September 2010

Incremental Magnetic Ring Encoder
ASM Sensors, Inc. has added new magnetic encoder rings, PMIR7 series, to the POSIROT family. These incremental encoder magnetic rings are available in three sizes to accommodate different shaft sizes and yield up to 184,320 pulses per revolution in conjunction with the quadrature encoder read head, PMIS4 series. Both units were designed to operate in harsh environments.

This non-contact incremental encoder system consists of a magnetoresistive read head, PMIS4 and a dual channel magnetic ring, PMIR7. The sensor head is completely enclosed in a metal housing and generates the industry standard A, B, Z output pulses for quadrature detection with reference mark. The PMIR7 magnetic rings come in three sizes that can be quickly press-fitted onto 27, 35 or 50 mm shaft diameters. This precise and robust encoder system can generate up to 184,320 pulses per revolution. The side tracking tolerance of this magnetic encoder is +/- 1 mm.

The shielded metal housing of the compact PMIS4 sensor read head offers a high level of protection against EMC interference and thermal overload. The enclosure has an IP67 rating to protect against dirty environments. Since this encoder operates magnetically, the read head still functions even when the magnetic scale is operated in dirty industrial environments with contamination such as oil and dust.

The available ring sizes offer either decade, binary or degree division that produce up to 102,400 pulses per revolution, 131,072 pulses per revolution or 184,320 pulses per revolution, respectively. The operating temperature range spans -40°C to 85°C. The available outputs are HTL, TTL and TTL24V with a maximum output frequency of 480 kHz.

Unique Inverter Duty AC Motors
Groschopp’s AC motors are inverter duty classified, as well as small and compact to reduce energy consumption. The smallest AC motor offered, the AC65, measures 2.882 inches and 5.22 inches in length. This motor series is designed to directly integrate with Groschopp’s standard reducer lines with minimal interface components optimizing both size and cost. Groschopp’s AC motor further reduces energy consumption with its ability to run at varying speeds.

The Groschopp AC motor is well suited in a long-life, continuous duty applications. It has no common wear parts such as brushes and commutators, so it is highly reliable, featuring long life potential and low maintenance. Since the AC motor maintains speed over a wide range of torque it integrates well with commercial ovens, conveyers, insulation blowers, augers, medical beds, x-ray tubes and other conveyer and continuous motion machines. With customization options for speed control and high heat resistance along with the convenient customization from standard to food-grade grease permits the AC motor to synchronize well with commercial, industrial and construction applications.

New Power Supplies for DC Brushless Motors
Automation Systems Interconnect, Inc. (ASI) has recently introduced a new line of high output power supplies. The 72 to 85 voltage output power supplies are designed for use with DC brushless motors. The output is protected to prevent failures due to overvoltage generated by motors during rotation and freewheeling. The reserve capacity allows these units to operate at 20 percent higher power levels at 45ºC/113ºF without exceeding standard temperature limits. 

Available in single or three phase with 3.1, 6.6 or 13.3 amp output. Short-circuit, overload and over-temperature protection are standard for heavy start up load. Housings are compact and are  designed for proper ventilation. Theses are not SELV sources as output voltage is higher than 60 VDC.

Worm Gear Replacement Operates at 90 Percent Efficiency
With an increasing need for energy savings in production, warehouse and distribution centers, every component must be scrutinized for efficiency.  The Grove Gear IronMan E series gear reducer operates at 90 percent efficiency to maximize system effectiveness.  

The new product has a compact housing design that offers a direct replacement to traditional worm gear reducers.  By utilizing helical-bevel gear technology, the E series has up to 60 percent more torque than many brands’ worm gear designs.  

Because of its modular versatility, the product fits 90 percent of the US worm gear market and allows reduced inventory.  With mounting base kits, the E series can drop-in and replace multiple sizes of worm gear speed reducers.  Providing an additional inventory reduction opportunity, shaft kits ranging from 1 inch to 1.5 inch were designed to plug into a standard hollow output shaft.

Four models are currently offered, with double reduction ratios from 7.8:1 to 60:1 and power capability to 8.50 hp.  Triple reduction units are available by adding a ratio multiplier.  The E series is packed with premium features, including synthetic lubricant, covers sealed with o-rings and Viton double-lip seals.

In addition to energy savings, the Grove Gear IronMan E series presents potential for rapid return on investment through reduced operating cost and motor downsizing.  

Powerex Introduces New Family of Medium Power DIPIPM at 600 V and 1,200 V Ratings
Powerex has announced a new DIPIPM family to serve three-phase inverter applications in the medium power range up to 20 HP for both 230 V and 480 VAC lines.

Continuing the Powerex strategy of providing solutions that help customers speed designs to market, this new family incorporates the latest CSTBT (Carrier Stored Trench Gate Bipolar Transistor) IGBT technology with on-chip current sense for short circuit protection. Design time is reduced by the use of application-specific HVICs and value-added features such as linear temperature feedback.

Applications include general purpose inverters up to 20 HP, such as variable speed pumps, variable speed compressors and small motor control.

Available products include PS21A79 and PS21A7A at 50 A and 75 A, 600 V. PS22A72 and PS22A78-E is available from 5 A to 35 A at 1,200 V.

Why the Motion Control Market Poised for Strong Growth in China
In 2009, revenues from the Chinese GMC (general motion controls) market grew 24 percent from 2008. Total (GMC and CNC) revenues are forecast to grow from 1.3 billion in 2009 to 2.3 billion in 2014, a CAGR of 12.1 percent. 
 
“The strong recovery seen in the Chinese motion control market is mainly driven by two reasons: high demand for motion control products used in end-equipments; and increasing utilization of industrial automation products such as servo systems in many machinery sectors” said IMS Research analyst, Wilmer Zhou, author of the recently published report “The Chinese Market for Motion Controls – 2010”.

The 4 trillion RMB stimulus package implemented by the Chinese government in early 2009 provided a significant source of financing to manufacturers in various industries. Many state-owned and private companies used the capital to install more advanced production lines in 2009 and the first half of 2010. The increasing demand for automation equipment and new machinery in turn raised the demand for motion control products.

Further, Chinese Government policies such as “Home Appliances to Rural Places”, “Automobiles to Rural Places”, “New-Replacing-Old Auto & Home Appliances” have increased consumer spending. For instance, the growing China automobile industry, supporting rapidly increasing vehicle ownership, has a very long production chain from the auto parts factory to the assembly plant; this uses many motion control products.

These factors are the main drivers of market growth. In addition, increasing utilization in new applications and industries is providing further opportunity. The penetration rate of motion controls in China is still very low compared with other regions. Only in recent years have many Chinese machine builders managed to integrate many motion control products into their equipment, to improve productivity or quality. With OEMs becoming more familiar with motion control products, motion controls are increasingly being used in ‘‘non-traditional’’ industry sectors.

Remy and MotoCzysz to Start Production of Electric Drive System
Remy Electric Motors, LLC has entered into an agreement with MotoCzysz LLC to bring a new generation electric drive system to market. The unique drive system leverages Remy’s patented High Voltage Hairpin (HVH) electric motor technology and patent-pending cooling and integration technology from MotoCzysz. The resulting breakthrough is a “complete electric drive system” optimized to elicit and manage the full performance benefit of the Remy motor. The new integrated D1g1tal Dr1ve is the first of its kind of a new classification of complete electric drive solutions. Its compact size is expected to provide an efficiency advantage to automobile and other vehicle manufacturers.

MotoCzysz is an internationally recognized design and engineering firm in the American motorcycle industry. Today, the company focuses primarily on electric drive systems and electric vehicles.

“I believe electric drives are the purest and best solution to propel the majority of automobiles around the world,” said Michael Czysz, founder and CEO of MotoCzysz. “The D1g1tal Dr1ve was designed specifically with that vision in mind. Our partnership with Remy Electric Motors will allow us to deliver a modern, simpler, evolved replacement for the 100 year-old gas engine. Remy is a powerhouse in electric motor design and manufacturing and our first choice for a partner in this emerging sector. Our mutual goal is for the D1g1tal Dr1ve to deliver the highest performance, greatest efficiency and most integrated packaging solution available for companies needing electric drive solutions.”

In typical electric vehicles, various components from a variety of vendors are assembled and then connected together via wires. The D1g1tal Dr1ve system optimizes and matches all high-voltage components in a single housing. The highly integrated system is packaged as a “super axle” located between the two drive wheels, delivering torque with unprecedented efficiency and compactness. Additionally the D1g1tal Dr1ve’s nearly wireless solution provides additional overall safety for the vehicle.

The first D1g1tal Dr1ve utilizing a liquid-cooled Remy internal permanent magnet (IPM) motor will create torque (250 ft/lbs) and 100 kW (135 hp) of power at 93 percent efficiency, measured at the rotor. Future models will extend the D1g1tal Dr1ve range to include an even more powerful drive as well as a smaller, more compact option. The D1g1tal Dr1ve unit will be available in the second quarter of 2011.

Emerson to Sell Motors and Controls Businesses to Nidec Corp.
Emerson has agreed to sell its Motors and Appliance Controls businesses to Nidec Corp. Over the past six months the company had undergone an evaluation of the potential for sale of the businesses. The resulting agreement reached with Nidec will provide a strong new US/North American presence for Nidec’s global motor and motor-related business. As such, Nidec said it intends to retain existing facilities and current management and employees. Further, Nidec will operate these businesses from a headquarters building on the Emerson campus that currently is home to the Motor Technology Center.

“Emerson was committed in this process to assuring that if the businesses were sold, they would end up in the hands of a strong company that would create a successful environment for its employees and customers”

“Emerson was committed in this process to assuring that if the businesses were sold, they would end up in the hands of a strong company that would create a successful environment for its employees and customers,” said Craig Ashmore, executive vice president, Planning and Development, Emerson. “While there was considerable interest from many solid companies, Nidec Corporation’s proposal provided overwhelming value for everyone: our customers, employees and shareholders.”

Included in the sale are two Emerson Motor Company businesses: Emerson’s Commercial and Industrial Motors (CIM) and Emerson Appliance Motors and Controls (EAMC). Combined, these businesses accounted for more than $800 million in sales in fiscal 2009.

Emerson will continue to operate its hermetic motors business, which serves Emerson Climate Technologies’ Copeland Scroll compressors, and also will continue to operate the large motor business based in Europe (Leroy-Somer) as well as Emerson Air Comfort Products in the US, which makes the popular Emerson Ceiling Fan.

Nidec, based in Kyoto, Japan, is about an $8 billion precision manufacturer of small and medium-size motors and fans for IT/consumer electronics, automobiles, home appliances and industrial applications. The company also manufactures electronic/optical components and machinery.

“We are very excited about the potential for future growth of these businesses as part of Nidec Corp.,” said Shigenobu Nagamori, founder and CEO of Nidec. “Emerson’s reputation for innovation, quality and service built over the years is very much aligned with Nidec’s principles and values. These businesses of motors and control technologies will be key to our long-term business strategy as we invest and further strengthen our capabilities in the North American market.”

Motor, Drive & Automation Systems 2011 Preliminary Program Announced
Motor, Drive & Automation Systems 2011, March 1-2 in San Antonio, Texas, has announced its preliminary program. This industry-leading conference is designed for OEM design and systems engineers, product developers that integrate motors, drives & automation systems into their products and equipment; developers and manufacturers of motors, drives and integrated systems; component, material and technology providers.

Motors, Drives and Motion Control - Global Market Update
Alex Chausovsky, Research Manager, Motion & Drives Group, IMS Research

Various Sensorless Control Methods for AC Motor Drives
Dr. Jae H. Park, Vice President of R&D, Drivetech, Inc.

Technical Considerations for the Testing of Small Motors
Emmanuel Agamloh, Motors and Drives Consultant, Advanced Energy

Adhesive Potting and Encapsulating for Explosion Proof Motors
Joel F. Nashett, Market Development Engineer, Henkel Loctite Corporation

Techniques for Improved Stepper Motor Control
Patrick Heath, Strategic Marketing Manager, Microchip Technology, Inc.

Motor and Drive Market Outlook and Success Strategies
Erik Halbert, Manager, Boston Strategies International

Magnetic Bearing Technology for Electric Motors and Other Rotating Machinery – Ready For Prime Time
John Rama, P.E., Vice President – Sales, Synchrony, Inc.

Active Front End Drives for Optimizing Power
Craig Nelson, Product Marketing Manager, Siemens Industry, Inc.

Speaking opportunities are still available. For details on submitting an abstract, please click here.

OCTOBER
18-20 • Electrical Manufacturing & Coil Winding Expo • Grapevine, Texas

19-20 • Thermal Management & Technology Symposium 2010 • Dallas, Texas

19-20 • Battery Power 2010 • Dallas, Texas

19-20 • Remote 2010 Conference & Expo • Dallas, Texas

19-21 • ISA Expo • Houston, Texas

Oct. 31-Nov. 3 • Pack Expo 2010 • Chicago, Ill.

2011

MARCH
1-2 - Motor, Drive and Automation Systems 2011, San Antonio, Texas

Design & Manufacturing Midwest
Donald E. Stephens Convention Center

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