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Figure 1-29 A linear ironless servomotor consists of an ironless magnetic way and an ironless coil assembly.
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sequently, very little magnetic flux exists outside the motor, thus minimizing residual magnetic attraction. Epoxy-core motors provide exceptionally smooth motion, making them suitable for applications requiring very low bearing friction and high acceleration of light loads. They also permit constant velocity to be maintained, even at very low speeds. Linear servomotors can achieve accuracies of 0.1 m. Normal accelerations are 2 to 3 g, but some motors can reach 15 g. Velocities are limited by the encoder data rate and the amplifier voltage. Normal peak velocities are from 0.04 in./s (1 mm/s) to about 6.6 ft/s (2 m/s), but the velocity of some models can exceed 26 ft/s (8 m/s). Ironless linear motors can have continuous force ratings from about 5 to 55 lbf (22 to 245 N) and peak force ratings from about 25 to 180 lbf (110 to 800 N). By contrast, iron-core linear motors are available with continuous force ratings of about 30 to 1100 lbf (130 to 4900 N) and peak force ratings of about 60 to 1800 lbf (270 to 8000 N).
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The linear motor windings that are phased 120 apart must be continually switched or commutated to sustain motion. There are two ways to commutate linear motors: sinusoidal and Hall-effect device (HED), or trapezoidal. The highest motor efficiency is achieved with sinusoidal commutation, while HED commutation is about 10 to 15% less efficient.
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In sinusoidal commutation, the linear encoder that provides position feedback in the servosystem is also used to commutate the motor. A process called phase finding is required when the motor is turned on, and the motor phases are then incrementally advanced with each encoder pulse. This produces extremely smooth motion. In HED commutation a circuit board containing Hall-effect ICs is embedded in the coil assembly. The HED sensors detect the polarity change in the magnet track and switch the motor phases every 60 . Sinusoidal commutation is more efficient than HED commutation because the coil windings in motors designed for this commutation method are configured to provide a sinusoidally shaped back EMF waveform. As a result, the motors produce a constant force output when the driving voltage on each phase matches the characteristic back EMF waveform.
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In a typical linear motor application the coil assembly is attached to the moving member of the host machine and the magnet assembly is mounted on the nonmoving base or frame. These motors can be mounted vertically, but if they are they typically require a counterbalance system to prevent the load from dropping if power temporarily fails or is routinely shut off. The counterbalance system, typically formed from pulleys and weights, springs, or air cylinders, supports the load against the force of gravity. If power is lost, servo control is interrupted. Stages in motion tend to stay in motion while those at rest tend to stay at rest. The stopping time and distance depend on the stage s initial velocity and system friction. The motor s back EMF can provide dynamic braking, and friction brakes can be used to attenuate motion rapidly. However, positive stops and travel limits can be built into the motion stage to prevent damage in situations where power or feedback might be lost or the controller or servo driver fail. Linear servomotors are supplied to the customer in kit form for mounting on the host machine. The host machine structure must include bearings capable of supporting the mass of the motor parts while maintaining the specified air gap between the assemblies and also resisting the normal force of any residual magnetic attraction. Linear servomotors must be used in closed loop positioning systems because they do not include built-in means for position sensing. Feedback is typically supplied by such sensors as linear encoders, laser interferometers, LVDTs, or linear Inductosyns.
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