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Motor and Motion Control Systems
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Figure 1-31 Cross-section of a hybrid stepping motor showing the segments of the magneticcore rotor and stator poles with its wiring diagram.
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Hybrid stepper motors are available in NEMA size 17 to 42 frames, and output power can be as high as 1000 W peak.
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Many different technical and economic factors must be considered in selecting a hybrid stepper motor. For example, the ability of the stepper motor to repeat the positioning of its multitoothed rotor depends on its geometry. A disadvantage of the hybrid stepper motor operating openloop is that, if overtorqued, its position memory is lost and the system must be reinitialized. Stepper motors can perform precise positioning in simple open-loop control systems if they operate at low acceleration rates with static loads. However, if higher acceleration values are required for driving variable loads, the stepper motor must be operated in a closed loop with a position sensor.
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Actuators for motion control systems are available in many different forms, including both linear and rotary versions. One popular configuration is that of a Thomson Saginaw PPA, shown in section view in Figure 1-32. It consists of an AC or DC motor mounted parallel to either a ballscrew or Acme screw assembly through a reduction gear assembly with a slip clutch and integral brake assembly. Linear actuators of this type can perform a wide range of commercial, industrial, and institutional applications. One version designed for mobile applications can be powered by a 12, 24-, or 36-VDC permanent-magnet motor. These motors are capable of performing such tasks as positioning antenna reflectors, opening and closing security gates, handling materials, and raising and lowering scissors-type lift tables, machine hoods, and light-duty jib crane arms. Other linear actuators are designed for use in fixed locations where either 120- or 220-VAC line power is available. They can have either AC or DC motors. Those with 120-VAC motors can be equipped with optional electric brakes that virtually eliminate coasting, thus permitting point-to-point travel along the stroke. Where variable speed is desired and 120-VAC power is available, a linear actuator with a 90-VDC motor can be equipped with a solid-state rectifier/speed controller. Closed-loop feedback provides speed regulation down to one tenth of the maximum travel rate. This feedback system can maintain its selected travel rate despite load changes.
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Figure 1-32 This linear actuator can be powered by either an AC or DC motor. It contains ballscrew, reduction gear, clutch, and brake assemblies. Courtesy of Thomson Saginaw.
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Motor and Motion Control Systems
Thomson Saginaw also offers its linear actuators with either Halleffect or potentiometer sensors for applications where it is necessary or desirable to control actuator positioning. With Hall-effect sensing, six pulses are generated with each turn of the output shaft during which the stroke travels approximately 1 32 in. (0.033 in. or 0.84 mm). These pulses can be counted by a separate control unit and added or subtracted from the stored pulse count in the unit s memory. The actuator can be stopped at any 0.033-in. increment of travel along the stroke selected by programming. A limit switch can be used together with this sensor. If a 10-turn, 10,000-ohm potentiometer is used as a sensor, it can be driven by the output shaft through a spur gear. The gear ratio is established to change the resistance from 0 to 10,000 ohms over the length of the actuator stroke. A separate control unit measures the resistance (or voltage) across the potentiometer, which varies continuously and linearly with stroke travel. The actuator can be stopped at any position along its stroke.
Stepper-Motor Based Linear Actuators
Linear actuators are available with axial integral threaded shafts and bolt nuts that convert rotary motion to linear motion. Powered by fractional horsepower permanent-magnet stepper motors, these linear actuators are capable of positioning light loads. Digital pulses fed to the actuator cause the threaded shaft to rotate, advancing or retracting it so that a load coupled to the shaft can be moved backward or forward. The bidirectional digital linear actuator shown in Figure 1-33 can provide linear res-
Figure 1-33 This light-duty linear actuator based on a permanent-magnet stepping motor has a shaft that advances or retracts.
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