Working steps and speed regulation methods of AC gear motors

1.General introduction to AC gear motors

AC gear motors‌ are devices that achieve the purpose of deceleration by transmitting the power of an electric motor or other high-speed transmission equipment to the gear of the output shaft through a reducer. It is usually used for transmission equipment with low speed and high torque, and has the characteristics of high efficiency, large transmission ratio, high mechanical strength, high reliability, good maintainability and strong adaptability. AC gear motors use gear transmission, which can effectively transmit power and reduce energy loss. By selecting a suitable gear reduction ratio, a large transmission ratio can be achieved to meet various application requirements

‌2.Advantages of AC gear motors

1.Low manufacturing cost‌: Due to its simple structure, the manufacturing cost of AC motors is relatively low, which is of great significance for cost control.

2‌.Simple structure and easy maintenance‌: The structure of AC motors is relatively simple, so maintenance and maintenance are easier, reducing maintenance costs.

‌3.Low environmental requirements‌: AC motors have low environmental requirements, strong adaptability, and can operate stably in various environments.

‌4.Energy saving and productivity improvement‌: AC motors have advantages in energy saving and productivity improvement, which helps to improve overall work efficiency and economy.

3.Working steps of AC gear motors

1.Power supply access and startup‌: First, connect the three-phase power supply to the power input terminal of the AC gear motor. When the power is turned on, the control system inside the motor starts to work and prepares for the normal operation of the motor.

2.Conversion of current and voltage‌: After the power is connected, the AC power of the three-phase power supply passes through the terminal inside the motor and enters the winding of the motor stator. In the winding, the AC power generates a rotating magnetic field.

3.Generation of rotating magnetic field‌: The rotating magnetic field magnetizes the iron core inside the motor stator, thereby generating a rotating magnetic field. This rotating magnetic field interacts with the current inside the rotor to generate torque.

4.Generation of torque‌: The rotor generates torque under the action of the rotating magnetic field, causing the rotor to start rotating. The rotor is connected to the gears in the gearbox and transmits the torque to the gears.

5.Conversion of mechanical energy‌: The rotor transmits the torque to the output shaft of the gearbox through the gears, converting the mechanical energy into a rotating mechanical output. The output shaft can drive various workloads, such as saw blades, drill bits, etc.

6.Speed ​​and steering control: By changing the phase and frequency of the AC power input to the motor stator winding, the rotation speed and direction of the rotating magnetic field can be controlled, thereby controlling the rotation speed and steering of the rotor.

7.Load regulation and protection: When the motor is running under heavy or light load conditions, the control system will automatically adjust the input voltage or current of the motor according to the change of load to maintain the stable operation of the motor. At the same time, a thermal protection device is installed inside the motor, which will automatically disconnect the power supply when the motor overheats to prevent the motor from overheating and damage.

8.Shutdown and shutdown: When the motor needs to stop running, the three-phase power supply can be disconnected and the motor will stop working. At the same time, the control system will perform self-checking to ensure that the motor is in a safe state.

4.Speed ​​regulation method of AC gear motor

1.Pole-changing speed regulation: Speed ​​regulation is achieved by changing the connection method of the motor winding to change the number of magnetic poles. This method has a simple control circuit, is easy to maintain, and has a low price, but the speed regulation range is limited and stepless speed regulation cannot be achieved.

2.Frequency conversion speed regulation: The motor speed is adjusted by changing the power supply frequency and voltage. It has the advantages of high efficiency and wide speed regulation range, but the technology is complex and the price is high.

3.Reversing motor speed regulation: The speed regulation is achieved by changing the power supply voltage and the commutation device inside the motor. The structure is simple and the speed regulation effect is good, but the overload capacity is low and the original motor capacity cannot be fully utilized.

4.Series pole speed regulation: The motor speed is adjusted by changing the resistance or inductance of the rotor circuit. The slip energy in the speed regulation process can be used repeatedly. The efficiency is high, but the power factor is low and there is harmonic interference.

5.Stator voltage regulation speed regulation: The motor speed is adjusted by changing the stator voltage. The circuit is simple, the device is small, and it is easy to use and maintain, but the speed regulation range is small and the power is low.

6.Electromagnetic slip clutch speed regulation: The motor speed is adjusted by the electromagnetic slip clutch. The structure is simple, the control device capacity is small, the operation is reliable, the maintenance is easy, and there is no harmonic interference, but the speed loss is large and the power is low.

7.Rotor series resistance speed regulation: The motor speed is adjusted by inserting resistors of different resistance values ​​in series in the rotor circuit. There is no harmonic interference and the technical requirements are low, but the maintenance requirements are high. Only step-by-step speed regulation can be performed, and serious heat is generated during speed regulation.

Source:https://www.deviantart.com/oahaue9/journal/Working-steps-and-speed-regulation-methods-of-AC-g-1092276541

Material requirements and specific classification of stepper motor encoders

1.What is a stepper motor encoder

A stepper motor encoder is a device used to test speed and positioning, usually installed on the rear end shaft of a stepper motor. Its main function is to be used with a stepper motor. As a feedback system, it detects the angular displacement or linear displacement of the stepper motor and converts it into electrical signals, and then feeds these signals back to the control system, such as a digital control group computer, a programmable controller, etc. By processing the electrical signals, the control system can achieve precise control of the stepper motor.

2.Functions of stepper motor encoders

1.Measuring position

The most basic function of a stepper motor encoder is to measure the position of the motor. As a limited displacement motor, the position of the stepper motor is determined by each step of the stepper motor. The encoder can accurately calculate the current position of the motor. The principle of the encoder is to measure the rotation angle of the motor by processing the photoelectron signal, thereby calculating the position of the motor.

2.Measuring speed

In addition to measuring position, stepper motor encoders can also be used to measure the speed of the motor. The encoder calculates the speed of the motor by calculating the position change of the motor at each moment. For applications such as high-precision positioning, motion control, and adaptive control, the speed information of the motor is particularly needed to help the system adjust the control parameters in real time. By measuring the current speed, the next position can be accurately predicted, thereby improving the motion accuracy and positioning accuracy.

3.Improve motion control accuracy

The encoder can improve the accuracy and stability of stepper motor motion control. By providing a deterministic feedback signal, the encoder can ensure accurate position control and eliminate errors caused by load changes or environmental factors in the motor. In addition, the encoder can also improve the motor's motion performance and reduce noise and vibration by providing more accurate speed feedback information.

3.Material requirements for stepper motors

1.Wear resistance: The stepper motor will perform repeated operations during operation, so wear resistance is a key factor in ensuring its functional stability and extending its service life. Wear-resistant materials can reduce the wear of the motor during operation, thereby maintaining its stable performance. ‌

2.Smoothness: Smoothness is also an important requirement for the material of the stepper motor encoder. Smooth materials can reduce friction during motor operation, help reduce wear, and are also conducive to the use of lubricants, thereby extending the service life of the motor. ‌

3.Anti-fatigue: Since the stepper motor will repeatedly perform the same action during use, anti-fatigue is the key to ensure that the motor meets the requirements in terms of use effect. Anti-fatigue materials can resist fatigue damage caused by repeated actions and maintain the performance and life of the motor.

4.Specific classification of stepper motor encoders

1.Photoelectric encoders use photoelectric sensors and encoder disks to measure the position and movement of the rotor. It senses the grating or encoding holes on the encoder disk through photoelectric sensors to measure the angle and position of the rotor. Photoelectric encoders are widely used in stepper servo motor systems that require high-precision position measurement. ‌

2.Magnetic encoders use magnetic sensors and magnetic scales to detect the position and movement of the rotor. It uses the interaction between the magnetic strips on the magnetic scale and the magnetic sensor to achieve angle and position measurement. Magnetic encoders are suitable for stepper servo motor systems that have certain requirements for accuracy and stability. ‌

3.Grating scale encoders are high-precision encoders, which are usually used in stepper servo motor systems with high accuracy requirements. ‌It uses the interaction between the grating texture on the grating scale and the photoelectric sensor to provide very accurate position measurement. ‌

4.The magnetic scale encoder is a high-precision encoder based on magnetic technology. It uses the interaction between the magnetic texture on the magnetic scale and the magnetic sensor to provide high-precision position measurement. The magnetic scale encoder is particularly suitable for stepper servo motor systems that require extremely high accuracy and stability. ‌

5.How to install the stepper motor encoder 

1.Select the appropriate location: First, you need to select an appropriate installation location. Usually, the encoder is installed on the motor shaft to achieve real-time monitoring of the motor's rotational position. When selecting a location, you need to ensure that there is enough space between the encoder and the motor and that it can be installed securely. ‌

2.Adjust the installation angle: During installation, you need to ensure that the relative angle between the encoder and the motor shaft is correct. This step usually requires the use of professional tools to ensure that the angle between the encoder shaft and the motor shaft is optimal. The correct angle is critical for accurate position feedback. ‌

3.Connect the cable: Once the encoder is correctly installed on the motor, you need to connect the cable correctly. Make sure that the cable is securely connected and not damaged by external objects. ‌ Use professional cable clamps to avoid unnecessary downtime caused by cable failure. ‌

4.Testing and calibration: After installation, testing is a critical step. Start the motor and monitor the signal output by the encoder to ensure that it accurately reflects the motion state of the motor. Depending on the specific installation location and requirements, some calibration work may be required to ensure that the encoder provides accurate feedback. ‌

5.Regular maintenance and inspection: After the motor encoder is installed, regular maintenance and inspection are key to ensure long-term stable operation of the system. Regularly check whether the connection is firm, whether the cable is damaged, and whether the encoder is working properly.

Benefits and application scope of brake stepper motor

1.What is a brake stepper motor

The so-called brake stepper motor is to add a brake device to the tail of the stepper motor, that is, a brake device. When the stepper motor is powered on, the brake is also powered on, and the brake device will also be separated from the stepper motor output shaft, allowing the motor to operate normally. When the power is off, the brake is released and tightly holds the motor shaft. A stepper motor is often started and stopped to ensure that the motor is powered on or powered off and locked.

2.Benefits of using a brake stepper motor

1.Maintaining stable position: The brake stepper motor can stop the rotation of the motor immediately when needed through its brake function, helping the stepper motor to lock in a specific position, avoiding the accumulation of position deviation, and thus maintaining a stable position. ‌

2.Reduce bearing wear: Using the brake can stop the rotation of the motor in time, reduce or eliminate the instability caused by inertia, thereby reducing the wear of the motor bearings and extending the service life of the motor. ‌

3.Improve motor stability: The brake stepper motor can reduce or eliminate the instability caused by inertia through its brake function, and improve the working stability of the motor. ‌

4.Provide safety protection: The brake stepper motor provides a safety protection mechanism to ensure that the motor maintains a stable position when stopped, thereby avoiding accidental damage or danger caused by unnecessary rotation of the motor. ‌

5.Achieve high-precision positioning and control: The brake stepper motor can accurately control the rotation angle and speed, so that it can achieve precise positioning and control in various applications. ‌

6.High-speed movement: The brake stepper motor has the characteristics of fast response and high-speed movement, and is suitable for occasions that require frequent rotation and switching of angles. ‌

7.Low noise: Compared with other types of motors, the brake stepper motor has lower noise and is suitable for application scenarios with high noise requirements. ‌

8.Controllable movement: By controlling the input and switching of current, stepper movement can be achieved, making it more flexible and controllable. ‌

9.High efficiency: Brake stepper motors can quickly accelerate, decelerate and reverse, and have high efficiency, becoming an important power source in the field of industrial automation. ‌

3.Application fields of brake stepper motors

1.Industrial automation: In the field of industrial automation, brake stepper motors can be used to control robotic arms, automated production lines, and mechanical equipment. It can achieve very precise positioning and control, and each step of movement can be accurately calculated and controlled, with good position feedback, thus ensuring high precision and high efficiency of industrial production. ‌

2.Aerospace: In the field of aerospace, brake stepper motors can be used in navigation systems, satellite communication equipment, and aircraft servo control. Its high precision and reliability are essential to ensure the precise operation and safety of aviation equipment. ‌

3.Medical equipment: In the field of medical equipment, brake stepper motors are used in various precision medical instruments and equipment to improve the reliability and stability of the system and ensure the high precision and high stability of the equipment during long-term operation. ‌

4.Instruments: Brake stepper motors are also widely used in various instruments to provide precise position control and feedback to ensure the accuracy and reliability of the instruments. ‌

5.Office equipment: In terms of office equipment, brake stepper motors are used in printers, engraving machines, automation equipment, etc. These devices require motors to respond quickly and accurately control the position. Brake stepper motors can provide better stopping performance and positioning accuracy. ‌

6.Prevent vertical motion mechanisms from sliding down: For vertical motion mechanical structures, such as some robots, lifting platforms, etc., the use of brake stepper motors can immediately brake when power is off or emergency stops, preventing the mechanism from sliding down due to gravity and ensuring safety. ‌

7.Improve stopping performance: In applications that require frequent starting and stopping, such as automated production lines, packaging machinery, etc., the use of brake stepper motors can improve stopping performance, reduce overshoot and vibration, and improve production efficiency

Source:https://teal-taro-kgp8cw.mystrikingly.com/blog/benefits-and-application-scope-of-brake-stepper-motor