we're going to go through some of the applications that are typically seen for
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this type of product and kind of explain how using the PBC solution it's going to
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help optimize and make those solutions as good as possible first up let's go over what a traditional mechatronics
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based solution looks like you're going to have the screw and nut of course there's two different types of screws
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involved you've got a lead screw which is going to be typically a metal or
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plastic on the screw or you may have a ball screw which
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is essentially rolling-element balls traveling on the screw typically those are going to be the two types of screws
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that you're going to see you're going to have interface Hardware this screw must connect to the motor in a traditional
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system you'll have a coupling and if you have the motor to the system you're going to need some type of motor adapter
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say like a NEMA 17 or NEMA 23 adapter let Annie talk about the different types
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of motors that you might see there's many types of motors obviously the moon's manufactures and with an
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integrated product we could look at a traditional stepper NEMA 1723 or any variety of both depending on your loads
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and torque requirements as well as a step servo product with my chrome Cheryl highlight from ANP which brings the
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technology closer to a servo type performance but with a stepper type commercial side by the motion products
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part of this picture is that we make motor drivers and integrated step motors using the moon's step motors we have
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both open and closed loop drivers including the step server technology that's that's shown there and that
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effectively puts a closed-loop motion controller on the back of the stepper motor which enables like Andy was saying the servo style performance in this
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cost-effective integrated package and we'll talk about that a little bit later moving on to the controller side of
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things in the traditional arrangement here the motor drive physically sits between the controller and the motor
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screw combination on the bottom there we have a standard motor drive an P drives
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all have built-in i/o and come in a wide variety of control options from step and Direction locally stored programs to a
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full range field bus control options this motor drive on the bottom is effectively identical to the one on the
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back of the step server smart motor next to it meaning you have a choice of where you want to put the drive electronics
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either directly on the line attached to the motor or back in your control panel where you cable out to your motor and
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then on the top there we see a PLC for many traditional applications a full-time controller like that PLC is in
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the mix either two coordinated motion across multiple axes or even just to monitor the status and a little more
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detail than using the drive digital outputs as I mentioned before our drive support a wide variety of these PLC
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control options from step into affection to various field buses really the drives can interact with pretty much
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any PLC you throw at it to enable control of this traditional motor lead screw system alright that was what a
Optimized System Overview
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traditional setup would look like and now this picture will kind of go over what the optimized PBC offering is going
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to entail we've got the lead screw and the lead screw nut as you can see and
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we'll talk about a little bit more later the coupling and motor mount adapter are not present as we've directly coupled
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the screw to the motor we've got the moon's stepper motor which is a hollow
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shaft as you can see from the picture below Andy maybe you could talk about that picture just a little bit what you
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see is a cutout of the motor and with this integrated solution or optimized system we've got a hollow bore offering
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that we'll talk about a few of the benefits of the hollow bore with with our partnership PBC essentially
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integrates that screw into the motor and allows for again a tighter package we eliminate some of the mechanical
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components that couple the screw it allows for a number of advantages and
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efficiencies on the customer side bigger bearings for your axial loads that are translated etc but we will touch on that
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a little bit more when we get into the details of the motor and if you can read the chart on the bottom left very well
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then you have better eyes than I do but perhaps my can elaborate a bit on what that means and what the back of the
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motor has on it there that picture is just a generic closed-loop control system on the control side we have the
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same basic drive interface that we had in a traditional system but here again it's closely coupled to the motor and
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the screw for a tight integrated package you get all the same local real control options as in the traditional system but
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here again they're optimized out-of-the-box for the specific motor and leave screw combinations to really produce the integration time now we're
Constant Force Nut Overview
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going to talk a little bit about the nut to nut that PBC is offering which we
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actually just released as a general product release a couple of weeks back is a patented anti backlash design if
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you look at the two pictures on the right hand side the one on the top is the PBC nut we're calling this nut a
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constant force anti backlash nut and you can see it looks quite a bit different than the traditional anti backlash
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spring nut what we have found through great amounts of testing is that we are
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offering better than two times anti backlash compensation using the constant
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force anti backlash nuts this also offers a more consistent
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preload over the life of the system to elaborate that a bit more typically when
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you use a spring loaded anti backlash nut as the nut wears in the amount of
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preload varies and it actually varies quite a bit what that normally means is
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that when you have an application you run it for some period of time until you see that backlash start to wear in and
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then you have to go into your system and do some adjustments to compensate for that backlash change the constant force
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technology essentially eliminates the need for that step as the backlash stays
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very consistent over the entire life of the nut also worth noting the PBC line
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which we are offering an anti backlash nut as you see here and a standard nut
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which is no anti backlash they're both going to be made as standard from a self
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lubricated PTFE type of Delrin and with that we would recommend using no
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lubrication in the system where with the traditional nut made of acetal or other
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types of plastic traditionally lubrication is going to be recommended we're saying this is two to four times
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better than traditional designs in terms of backlash and wear the next slide is a
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45 second video which will go over a comparison of these two nuts
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side-by-side PBC is proud to introduce a full line of lead screw products
Constant Force Overview
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featuring an anti backlash technology and we call constant force the visual difference is evident let's take a
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closer look the conventional design has a variable and inconsistent radio force which changes
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dramatically over the life of the application the traditional product uses a spring while the constant force uses a
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band the constant force band applies uniform pressure to the three fingers which means the preload is consistent
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most importantly testing has shown that our technology maintains preload better over the life of the application
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[Music]
Screw Manufacturing Process
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all right on to the next slide we're going to talk about the actual manufacturing of the screw process which
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is done at PBC here in Illinois we have come up with a unique roll threading
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process and this unique roll threading process will help reduce the amount of
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pitting and flanks compared to a traditional lead screw if you look on the pictures on the right-hand side
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you'll see the PBC screw at the top is very smooth where the screw at the
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bottom is much more rough and jagged essentially what we found through lots
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of life testing is that the smoother screw helps reduce the wear on the plastic nut which was able to allow us
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to get in excess of 6,000 linear miles in a system without failure we also have
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a medical customer that had done some life testing and came up with very
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similar results and of course we'll put the asterisk in there and say depending
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on the application he may or may not see 6000 miles but we were very pleased with
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the results that we found in comparing traditional screw to the screw that PBC
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has come up with in our proprietary manufacturing process also note on here
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and it kind of talked about it at the end of the video we do have an online configurator already set up that will
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allow you to configure 8 the screw nut or lead screw motor in its entirety and
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give you this pricing CAD models pretty much everything that you would expect and doing design type of work to talk
Screw Accuracy
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about accuracy a little bit the screw that we are offering at PBC has about
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two to three times better lead accuracy than a standard industry brew we're at
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plus or minus three thousandths per linear foot traditionally it really depends on the actual manufacturer but
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some of them go as high as 10,000 per linear foot it's definitely better than a traditional screw we've also got
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sophisticated process for testing the screws to ensure that we're actually achieving the accuracy that we are
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stating as you can see on the right hand side we're measure during every single screw that comes off
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of the line over the entire length and we do offer as a special a precision
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screw that's 1000 plus or minus one thousandths over the course of each foot
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and lastly I want to talk a little bit about the motor and screw integration
Motor Screw Integration
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which was sort of alluded to at the beginning here but essentially the top
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picture shows you the motor coupling and screw and the bottom picture shows you
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the PBC solution which has this screw directly connected to the motor via
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laser welding benefits of this is that you've got factory alignment with the
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PBC solution so it's coming to you guaranteed to be very well aligned
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you're going to have fewer components which is going to give you higher rigidity and of course with your
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components you're going to have more reliability and you're going to save money on couplings and other components
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if I could add one other thing with regards to the integration of the previous slide you're actually saving
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space as well so an customer the OEM gets the benefit from either additional
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travel in the same package or they would be able to reduce the size of their package which obviously helps in
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tabletop solutions real estate is always a premium regardless of where your
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machines are going that is an added benefit to squeeze out that extra travel or extra space looking at the motor
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specifically moons as manufacturing over 10 million hybrid steppers a year and growing and we're constantly innovating
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and looking at the technology to see where we can squeeze more out of every single motor leads manufacture whether
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it's our standard or looking at special technology I'll highlight a few of them a couple of them are specific to the
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integrated package but we're also looking at the entire motor technology and capability of moons here just to
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highlight some of the benefits of working with a partner that specializes in motor technology we do have products
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that are available with 30% more torque in the same package we are able to do
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this by adding additional magnets into the rotor and backing into the stator and allowing the direction of the flux to
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increase the amount of torque output this leads to better acceleration and deceleration performance which
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inevitably leads to better cycle times just improve the efficiency on the customer side as well as again the space
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savings in terms of the motor package itself for the amount of torque that you can get out of it interesting technology
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to apply to specific applications for the hollow bore motors we add larger
Hollow Bore Motors
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bearings into the motors themselves because of the additional thrust coming
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from the screw and a linear translation it allows for better support in the axial direction which allows for longer
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life we want to keep up with the 6,000 miles I'll say of linear translation from the PBC screws we need to make sure
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that our motors can withstand that type of travel and life as well and we do that by adding larger bearings in order
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to withstand that load the hollow shaft concentricity doesn't Jamie mentioned factory established type of quality
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coming right out of the line we make sure that the concentricity is tight on the hollow bore which allows PBC to join
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the shaft onto the motor without having any sort of issues in terms of run-out this again inevitably leads to longer
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life smoother operation quieter operation you're getting a quality product straight out of the factory we
Wave Washer
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add a preload to the bearings to eliminate axial play so a standard rotary motor will typically have a wave
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washer installed on one of the sides of the motor so either the front or the rear what this does is it allows for a
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bit of plane give in a traditional rotary application which is good because it extends the life of the bearing but
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for a linear application where you're positioning is critical that's kind of the whole point here you can't have
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essentially 0.9 millimetres of place sometimes with the traditional NEMA 17 it eliminates all of the accuracy the
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precision that is required in a lot of these applications we apply preloaded up
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to eliminate that plate and allow for very good positioning a linear
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applications and then in terms of encoders feedback etc quite often when
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you're relying on that precision accuracy you need the feed do I ensure you're moving ensure you're
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in position and it's standard for us to apply a rear shaft as well as have encoder holes on the back of the motors
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that's easily done and a variety of feedback options available from us again
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depending on the application requirements extremely flexible manufacturing very customized for OEMs
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very flexible and top of the line in terms of technology and always pushing
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furthers we work with customers quite a lot in understanding their applications and using our education along the way in
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order to provide them with the best solution just a quick comment on that
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encoder mounting provisioning the motor lines that we're offering for our leadscrew motors are NEMA 8 through NEMA
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23 and the moons motors that Andy is talking about all have the two holes as
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standard in the back of the motor or for that encoder mounting and since it's a
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hollow shaft motor you'd need to get an option to wear the lead screw would actually stick out the back so that you
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can mount that encoder on there and get the encoder feedback if that's something that your application requires the only
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one that doesn't have the holes would be the aneema eight I don't think they've got poles in that one but the other ones
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all definitely do have encoder mounting capability if we move on to a little bit
Special Capabilities
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more detail on the special capabilities of moons a few of the things I'd like to
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highlight there's a number of ways to address each one some of them I'll highlight here in regards to velocity
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smoothness and scanning Jamie mentioned that all of the meat screws from PBC are
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tested for their precision and linear accuracy and in terms of scanning
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applications absolutely required to have the smoothness not only on the screw but as well as the motion we do have 0.9
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degrees step angles available a traditional step motor is 1.8 degrees so giving you 200 full steps per revolution
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the point nine degrees stepper cuts that in half and allows for 400 full steps and again with micro stepping technology
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which mic might hit on you're able to make those it's even smaller we minimize the torque
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ripple through a variety of ways but one of the main ones is to offer a three-phase stepper which minimizes that
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torque ripple we can talk about that more offline if anyone has any questions high speed motors so we do have stub
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motors that do actually get up to 8,000 rpm if not 20,000 in certain special
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applications this allows for us to get into a higher torque reign the slower
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you go the more torque you have with a step or just to simplify things by allowing a step angle to increase we
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reduce the resolution however we push the amount of torque that you can get to higher speeds again application
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dependent what your requirements are for your linear speed and force we're able
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to adjust either the type of motor we're providing to you guys or able to adjust
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the linings themselves depending on what the application requires and the power you have available to input together
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with a high lead screw either a 25 millimeter per rev range per Rev we have been able to achieve over 1 meter per
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second with a traditional stepper and a high lead lead screw the speed range
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gets quite nice and the flexibility is there to address any application challenging environments temperature
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extremes who get up to class F classification on the motors themselves we've done higher temperature designs
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really comes down to the windings the cables the bearing life we address those
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on an everyday basis IP 65 67 beyond will highlight an anti-corrosion
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technology that we also have available we have seen a number of applications we take that knowledge and it's available
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to our customers in order to benefit from that and get a shortcut in their design process and then customized
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cabling and wire harnesses our company has a division for 600 people strong that focus strictly on wire harnesses
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and that allows us to pass that benefit and optimization on to our end user
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whether it's cables or connectors or shaft modifications but in this case PTC does a great job of that with the Linney
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lead screws you can get those customizations and configure those as needed Mike tell yours yeah thanks Annie I'm
StepServer Technology Advantages
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going to talk a little bit about the step server technology advantages that we mentioned earlier and then a bit about your control
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options to make these systems actually move on the right there you see one of amps step server integrated motors this
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has a moons motor on the front and a full closed-loop control system with a 20,000 line incremental encoder on the
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back but one of the biggest advantages of the steps or technology over a standard stepper motor system is that
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closed loop servo file performance if you think about a classic stepper motor
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drive it has a motor current setting and the motor drive always delivers that set current into the motor regardless of the
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actual load this means that you to set your drive to deliver the maximum required at any point in your move even
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when your motor doesn't need it so as an example if you need five amps to do a quick accel during a long move the drive
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will deliver five amps during the Axelle also five amps during the move and also five answering the D cell to ensure that
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you won't stall and lose position this means that during the long move in the D cell you're potentially burning energy
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you don't need and you pay for that in motor heating and energy costs by contrast this step server technology
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only delivers the current it needs to move the motor as requested in that same example above will set the motor current
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to five amps maximum the motor will accelerate into the move and use the full five amps but once that
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acceleration is complete the torque requirements drop and so the current backs off to the minimum required to
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maintain the desired move profile using that twenty thousand line encoder for reference so this automatically lowers
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the current consumption of the motor which saves energy and heat because that peak torque is generally required for a
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small portion of the move usually the axle of the D so we typically see heat loads reduced up to 65 percent as a
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result of that sort of automatic current adjustment now in addition to dynamically lowering the current draw
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the step servers have the ability to peak the motor current up to 50 percent higher than the rated current of the
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motor for short bursts very short bursts again taking that same example of the long move requiring the accel current
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burst you can now potentially switch to a smaller motor since a three and a half amp motor can burst up over five amps
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for a few seconds to get you through that high torque requirement or even better if you keep the same five amp
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motor you can actually increase your available acceleration current to seven-and-a-half amps which enables faster acceleration
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and with the fixed move length that means you can decrease your cycle time to increase your throughput with the
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same size motor but now in this whole package you have increased cycle time and with the increased travel that the
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integrated screw brings to the picture you really have a very efficient system switching gears to talk a little bit
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about motor control you can see on that drive in the picture which is our SS M series there's a communication support
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in this case of Ethernet and an i/o connector the drives have two basic operating modes standalone or streaming
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control and we have a full suite of software configuration tools to help set up the drive as easily as possible
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stand-alone drives can be programmed using our Q programming language to perform complex motion profiles react to
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analog digital inputs and outputs and manipulate registers the programs can be executed automatically on powerup or
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triggered by digital inputs and again all this is configured through our software tools streaming commanded
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drives can be even more powerful when you have a plc or other control system in the mix in addition to being able to
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support stored cue program execution the drives can be controlled and modern real-time over your preferred
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communication protocol to monitor and command position IO States and Drive status one key advantage here is mixed
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control mode operation for example on powerup you can program the drive to execute a complex homing procedure and
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then set an output to tell your PLC that homing is complete and switch automatically in the step indirection
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mode so wait PLC control and give the PLC confidence that the drive is now in an own home position so it can start
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moving freely and then finally our drive support a lot of different field bus options for those plcs we have full
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command and stored program execution over Ethernet IP EtherCAT can't open
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Modbus TCP and rtu and we have a team of Apps engineers in California that can
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support the various integration challenges from motor sizing and drive selections through field bus and TLC
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integration issues all right let's run through a few different applications here we're going
High Accuracy Positioning
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to talk about what the applications require and how the integrated leadscrew
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motor can be a great fit for those applications first up is going to be a
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high accuracy positioning type of application as you can see from the picture we've got a DLP printer that's
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moving in a z-axis direction the key requirements for the application are a super-tight 20 micron layer resolution
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we've got retract followed by a step move and of course if you see the word
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printer in an application it's almost always going to be very cost competitive the way that the solution really shines
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here is for the screw in that nut we offer the constant force anti backlash nut which is going to help with enhanced
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repeatability the application is going to require bi-directional z-axis moves that's going to have a decent effect on
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the column err viscosity so it should actually be benefit of using the type of
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nuts that PBC offers and then we talked about the improved lead accuracy of plus
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or minus three thousandths per foot so that could potentially eliminate the need for an encoder which of course if
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you can start skipping out on encoders and then other components you're going to save money on the application the
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smart rotor here this is going to use as I was mentioning before mixed control mode the home the hard stop feature
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which is mentioned at the bottom there that allows you to have completely sensorless homing you can write a
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program that's saved in the drive to monitor the position of the motor turn the current down very low and
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essentially move the screw until your load hits a hard stop the motor can
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detect that very quickly thanks to that encoder and you can back off and know ok now I'm in my home position and then you
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switch over into seven Direction mode and the PLC can move knowing that you are in your home position
Digital Scanning
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for the next one we've got a digital scanning application which is going to offer a nice horizontal move the key
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requirements for the application are going to be minimum torque ripple and a precise lead accuracy again if we go
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back to the complete PBC leads for motor solution to summarize we're offering a
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superior lead accuracy for this application it's definitely required any variation in the lead accuracy results
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in variable linear velocity even if the motor rpm is 100 percent constant anti
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backlash nut is going to also help in this application be consistent preload
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and the ability to maintain a consistent preload over the life is also going to be very important in regards to the
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motor technology the whole system here is important not just one of the parts but all of them and with the addition of
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0.9 degrees stepper the increased resolution on the full steps this kind of allows for better motion across the
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entire plane allows for better resolution paired with the controls of microstepping just increases the ability
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to scan in a consistent way across the length of the travel and then in terms
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of the deep end torque everything that I've seen in terms of other motors that are out there available the deep end
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torque is all over the place I've found that moons as motors have controlled the deep end torque to a minimum and quite
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often our effect out much lower than competition and this also improves the
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scanning capability without affecting the motion itself I'll let Mike talk about the controls a little bit again
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this is using that same load torque ripple and 400 pull motor that you mentioned really with the 20,000 line
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encoder we can achieve very very precise move profiles not much more to say than
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that okay let's go over to the next application this is a high duty cycle application
High Duty Cycle
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it's another printer this is actually going to look something like company that some of you might be familiar with
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the three DP type of printer where it's a large scale large print type of application on this application we've
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got high precision XYZ requirement of course we're 3d printing so we want to
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add lair resolutions around 60 to 70 microns as you can imagine when you're printing
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something you need a lot of short-stroke moves but then you also need to be able to move long distances up to one and a
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half meters even at a fairly quick bead in this slide is saying 500 millimeters a second you've definitely got to have
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reliable life on your product because a lot of these prints especially if you're
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printing as it says here an engine block or I know 3d P is actually printed large
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like scaled people the larger the print the longer it's going to take to printed and the whole time the print is taking
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place the leadscrew motor everything else is moving continuously for that whole period of time and of course
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anything that has the word printer in it it's got to be cost-competitive because everybody wants to get it done for the
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least amount of money possible looking again at leadscrew motor solution we definitely want an anti backlash you nut
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to enhance that repeatability we want to use bi-directional XY moves which again
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the anti backlash nut is going to help with and then the lead screws that we offer have a variant lead availability
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in this case the lead that was being used as a 25 millimeter lead we could accommodate all of those things with the
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PBC offering in regards to the motors Jamie's mentioning the high lead and the
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higher torque available from the motor in order to improve efficiency and throughput on the customer side because
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when they're printing things they're not always necessarily printing but they need to translate from one position to
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another and the quicker you can do that the more capacity you're able to get out of your print machine and process having
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a motor that's got more torque allows you to do that with higher acceleration translate the move and then decelerate a
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lot quicker so you've got that fine control in terms of miss steps etc all that might talk a little bit about that
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because that's tied to the encoder and the controls one of the big advantages here again is that integrated encoder
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when you think about a step in Direction application a lot of people think okay I'm going to feed a step in and the
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motor is going to move one step with stepper motors without encoder feedback that's not necessarily the case the
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motor is going to try to move one step but you have no idea whether or not it got there with these types of smart controllers on
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the smart motor you can feed in steps and the motor is guaranteed to move that
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number of steps long as your step input signal is cleaned the motor is going to make it there and it will let you know
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if it's taking more torque it'll let you know if it's taking longer than expected but the motor will make it there let's
Application Solutions
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look at an application solution for harsh environments and there's some gruesome pictures on the next slide that
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look at some of the different types of motors that can withstand that for the screw material we haven't talked about
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this yet at all the video talks about it a little bit of the screws are all 300 series stainless steel so inherently
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those are going to be good for harsh environments we do also offer a PTF coating option which is why this screw
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in the picture is black PTFE coating is going to reduce the wear it's going to
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depend on the application again but around 20 to 30 percent reduce wear that's going to give you even more life
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we do have specialty materials like I said it's a Delrin self lubricated with
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PTFE we've also made custom brass and bronze nuts for customers depending on
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the application and their needs and then of course the inevitable other options
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if your customer has an application where they need something that doesn't look like we might have it let us know
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and if the opportunities there for us then we will definitely be glad to look into that for you
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this is an anti-corrosion technology that moons has available typically what customers do when they've got a harsh
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environment is they try and seal all the electronics seal the motors and seal all the moving parts to avoid any sort of
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ingress of external material whether it's liquid thus that kind of thing with humidity and liquid in particular
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chances are with the temperature changes of the motor quite often the motor acts as a vacuum and inevitably some moisture
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will get sucked in and if you're sealing the motor you're trying to stop the material from getting into the motor
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itself which will cause it to die eventually but when you seal it you're actually stopping anything that does
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come in from getting out as well there's two ways to handle that type of application what we do with the anti-corrosion is we do not seal the
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motor itself but we coat all of these surfaces so we allow the moisture to come in and leave without affecting the
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performance of the motor that's how we tackle out with this very unique product all of the materials are coated both
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internal and external and the motor can run in extremely harsh environments and you can see what type of salt water does
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to a standard motor on the left bottom picture versus to what the anti-corrosion motor looks like after
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the same amount of time in the salt water spray test okay to summarize what
Summary
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we talked about at the start was what a traditional the leadscrew motor looks like with the interface hardware and all
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of the other motion controls and etc that are required to make that happen and then we compared that to the PBC
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solution which is an integrated lead screw stepper motor it's also really worth mentioning one more time that this
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can be ordered with one part number which in its own right is going to help save you time because you could go to
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one place by one thing that accomplishes everything that the application is going to need it's going to increase your
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performance with all the wonderful advances that Andy and Mike talked about and motor and control technology it's
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also going to reduce your cost and it's going to reduce your size with that
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being said I'm done Thank You Jamie Andy and Mike for a very
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thorough presentation that was very well done if you do have questions you will
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be able to reach the presenters and I'd like to thank you guys again for an
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excellent presentation