There are many different benchmarks in the marketplace for the sterilisation capabilities of devices. maxon motor explain the cycle and testing process for Autoclavable brushless DC motors.
maxon motor develop brushless DC motors that can be sterilised for medical and dental applications. Recently released is the new ECX range of motors with sterilisation capability on 13,16,19 and 22mm diameter versions. The new range of motors complement the existing 4 pole sterilisable 30mm brushless 150W motor and offer high speed capability up to 120,000rpm. maxon motor test the brushless motors to either 1000 autoclave cycles or 2000 cycles depending on the product. For motors with hall sensors fitted the motor is typically cycled through 1000 autoclave cycles and without hall sensors 2000 cycles. Gearheads are available with additional shaft seals. With the additional seal they are tested to 2000 cycles and without, 1000 cycles. Another new product that offers a completely sterilisable positioning system for the first time is an encoder rated and tested for 1000 cycles.
The maxon motor internal autoclave testing is carried out with the autoclave with a vacuum phase. The motors are unpacked and mounted without any additional protection. Three vacuum cycles are made at the beginning to ensure the internals of the motor become damp. The sterilisation atmosphere is built up with steam which remains constant for 18 minutes at 134˚C, 100% humidity and 2.3 bar of pressure. The unit is then cooled to 70˚C and dried. Each individual autoclave cycles takes approximately 1 hour. After 100 cycles the motors are removed from the autoclave and visually checked and motor operation is checked. Following this the motor is then removed after 250 cycles and visually checked in addition to data acquisition of the running data, motor noise, vibration and electrical strength test at up to 500V DC. Typical batch test cycles are conducted with 10 pcs and the tests are repeated with design changes. Internal testing of the motors to 2000 cycles takes approximately six months.
Contact maxon motor Australia for assistance with Autoclavable brushless DC motor options Tel. +61 2 9457 7477.
When prototyping for applications with extreme requirements for brushless DC motors, fast condition monitoring is critical.
Motor applications with limited space available and comparatively large power requirements can push a motor very close to burning out. In theory, it is possible to use temperature calculations for the motor winding with the help of thermal resistance rating from the motor data sheets, ambient temperatures, heat sinking details and housing characteristics. This is always considered first and then tolerances and safety margins are considered. Following this thermal modelling software and imaging can be evaluated. However some applications push a motor so close to the edge, that only real product prototype testing can be relied upon. Simply installing motors and testing how hard you can push them can also be a costly exercise and does not give enough reliable data. Actual winding temperature sensing on the motor is a solution maxon motor offer for these extreme cases. By inserting sensors through ports in the magnetic return stack and in direct contact with the winding, maxon motor can give customers a device that monitors winding temperatures without the thermal time constant delays experienced when measuring winding resistance and using housing thermal time constants.
For more information please contact maxon motor Australia tel. +61 2 9457 7477.
Norwegian company Petro-Marker, developed a device that is able to collect data up to 5,000 meters underneath the seabed. The technology scans the bottom of the ocean in great detail providing information as to the location and size of oil reservoirs.
1,000 metres below the sea the environment is harsh, ice cold and very dark with no natural light. An ROV has strong floodlights that identify tri-pod objects anchored to the bottom of the seabed. These are receiver stations for electromagnetic waves transmitted into the seafloor, giving feedback on the seabed itself and finding resource deposits.
When oil companies want to find out whether drilling at depth is worth the cost, they often rely on Controlled Source Electro Magnetic (CSEM) technology. This technology utilises the differences in the electrical resistance of different bottom layers to provide signs of the location and size of oil fields. The CSEM technology uses a very strong power source to generate an electro-magnetic field, as well as several receivers to record the fields. These tripod receivers are placed on the sandy bottom and pick up electromagnetic signals that have been changed by the layers through which they passed.
In 2016 Petro-Marker placed 25 new tripods in the North Sea. What sets this technology apart is a new measuring method that uses a vertical transmitter and receiver to find resources. This enables a much more detailed resolution and data measurement up to 5,000 meters beneath the seafloor.
The tripods are about 4 meters high and made from a combination of glass fibre and special foams. Due to the sensitive electronics, metal parts cannot be used. This far below the surface, the pressure is extreme, and the salt water is hostile. At the center of the tripods (receivers), the antennas are aligned as vertically as possible on the seabed.
The system uses a maxon controller (EPOS) and a compensator. The units are encased in plastic to protect them from salt-water corrosion. Several modifications were required to meet the requirements of this application: An EC-i 40 motor, GP 42 planetary gearhead and compensator that were all customised. A dual seal, that imitates typical submarine technology, ensures the system is able to resist the enormous water pressure. The control electronics of the underwater drive are housed in a pressure-neutral glass ball that is able to resist the pressures of up to 600 bar – one of the challenges of this extreme application.
For more information or to speak to one of our Sales Engineers call tel. +61 2 9457 7477.
Throughout 2016 maxon invested significantly in expanding its facilities, bringing a large number of new technologies & innovations to market and expanded on their market leading position.
Sachseln/Switzerland – The maxon motor group further increased its revenues in 2016. Compared with the previous year, revenues grew by 5% to a new record level of CHF 422.5 million (from CHF 402.5 million in the previous year). The number of employees rose to 2,500 and for the first time in company history, maxon employs more people abroad than in Switzerland. The highest revenues were achieved in medical technology (43% market share), followed by industrial automation & robotics (26%) and aerospace industries (6.5%). Investment in R&D rose to CHF 28.5 million in 2016 (up from 27.1 million).
Maxon is increasingly becoming a specialist in mechatronics and systems, launching the first fully sterilisable drive system this year. Drive combination units consisting of brushless DC motor, gearhead and sensor are designed to withstand 1000 autoclave cycles. Maxon’s new DC motor controllers also stand up to extreme ambient conditions. The electronics are protected against contaminants and corrosion by a polymer coating. In addition, the device is highly resistant against vibrations and shocks.
For the e-bike market, maxon motor developed a new S-Peledec motor with a 500 Wh battery and intuitive operation for urban applications. The bike reaches speeds of up to 45 km/h and the device stands out because it can convert any regular bicycle into an e-bike. maxon is also active in the field of autonomous delivery robots. This is a market where the energy-efficient and lightweight drive systems by maxon are in particularly high demand.
For more information on DC motors and accessories please contact maxon motor Australia tel +61 2 9457 7477.
Close inspection of the gear motor combination reveals the extent of motor customisations possible, normally for niche hand built servo motor and gearhead combinations that the Swiss engineers have become famous for.
Completely configured by the end user, maxon motors new micro DC motors system of online motor design and fully automated construction is set to change the future of motor manufacturing technology. Without human interference the tiniest of microdrives can be tailored to the application via an online tool. From the shaft length, diameter and flat features to the mounting method, gearhead reduction, winding characteristics, cable length and connector type. All direct from the motor design portal to the automated manufacturing line. Laser welded steel construction, dual stainless ball bearings and integral strain relief on a motor with only 6mm outer diameter beguiles Australian engineers. Over 17,000rpm at much lower noise levels than previously attained and torque levels to 200mNm make the new 6mm and 8mm servo gear motors incredibly power dense.
The ultra-small DC servo motors have linear control characteristics, zero magnetic detent (cogging) making them suitable for applications such as micro pumps, medical and laboratory dosing devices and robotics.
Contact maxon motor Australia for application, engieering or project assistance.
Ph: +61 2 9457 7477.
The latest issue of the maxon motor magazine, driven, contains interviews, technological insights and the latest from maxon’s DC motor experts.
maxon motor’s first issue of 2017 looks at:
- Electric motors and the role they play in our day to day life
- Roboy! Where is he now?
- Women in engineering: an interview with two maxon motor engineers
- Examples of the latest applications containing maxon DC motors.
driven focuses on drive technology and is published twice per year in three languages. The print version is available free of charge at magazine.maxonmotor.com
All issues are also available on the driven app, which can be downloaded from the App Store and Google Play Store.
For more information on DC motor technology please call maxon motor Australia on +61 2 9457 7477.
maxon motor’s new motion controller for DC motors is very small indeed. Just 17g and 39mmx54mm the position controller can also control both brushed DC motors and brushless DC motors (BLDC motors).
Available on request is the newest version of the successful EPOS DC motor control modules, the EPOS4 24/1.5. The tiny dimensions of the controller belie it’s capabilities. It retains the full motion control capabilities of much larger controllers including RS232, USB, CanOpen and EtherCAT communications onboard or via adaptor modules. Feedback from the DC or BLDC motor is achieved using either hall sensors, incremental encoders or absolute encoders. It can be used with current / torque control, closed loop speed control and position control. Designed primarily for use on 12V or 24V systems the controller is based on a very high PWM frequency of 100kHz for adaption with highly dynamic ironless and coreless DC motors that have low inductance levels. Current limiting, overcurrent, over temperature, under voltage, overvoltage and short cct protective functions are all included as standard. Free setup software for auto configuration and tuning of motors is supplied along with programming examples for PC, PLC, Labview and Linux environments. IEC61800-5-2 based Safe Torque Off (STO) also makes the controller suitable for use in critical applications such as manufacturing processes and collaborative robotics.
For further information or for application assistance contact maxon motor Australia tel. +61 2 9457 7477.
Maxon actuators, DC motors, gearheads and encoders help to improve the handling and overall driving stability of a race car through rear wheel steering, with up to 3 degrees transfer per side.
A maxon supported Young Engineers Student project is developing mechatronics for steering the rear wheels of a race car. At the heart is a maxon spindle drive (linear actuator) that converts rotational movement into linear movement. Fitted with an EC-4 pole brushless DC motor to provide up to 200W of power, GP32 planetary gearhead for torque and two maxon EPOS2 position controllers with HEDL encoders to set the steer angle of the wheels. The maxon drive system is connected to the cars internal controls to calculate the desired steer angle.
The main issues for the engineers were lightweight, small components, with enough force to set the required steer angle and trustworthiness of the components to work reliably without fail.
For more information on spindle drives or mechatronic engineering applications please contact maxon motor on +61 2 9457 7477.
maxon products in this article
|Linear Actuator||EC-4 pole DC motor||GP32 Planetary gearhead|
|maxon’s linear actuator (spindle drive) convert the power generated by the motor into feed velocity and feed force.||The EC-4 pole DC motors have no cogging torque, high efficiency, and excellent control dynamics.||Planetary gearheads are suitable for transferring high torque up to 180 Nm.|
|EPOS2 encoder||HEDL sensor|
|EPOS is a modular, digital positioning controller by maxon motor. It is suitable for permanent magnet-activated motors plus encoders with a range up to 750 W continuous output power.||maxon encoders allow accurate evaluation of the speed & angle position and form the framework for high-precision control loops.|
Getting the balance right with mechatronic systems involves the focus on a whole system and using modular motor system components for successful integration.
The new educational website by maxon motor drive.tech showcases the latest technologies and applications in the advanced motion control world. Dr Urs Kafader’s new article explains the process of getting the balance right in the critical motion control application of modern prosthetics.
Artificial limbs have rapidly moved into the world of advanced mechatronics. The synchronisation of multiple DC motors, sensors, transmissions and processors has become decentralised. The DC motors in these systems are required to fulfil an increasing number of functions that could soon encompass every human (or animal) movement. As such a huge variety of dynamics within the DC motor are required and modularity of components becomes a powerful ally. Each motor in these dynamic multi axis coordinated systems can now be locally controlled with real time field buss communication with full interpolation.
Visit drive.tech for full application white papers or contact maxon motor Australia on +61 2 9457 7477.
When you only have 0.2seconds to move your load maxon motors and gearheads are required.
In 2016 the Academic Motor Sports Club Zurich set a world record for electrically powered vehicles by accelerating to 100km/h in 1.513s. Maxon motors are used in the vital race car Drag Reduction System (DRS). The maxon 22mm Brushless DC motor and high powered 22mm planetary gearhead drive rear airfoil. Rotating 165˚ in 0.2 seconds means the gearhead had to withstand very high forces.
To read the full article please visit the applications area of our website. Or contact our Australian office for application assistance. Ph: +61 2 9457 7477.
Above: maxon GP22 HP – Planetary gearheads are suitable for transmitting high torques of up to 120 Nm.
Main picture: maxon EC22 – the EC motors have excellent torque characteristics, high power, and a wide speed range of up to 100,000 rpm.