AKRODYN X1 Specialized Brushless Motor Controllers Instruction Manual
- June 1, 2024
- AKRODYN
Table of Contents
AKRODYN X1 Specialized Brushless Motor Controllers
Overview
Servo motor controllers are an integral part of many technical systems and are used in a wide range of applications. In industrial automation, servo motor controllers are revolutionizing production processes. They enable a high degree of automation and optimization of production processes, significantly increasing production efficiency and quality. In robotics, they are used to implement complex motion sequences for locomotion or other power settings. In the fitness sector, servomotor controllers are used to simulate weights and generate force profiles with a high bandwidth. Together with our customers, we have repeatedly found in the past that “ready-made control systems” cover many applications in a generalist way, but do not meet the requirements of specific applications.
Product solutions
- 24-48 VDC motor controller
- 1.5 kW for PMSM (BLDC) motors
- with STO PLe
- Brake chopper
- 80-264 VAC motor controller
- 1.5 kW for PMSM (BLDC), IPM motors, AC servos
- with STO PLe
- Brake chopper
Customized adaptations possible
The next page lists several case studies where customized drive solutions
based on our modular X1 control system were used.
Features
- Customizable to your specifications
- More complex behaviour with high bandwidth through direct µC programming
- Reliable multi-layer protection system
- Real-time data with up to 300 Hz
Applications
- Electrical fitness equipment (not physical weights or inertial simulators)
- Lifts and lifting devices
- Automated cable winches
- Conveyor technology, linear drives
Customizable to your specifications not reducing your specifications to available controls! With its specialization in drive technology, Akrodyn offers a great deal of expertise to help you select suitable control units, solve existing problems or develop your motor control unit tailored to your products.
Compatible with a wide range of motors
We are partners with various motor manufacturers. This enables us to provide
you, the customer, with customized motors promptly. For example, a special
motor is only available as a 230 V version. We have it rewound to 48 V.
Selected case studies
Fitness equipment – replacing steel weights with an electric drive.
Initial situation
Sliding weights were invented in the 1970s and are still the most common choice for setting the training weight. However, the training sciences have known about electrically generated resistance for well over 25 years and the advantages of this for the end user – safe training until total muscle exhaustion – must be emphasized. Training progress is greater and time is saved at the same time, as the system can dynamically adjust the weight within each repetition. In the past, however, such systems were not only very expensive and large but also too slow, as the bandwidth of the bus systems was too small and the algorithms were not executed on the motor controllers.
Implementation 1
Based on our modular X1 control system, an additional plug-in board was
developed that offered connectivity for the CAN bus system and a touch panel.
Wireless communication via Bluetooth® Low Energy was also integrated.
According to the specifications, the fitness algorithms were programmed
directly into the microcontroller of the controller, which offered previously
unattainable dynamics and adaptability of the training resistance. In a later
step, the system was expanded to include a synchronized dual-motor setup for
up to 180 kg of simulated weight.
Implementation 2
Using an electric motor for cardio equipment enables a more immersive training
experience, as the behaviour of spinning bikes, for example, can be
synchronized with the playback of the video. Example: Braking force is
increased on the uphill and downhill and slightly self-spinning when
descending. Other features include new device designs with a lower transport
weight and increased training safety. The project was expanded in line with
the first implementation. The challenge was to realistically reproduce the
moment of inertia of a flywheel in conjunction with a freewheel and a bicycle
brake.
Automated, slip-correcting underground winch system
Initial situation
A probe was to be pulled underground through channels with a length of up to
300 meters. The movement profile was to pull a certain distance, then stand
still, and then pull a certain distance again. This automatic rope pulley was
only to be designed as a pulling station and not as a rope winding pulley due
to the limited installation space at the end of the duct. The maximum force
should be adjustable and the position, speed and required force should be
readable in real time.
Problems
As the rope could not be rolled onto this winch, which was only responsible
for pulling, the rope could slip on the shaft. Furthermore, requirements due
to the ambient conditions had to be taken into account.
Implementation
Akrodyn was able to provide a special motor with an integrated winch. This
fitted into the installation space and the customer was able to make massive
cost savings for the overall system, as the design could be simplified and
fewer parts such as toothed belts were required. However, the motor had to be
specially wound for 48 V. Thanks to good relationships, we were able to
organize prototypes for the customer quickly.
The slippage of the rope on the winch was solved by installing an additional encoder in the system, which measured the passage of the rope. The commutation of the motor (FOC) then continued to run via the encoder integrated into the motor, but in position control mode the external encoder was used as the actual position to compensate for the slippage. The mechanical design was implemented together with the customer. The key data was streamed at 50 Hz to a control PC and helped our client obtain important data points regarding rope forces. By automating the previously manual process, the efficiency of the construction site and the data quality of the measurements were increased.
Development of a four-axis linear system with a lifting weight of up to 15,000 N
Initial situation
The customer wanted a machine with four independently driven linear axes with
a maximum lifting force of 15,000 N each on three axes, whereby the fourth
axis was a special axis with significantly different requirements. Certain
axes were to be equipped with two force sensors each to be able to accurately
measure the actual applied push/pull force as well as limit switches for
precise referencing. As the machine is also to be sold in the USA in the
future, a decentralized motor control with 48 VDC was required.
Implementation
Due to the high forces, three axes were built with ball screws (KGT) and the
fourth, very short axis with low forces with a trapezoidal thread with an
automatic lubricator. To reduce production costs, the mechanics had to be able
to compensate for manufacturing tolerances, including the use of floating
bearings for the carriages.
We were allowed to design and produce several electronic circuit boards per device for the order. Our X1 motor controller was specifically adapted and predefined behaviours were programmed indirectly. Each axis was equipped with an electrical box (see picture above) so that only the CAN and the power supply had to be connected to the axes. Peripherals such as the force sensors are plugged directly into the respective box; brake choppers protect against overvoltage in the intermediate circuit during braking.
Testing
The individual subcomponents were tested independently of each other to gain
early insights. A dev kit was constructed consisting of an axis, limit
switches and sensors to develop and test both the firmware and the software
for controlling the machine. A functional model was created before the
prototypes were produced. The counterforce was generated using pneumatic
cylinders and an endurance test of 100,000 cycles was carried out. Thanks to
the high data rate of up to 300 measuring points per second (double force
measurement, position, speed and current), the smallest changes such as an
increase in friction could still be detected and subsequent mechanical damage
avoided. The test results were incorporated into further mechanical
development.
We look forward to your inquiry!
leakage current measurements & improvements with galvanically isolated power
supply unit
Akrodyn GmbH | Thurgauerstrasse 40 | 8050 Zurich |
www.akrodyn.com |
[email protected] | +41 76 433 20 60
V2.5c | This publication contains basic technical details and is intended for
general information only. Specifications are subject to change without notice.