BX-4 Modular Variety
The extension of the 4-pole drive series BX4 offers many possible combinations
Improved materials, new production methods and smaller electronic components for internal sensor technology are bringing momentum to modern DC-servomotors. Their performance characteristics can be well-adapted to the requirements at hand by varying the magnet material, winding technology or geometrical calibration. In order to use the various possibilities quickly and optimally, a modular concept for the drive configuration is a basic prerequisite. A new servomotor range has consistently pushed this development forward, achieving optimum values for performance, energy consump-tion and adaptation to the application requirements.
Higher, faster, further: these objectives also apply to miniature drives. The require-ments for better performance and de-pendability, and, at the same time, more rational manufacturing methods, cannot be achieved through rigorous devel-opment alone. This is the exact strategy pursued with the drive series BX4. A new motor concept, based on four-pole technology and the use of molded thermosets instead of adhesives for component assembly, has not only brought success, but also a range of further smaller innovations. Simultaneously, an emphasis was placed on a modular structure for the new BX4 motor generation, allowing customized drives to be assembled quickly and inexpensively as standard components.
Technical characteristics
In practice, drives should not lose speed under higher loads. So from the very outset, developers placed a firm emphasis on a particularly strict characteristic curve. When applying load, a broad speed range provides a high torque; the motor continues to work with only minimal speed loss.
With this goal in mind, the general design of magnet material, winding technology and geometrical calibration was optimized. Four-pole motors revolve more slowly than their two-pole counterparts. This brings advantages for both the gearhead design and life span.
In order to simplify production, the Schönaich-based specialists have dispensed with all adhesives. A form-locking joining technology, able to equalize tolerances, was introduced using a transfer molding process with thermosetting plastic. This impregnates the winding on all sides, protecting it both thermally and mechanically. The new stator structure additionally reduces eddy current losses in the laminated core. In order to provide the broadest product range possible, the entire motor concept is modular.
Modular system
Currently, motors are available in two versions of 22 and 32 mm diameters. Each has two installation lengths, for a total of four motor sizes. The thermally per-missible continuous torques range from 17 to 97 mNm with a power output of up to 60 W and an efficiency factor of up to 80%. The permissible temperature range for all the motors lies in a wide range between –40 and +100 °C. Using finely gradated reduction gears, durable metal planetary gearheads with matching diameter allow torque increases at the output shaft and a simultaneous reduction of speed. The continuous torque ranges from 1,500 mNm for the 22 mm gearheads to 4.5 Nm for the 32 mm version; for short periods, even 6 Nm can be attained. The maintenance-free gearing with lifetime lubrication and robust shaft bearing produce a long life-span, in line with the motor concept. Customized adaptations of the shaft, flange, cable, etc. – a core competence of FAULHABER – are also possible for the BX4 product range.
Modular practice
In their basic versions, the motors can be integrated as pure drives and controlled externally. Motor versions with integrated encoder in the casing are available in four factory-preset adjustable resolutions of 32, 64, 128 or 256 pulses per revolution plus additional index channel. A line driver version with differential output is also available. Alternatively, for more demanding tasks, compact versions are also available with integrated motion controller (Cx) or in-tegrated speed controller (SC). The Cx version has been assembled on the basis of proven and tested FAULHABER motion control systems, and its compact design represents a major advantage for many applications. The motors feature an RS232 serial interface and can be parameterized with the motion manager software 4. With its dual-wire connection, the new SCDC model is very easy to operate. It can replace a conventional brushed motor, for example, should specific applications place higher requirements in terms of lifespan. In addition, it is equipped with reverse voltage protection, and the rotational direction is preselected by the connector pin assignment. All products with integrated electronics feature the electronic limitation of peak and conti-nuous current, thus protecting the motor and the electronics. If necessary, both motor and electronics can also be operated with separate supply voltages.
The new drives are predestined for applications which rely on a long life-span or a high torque. With integra-ted motion controller, they are also highly suitable for positioning tasks; with integrated speed control, they are perfect for pumps and ventilators. The combi-nation with gearing is ideal, as the low speed increases both gear efficiency and lifespan. The modular structure also ensures a large application variety. In this way, the optimal drive can be quick-ly and inexpensively assembled from the individual components. And the manu-facturer’s longstanding expertise guarantees a high-performance solution.
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