BRUSH DC motors
Brush DC 8mm
Motor Coil Cross Section
Brush DC 16mm
Brush DC 35mm
Your miniature motion challenges are unique and your
Why a Brush DC motor
50
ideas for meeting those challenges are equally unique.
Brush DC Spotlight on Innovation
51
Brush DC Motor Basics
52
Brush DC Working Principles
55
From medical to aerospace or security and access,
Portescap’s brush DC motion solutions are moving
life forward worldwide in critical applications. The
following Brush DC section features our high efficiency
and high power density with low inertia coreless brush
DC motor technology.
How to select your Brush DC motor
57
Brush DC Specifications
58
Where to apply Brush DC motors
59
Brush DC motors at Work
60
Why a Brush DC motor
Long life Patented
Commutation Sysyem
Virtually Eliminates
Brush Maintenance
Models Available from
8mm to 35mm Diameter
Select Either Sleeve
or Ball Bearings
Ironless Rotor Coil
Enables High Acceleration
High Efficiency Design Ideal for Battery-Fed Applications
Optional Gearboxes and
Magnetic or Optical
Encoders Are Easily Added
Innovation & Performance
Portescap’s brush DC coreless motors incorporate salient features
like low moment of inertia, no cogging, low friction, very compact
commutation which in turn results in high acceleration, high
efficiency, very low joule losses and higher continuous torque.
Ideal for portable and small devices, Portescap’s coreless motor
technologies reduce size, weight, and heat in such applications.
This results in improved motor performance in smaller physical
envelopes thus offering greater comfort and convenience for endusers. In addition, the coreless design enables long-life and higher
• Brush DC commutation design
Longer commutator life because of the design.
• REE system
Stands for Reduction of Electro Erosion. The electro erosion,
caused by arcing during commutation, is greatly reduced in low
inertia coreless DC motors because of the low inductivity of their
rotors.
• NEO magnet
The powerful Neodymium magnets along with enhanced air gap
design thus giving higher electro-magnetic flux and a lower motor
regulation factor.
• Coreless rotor design
Optimized coil and rotor reduces the weight and makes it compact.
energy efficiency in battery-powered applications.
Portescap continues innovating coreless technology by seeking
design optimizations in magnetic circuit, self supporting coreless
Your Custom Motor
coil along with commutator and collector configurations.
• Shaft extension and double shaft options
• Custom coil design (different voltages)
Get your products to market faster through Portescap’s rapid
prototyping and collaborative engineering. Our R&D and
• Mounting plates
application engineering teams can adapt brush DC coreless motors
• Gear pulleys and pinion
with encoders and gearboxes to perform in different configuration,
• Shock absorbing damper and laser welding
environment, or envelope.
• Special lubrication for Civil aviation and medical applications
Standard Features
• EMI filtering
• Max continuous torque ranging from 0.66 to 158.6 mNm
• Speed ranging from 11,000 RPM (8mm) to 5,500 RPM (35mm)
• Motor regulation factor(R/K ) ranging from 1,900 to .3 10 /Nms
2
3
• Cables and connectors
• Gearboxes
SPOTLIGHT ON
INNOVATION
Innovation is a passion at Portescap. It defines your success, and defines our future. We help you get the
right products to market faster, through rapid prototyping and collaborative engineering. With experienced
R&D and application engineering teams in North America, Europe, and Asia, Portescap is prepared to create
high-quality precision motors, in a variety of configurations and frame sizes for use in diverse environments.
Demanding application?
Portescap is up for the challenge. Take our latest innovation Athlonix in high power density motors. Ultra-compact, and
designed for lower joule heating for sustainable performance over the life of your product, Portescap’s Athlonix motors deliver
unparalleled speed-to-torque performance. And better energy efficiency brings you savings while helping you achieve your
green goals.
Athlonix motors are available in 12, 16, and 22mm.
More Endurance. Higher Power Density. Smaller Package
Looking for a lighter motor with more torque?
35GLT brush dc coreless motor from Portescap might be the solution for your needs.
The 35GLT provides a 40% increase in torque-to-volume ratio over most average iron
core motors. A featured multi-layer coil improves performance and offers insulating
reinforcement, resulting in improved heat dissipation. Weighing in at only 360 grams
and providing an energy efficiency of 85%, the 35GLT offers less power draw and
excellent space savings.
The quest for high-resolution feedback with accuracy in speed is the essence
of Portescap’s innovative MR2 magneto resistive encoder. These miniature
encoders accommodate motors from frame sizes of 8mm to 35mm with superior
integration schemes to facilitate a compact assembly with motors. And, with a
resolution of 2 to 1024 lines, Portescap’s MR2 encoders meet your application
requirements today - while flexibly adapting to your evolving needs.
Brush DC Motor Basics
Construction of Portescap motors with
iron less rotor DC motors
All DC motors, including the ironless rotor motors, are composed of three principle sub assemblies:
1. Stator
2. Brush Holder Endcap
3. Rotor
Stator Tube
Self Supporting High Packing
Density Rotor Coil
Sleeve or Ball
Bearing
Collector
High Efficiency High Strength
Rare Earth Magnet
Cable
Clamp
Metallic Alloy Brush
Commutation System
1. The stator
The stator consists of the central, cylindrical permanent magnet, the core which supports the bearings, and the steel tube
which completes the magnetic circuit. All three of these parts are held together by the motor front plate, or the mounting
plate. The magnetic core is magnetized diametrically after it has been mounted in the magnetic system
2. The Brush Holder Endcap
The Brush Holder Endcap is made of a plastic material. Depending on the intended use of the motor, the brush could be
of two different types:
• Carbon type, using copper grahite or silver graphite, such as those found in conventional motors with iron rotors.
• Multiwire type, using precious metals.
3. The Rotor
Of the three sub-assemblies, the one that is most characteristic of this type of motor is the ironless, bell-shaped rotor.
There are primarily four different methods of fabricating these ironless armatures utilized in present-day technology.
A — In the conventional way, the various sections of the armature are wound separately, then shaped and assembled
to form a cylindrical shell which is glass yarn reinforced, epoxy resin coated, and cured. It is of interest to note the
relatively large coil heads which do not participate in the creation of any torque.
B — A method which avoids these coil heads uses an armature wire that is covered with an outer layer of plastic for
adhesion, and is wound on a mobile lozenge-shaped support. Later, the support is removed, and a flat armature package
is obtained, which is then formed into a cylindrical shape (Figure 1). The difficulty with this method lies in achieving a
completely uniform cylinder. This is necessary for minimum ripple of the created torque, and for a minimum imbalance of
the rotor.
Figure 1 - Continuous winding on mobile support
2a
3
1
1a
2
5
a) support arrangement
b) armature as flat package
c) forming of armature
in cylindrical shape
C — A procedure which avoids having to form a perfect cylinder from a flat package consists of winding the wire directly
and continuously onto a cylindrical support. This support then remains inside the rotor. Coil heads are reduced to a
minimum.
Although a large air gap is necessary to accommodate the armature support; this method is, however, easily automated.
D — The Skew-Wound armature method utilizes the same two-layer plastic coated wire described in Method B. This Wire
is directly and continuously wound onto a cylindrical support which is later removed, thus eliminating an excessive air gap
and minimizing rotor inertia. In this type of winding, inactive coil heads are non-existent. (Figure 2). This kind of armature
winding does require relatively complex coil winding machines. Portescap thru its proprietary know how has developed
multiple automated winding machines for different frame sizes and continues to innovate in the space so that dense coil
windings can be spun in these automated machines.
Figure 2
Features of Ironless Rotor DC Motors
The rotor of a conventional iron core DC motor is made of copper wire which is wound around the poles of its iron
core. Designing the rotor in this manner has the following results:
• A large inertia due to the iron mass which impedes rapid starts and stops
• A cogging effect and rotor preferential positions caused by the attraction of the iron poles to the permanent magnet.
• A considerable coil inductance producing arcing during commutation. This arcing is responsible on the one hand for an
electrical noise, and on the other hand for the severe electro—erosion of the brushes. It is for the latter reason that carbon
type brushes are used in the conventional motors.
A self supporting ironless DC motor from Portescap has many advantages over conventional iron core motors:
• high torque to — inertia ratio
• absence of preferred rotor positions
• very low torque and back EMF variation with armature positions
• essentially zero hysteresis and eddy current losses
• negligible electrical time constant
• almost no risk of demagnetization, thus fast acceleration
• negligible voltage drop at the brushes (with multiwire type brushes)
• lower viscous damping
• linear characteristics
REE System proven to increase
motor life up to 1000 percent
The two biggest contributors to the commutator life in a brush DC motor
are the mechanical brush wear from sliding contacts and the erosion
of the electrodes due to electrical arcing. The superior surface finish,
commutator precision along with material upgrades such as precious
metal commutators with appropriate alloys has helped in reducing the
mechanical wear of the brushes. To effectively reduce electro erosion
in while extending commutator life Portescap innovated its proprietary
REE (Reduced Electro Erosion) system of coils. The REE system reduces
the effective inductivity of the brush commutation by optimization of the
mutual induction of the coil segments. In order to compare and contrast
the benefits of an REE system Portescap conducted tests on motors
with and with out REE coil optimization. The commutator surface wear
showed improvements ranging from 100 -300 percent as shown in Figure
5. Coils 4, 5 and 6 are REE reinforced while 1, 2 & 3 are without REE
reinforcement.
Brush DC Working Principles
The electromechanical properties of motors with an ironless rotor :
Graphic
express
U
=
M
x
R
+
k
x
ω
(4)
with ironless rotors can be described by
characteristic:
means of the following equations:
n
By calculating the constant k and k from the
n
1. The power supply voltage U is equal to dimensions of the motor, the number of turns
U
the sum of the voltage drop produced by the per winding, the number of windings, the
current I in the ohmic resistance R of the diameter of the rotor and the magnetic field
rotor winding, and the voltage U induced in in the air gap, we find for the direct-current
micromotor with an ironless rotor:
the rotor :
0
(5)
U = I x R + U (1) M = U = k M
I ω
0
M
“speed-torque”
E
E
T
0
0
I
0
M
i
0
M
I
i
i
M
L
L
M
M
L
To overcome the friction torque M due to
the friction of the brushes and bearings, the
motor consumes a no-load current I . This
The identity k = k is also apparent from the gives
following energetic considerations:
M =kxI
f
R
Which means that k = k = k
E
I
T
0
M
E
U
0
T
f
U
The electric power P = U x I which is supplied
to the motor must be equal to the sum of the
mechanical power P = M x ω produced by
the rotor and the dissipated power (according
2. The voltage U induced in the rotor is to Joule’s law) P = I x R :
proportional to the angular velocity ω of the P = U x I = M x ω + I x R
=P +P
rotor :
I
e
0
m
2
v
i
M
2
e
0
M
m
U = k x ω i
E
v
(2)
0
and:
U = I x R + k x ω where
ω = 2π x n
60
hence:
k = U - I x R ω
0
0
0
M
0
0
0
0
(8)
M
0
Moreover, by multiplying equation (1) by I, we
It should be noted that the following also obtain a formula for the electric power Is it therefore perfectly possible to calculate
relationship exists between the angular P :
the motor constant k with the no-load speed
velocity ω express in radians per second and P = U x I = I x R + U x I
n , the no-load current I and the rotor
the speed of rotation n express in revolutions
resistance R .
The equivalence of the two equations gives
per minute:
Mxω=U xI
ω = 2π n
The starting-current I is calculated as
or U = M and k = k = k
60
follows:
ω I
I =U
3. The rotor torque M is proportional to the Quod erat demonstrandum.
R
e
2
e
0
M
i
0
0
M
i
i
d
E
T
d
0
M
rotor current I:
M = k x I (3) Using the above relationships, we may write
the fundamental equations (1) and (2) as
It may be mentioned here that the rotor torque follows:
(6)
M is equal to the sum of the load torque M U = I x R + k x ω supplied by the motor and the friction torque and :
U = M x R + k x ω (7)
M of the motor :
k
M=M +M
T
L
0
0
f
L
M
M
It must be remembered that the R depends
to a great extent on the temperature; in other
words, the resistance of the rotor increases
with the heating of the motor due to the
dissipated power (Joule’s law):
R = R (1 + γ x ∆T)
M
M
M0
f
By substituting the fundamental equations (2)
and (3) into (1), we obtain the characteristics
of torque/angular velocity for the dc motor
Where γ is the temperature coefficient of
copper (γ = 0.004/°C).
As the copper mass of the coils is
comparatively small, it heats very quickly
Brush DC Working Principles
through the effect of the rotor current,
particularly in the event of slow or repeated
starting. The torque M produced by the
starting-current I is obtained as follows:
M = I x k - M = (I - I )k (9)
d
d
d
d
f
d
0
required for obtaining a speed of rotation n
for a given load torque M (angular velocity ω
= n x 2π/60). By introducing equation (10) into
(6) we obtain:
U = M + I R + k x ω
(13)
k
L
(
0
)
L
0
M
By applying equation (1), we can calculate the
angular velocity ω produced under a voltage
U with a load torque M . We first determine
the current required for obtaining the torque
M=M +M:
I=M +M
k
Since M = I
k
0
f
L
f
f
0
we may also write I=M +I
k
L
d
0
0
M0
0
0
M
M
L
f
2
M
M
d
L
0
d
M
M
d
L
0
L
0
0
3. Let us now calculate the torque M at a
given speed of rotation n of 3000 rpm (ω = 314
rad/s) and a power supply voltage U of 15V;
equation (12) gives the value of the current:
I=U −kxω=I −k xω
R
R
= 1.18 − 0.0232 x 314 = 0.466A
10.2
0
0
d
M
M
and the torque load M :
M = k(I − I )
= 0.0232 (0.466 − 0.012)
= 0.0105 Nm
(M = 10.5 mNm)
L
L
0
L
0
d
M
M0
M0
M
0
M
d
For the angular velocity ω, we obtain the By introducing the values ω , I , R and U into
the equation (8), we obtain the motor constant
relationship
ω = U − I x R (11) k for the motor 23D21-216E:
k = 12 − 0.012 x 9.5 = 0.0232 Vs
k
= U − R (M + M )
15
k k
Before calculating the starting-current, we
In which the temperature dependence of the must calculate the rotor resistance at 40°C.
rotor resistance R must again be considered; With ∆T = 18°C and R = 9.5Ω, we obtain
in other words, the value of R at the working R = (1 + 0.004 x 18) = 9.5 x 1.07
temperature of the rotor must be calculated.
= 10.2Ω
On the other hand, with the eqation (6), we
can calculate the current I and the load The starting-current I at a rotor temperature
torque M for a given angular velocity ω and a of 40°C becomes
I = U = 12 = 1.18A
given voltage U :
I = U − k x ω = I − k ω
R 10.2
(12)
R
R
and the starting-torque M , according to
equation (9), is
And with equation (10)
M = k(I − I ) = 0.0232 (1.18 − 0.012)
M = (I − I )k
= 0.027 Nm
We get the value of ML:
M = (I − I )k − k ω
2. Let us ask the following question: what is
the speed of rotation n attained by the motor
R
with a load torque of 0.008 Nm and a power
The problem which most often arises is that supply voltage of 9V at a rotor temperature
of determining the power supply voltage U of 40°C?
0
0
0
0
0
0
L
Practical examples of calculations
Please note that the International System of Equation (11) gives the angular velocity ω:
Units (S.I.) is used throughout.
ω = U − I x R = 9 − 0.357 x 10.2
k
0.0232
®
1. Let us suppose that, for a Portescap
= 231 rad/s
motor 23D21-216E, we wish to calculate the
motor constant k, the starting current I and and the speed of rotation n:
the starting torque M at a rotor temperature n = 60 ω = 2200 rpm
2π
of 40°C. With a power supply voltage of 12V,
(10) the no-load speed is n is 4900 rpm (ω = 513
rad/s), the no-load current I = 12 mA and the Thus the motor reaches a speed of 2200 rpm
and draws a current of 357 mA.
resistance R = 9.5 Ω at 22°C.
i
L
Using equation (10) we first calculate the
current which is supplied to the motor under
these conditions:
I = M + I = 0.008 + 0.012
k
0.0232
= 0.357A
d
d
0
4. Lastly, let us determine the power supply
voltage U required for obtaining a speed
rotation n of 4000 rpm (ω = 419 rad/s) with
a load torque of M of 0.008 Nm, the rotor
temperature again being 40°C (R = 10.2Ω).
.
As we have already calculated, the current I
necessary for a torque of 0.008 Nm is 0.357 A
0
L
M
2
M
0
U =IxR +kxω
= 0.357 x 10.2 + 0.0232 x 419
= 13.4 volt
0
M
How to select your Coreless motor
PRODUCT RANGE CHART
FRAME SIZE
Max Continuous
Torque
Motor Regulation R/K
2
Rotor Inertia
08G
13N
16C
16N28
16G
mNm (Oz-in)
0.66
(0.093)
0.87
(0.102)
3.33 (0.47)
1.0 (0.14)
2.4 (0.34)
5.4 (0.76)
10 /Nms
1900
1200
166
1523
380
77
Kgm 10
0.03
0.035
0.33
0.27
0.51
0.8
17S
17N
22S
22N28
22V
23L
mNm (Oz-in)
2.6 (0.37)
4.85 (0.69)
9.5 (1.34)
7.3 (1.04)
8.13 (1.15)
6.2 (1.16)
10 /Nms
250
97
33
73
58
54
Kgm 10
0.5
0.8
1.9
3
2.4
3.6
3
2
Max Continuous
Torque
Motor Regulation R/K
08GS
2
Rotor Inertia
-7
3
2
-7
FRAME SIZE
23V
mNm (Oz-in)
Max Continuous
Torque
23GST 25GST
25GT
26N
28L
28LT
13 (1.8)
22 (3.1)
27 (3.8)
41 (5.8)
17.3 (2.4)
21.0
(2.97)
22.8
(3.23)
Motor Regulation R/K
10 /Nms
30
11 (0.4)
8
4.2
18
12
13
Rotor Inertia
Kgm 10
3.7
4.7
10
13
6
17.5
10.7
28D
28DT
30GT
Max Continuous
Torque
mNm (Oz-in)
33.6
(4.8)
41 (5.8)
93
(13.2)
58.3 (8.3)
115 (16.3)
158.6
Motor Regulation R/K
10 /Nms
6.69
5.9
1.1
3.12
0.83
0.39
Rotor Inertia
Kgm 10
17.6
20
33
52
71.4
70
2
3
2
2
-7
3
2
-7
35NT2R32 35NT2R82
35GLT
Motor Designation
22
Motor diameter (in mm)
N
2R
2B - 210E
Bearing type:
blank = with sleeve
bearings
2R = with front and
rear ball bearings
Coil type:
nb of layer
wire size
type connexion
Commutation size & type/ magnet type:
Alnico/ Precious Metal = 18, 28, 48, 58
Alnico/ Graphite & Copper = 12
Motor generation/ length:
L, C = old generation (C: short, L: long), Alnico Magnet
S, N, V = middle generation (S: short, N: normal, V: very long)
G, GS = new generation (high power magnet), S: short version
286
Execution coding
NdFeB/ Precious Metal = 78, 88, 98
NdFeB/ Graphite Copper = 82, 83
Explanation of Specifications
MOTOR PART NUMBER
MEASURING VOLTAGE
V
16N28 205E
Explanation
18
Is the DC voltage on the motor terminals and is the reference at which all the data is measured
NO LOAD SPEED
rpm
9600
This is the the speed at which motor turns when the measuring voltage is applied with out any load
STALL TORQUE
mNm (oz-in)
2.9 (0.41)
Minimum torque required to stall the motor or stop the motor shaft from rotating at measuring voltage
AVERAGE NO LOAD CURRENT
mA
4.9
The current drawn by the motor at no load while operating at the measured voltage
TYPICAL STARTING VOLTAGE
V
0.45
The minimum voltage at which the motor shaft would start rotating at no load
MAX RECOMMENDED VALUES
MAX CONT CURRENT
A
0.15
The maximum current that can be passed through the motor with out overheating the coil
MAX CONT TORQUE
mNm (oz-in)
2.5 (0.35)
The maximum torque that can be applied without overheating the coil
182
The maximum feasible rotor acceleration to achieve a desired speed
3
2
10 rad/s
MAX ANGULAR ACCELERATION
INTRINSIC PARAMETERS
BACK-EMF CONSTANT
V/1000 rpm
1.8
Voltage induced at a motor speed of 1000 rpm
TORQUE CONSTANT
mNm/A (oz-in/A)
17.3 (2.45)
Torque developed at a current of 1 A
TERMINAL RESISTANCE
ohm
109
Resistance of the coil at a temperature of 22 oC
3
MOTOR REGULARION
10 /Nms
360
It is the slope of speed torque curve
ROTOR INDUCTANCE
mH
3
Measured at a frequency of 1 kHz
ROTOR INERTIA
2
kgm 10
0.55
Order of magnitude mostly dependent on mass of copper rotating
MECHANICAL TIME CONSTANT
ms
20
Product of motor regulation and rotor inertia
-7
Speed vs Torque curve • 16N28 at 18V
14000
12000
N (RPM)
10000
8000
6000
4000
Continuous
Working range
2000
Temporary
Working range
0
0
1.337 2.673
4.01
5.347 6.683
M (m Nm )
8.02
9.356 10.69
Markets & Applications
MEDICAL
• Powered surgical instruments
• Infusion, Volumetric & Insulin Pumps
• Dental hand tools
• Diagnostic & scanning equipment
Benefits: Reduced footprint analyzers with high efficiency & precision sample positioning
SECURITY & ACCESS
• Security cameras
• Bar code readers
• Locks
• Paging systems
Benefits: Low Noise & Vibration, High Power & Superior Efficiency
AEROSPACE & DEFENSE
• Cockpit gauge
• Satellites
• Indicators
• Optical scanners
Benefits: Low Inertia, Compactness and Weight, High Efficiency
ROBOTICS & FACTORY AUTOMATION
• Conveyors
• Industrial robots
• Remote controlled vehicles
Benefits: High Power & Low Weight
POWER HAND TOOLS
• Shears
• Nail guns
• Pruning hand tools
Benefits: High Efficiency, Compactness and Weight, Low Noise
OTHER
• Office equipment
• Optics
• Semiconductors
• Automotive
• Model railways
• Transportation
• Document handling
• Audio & video
Benefits: Low Noise, High Power, Better Motor Regulation
Brush DC Motors at Work
MEDICAL ANALYZERS
Portescap solves multiple application needs in analyzers, from sample draw on assays to rapid scanning
and detection of molecular mechanisms in liquids and gases, with its coreless brush dc motors.
For high throughput applications—those where over 1,000 assays are analyzed in an
hour—high efficiency and higher speed motors such as brush DC coreless motors
are a suitable choice. Their low rotor inertia along with short mechanical
time constant makes them ideally suited for such applications. As an
example, a Portescap 22-mm motor brush coreless DC motor offers no-load
speed of 8,000 rpm and a mechanical time constant of 6.8 milliseconds.
Another analyzer function that plays a vital role in their output is collecting
samples from the vials or assays, and serving them up to measurement
systems based on photometry, chromatography, or other appropriate schemes.
Here again, a brush DC coreless motor is highly applicable due to the power
density it packs in a small frame size. You can maximize your application’s
productivity with a 16 or 22mm workhorse from Portescap.
INFUSION PUMPS
Coreless brush DC motors offer significant advantages over their iron core brush counterparts for some
of the critical care pump applications where, the benefits range from improved efficiency to higher
power density, in a smaller frame size. One of the factors that deteriorates motor performance over long
term usage is the heating of the motor with associated Joule loss. In motor terminology this is governed
by the motor regulation factor determined by the coil resistance, R, and the torque constant, k. The
lower the motor regulation factor (R/k2) the better would the motor perform over its life while
sustaining higher efficiencies. With some of the lowest motor regulation factors
Portescap’s latest innovation in Athlonix motors is already benefiting applications
in the infusion pump space by offering a choice of a higher performance motor
with less heat loss, higher efficiency and power density in compact packages.
ELECTRONICS ASSEMBLY
SURFACE MOUNT EQUIPMENT
Portescap’s versatile 35mm coreless motors with carbon brush commutation excel in electronic
assembly, robotics and automated machinery equipment and have been a work horse in
some of the pick and place machinery used in surface mount technology. Our
35mm low inertia motors can provide high acceleration, low electro
magnetic interference, and frequent start stops that the machines need
while maintaining smaller and light weight envelopes.
BRUSHLESS DC motoRS
BLDC 22mm
BLDC Gearmotor Size 9
nuvoDisc 32BF
BLDC Gearmotor Size 5
Portescap Brushless DC motors are extremely reliable and
Why a Brushless Motor
12
built to deliver the best performances. Their high power density
allows a reduction in the overall size of most of the applications.
How to select your
Brushless Motor
13
They feature silent running even at high speed. The autoclavable
Brushless Terminology
14
option is ideal for medical applications.
Where to apply your
Brushless Motor
15
Specifications
16
Why a Brushless motor
Housing
Lamination Stack
Flange
Winding
Print with Hall sensors
Shaft
Permanent
magnet
Bearing
Brushless technology
Conventional DC motors use a stationary magnet with a rotating
armature combining the commutation segments and brushes to
provide automatic commutation. In comparison, the brushless DC
motor is a reversed design: the permanent magnet is rotating
whereas the windings are part of the stator and can be energized
without requiring a commutator-and-brush system. Therefore this
motor type achieves very long, trouble-free life even while
• No mechanical commutation
Long life (limited only by wear on ball bearings)
• Mainly linear motor characteristic
Excellent speed and position control
• Static winding attached to motor housing
Improved heat dissipation and overload capability
operating at very high speeds.
• High efficiency
Slotted & Slotless
technologies
• Autoclavable Option Available
lamination with winding placed in the slots that are axially cut
along the inner periphery.
Your Custom motor
This is called the BLDC motor, slotted iron structure.
• Various stack lengths available in each frame size
One technology uses a stator that consists of stacked steel
• Autoclavable option
The other technology uses a self-supporting cylindrical ironless
coil made in the same winding technique as for our ironless rotor
• Custom winding
DC motors.
• Shaft modification including hollow shaft
This is called the BLDC motor, slotless iron structure.
• Special material, coating and plating
Standard Features
• Lead length, type, color and connector
• Max Continuous stall torque up to 39 oz-in (276 mNm)
• Gearhead
• Peak torque up to 332.7 oz-in (2’278 mNm)
• Encoder
• Speed up to 100’000rpm
• Standard diameter from 0.5 to 2.3 in (12.7 to 58 mm)
How to select your Brushless motor
Hall Sensors
In general, BLDC motors have three phase windings. The easiest way is to power two of them at a time, using
Hall sensors to know the rotor position. A simple logic allows for optimal energizing of the phases as a function
of rotor position, just like the commutator and brushes are doing in the conventional DC motor.
Possible applications: high variation of speed and/or load, positioning
Sensorless
With this solution the motor includes no sensors or electronic components and it is therefore highly insensitive to hostile
environments.
In all motors, the relation of back-EMF and torque versus rotor position is the same. Zero crossing of the voltage induced
in the non-energized winding corresponds to the position of maximum torque generated by the two energized phases.
This point of zero crossing therefore allows to determine the moment when the following commutation should take place
depending on motor speed. This time interval is in fact equivalent to the time the motor takes to move from the position
of the preceding commutation to the back-EMF zero crossing position.
Electronic circuits designed for this commutation function allow for easy operation of sensorless motors. As the backEMF information is necessary to know the rotor position, sensorless commutation doesn’t work with the motor at stall or
extremely low speed.
For applications: constant speed and load (spindle), cable diameter limitation
Slotted
B
05
Motor Type
B = BLDC Motor
Diameter
05 = 0.5 in
06 = 0.6 in
09 = 0.9 in
11 = 1.1 in
15 = 1.5 in
motor Designation
08
Stack Length
04 = 0.4 in
05 = 0.5 in
06 = 0.6 in
08 = 0.8 in
09 = 0.9 in
12 = 1.2 in
18 = 1.8 in
25 = 2.5 in
050A
-
Winding
R
0
0
05
Type
O = Motor only
G = Gearhead
Shaft Option
R = Round
F = Flat
D = 2 fiats
spaced 180°
Gear Ratio
04 = 4:1, 05 = 5:1, 07 = 7:1,
12 = 12:1, 15 = 15:1, 16 = 16:1
20 = 20:1. 25 = 25:1. 28 = 28:1,
35 = 35:1, 49 = 49:1
R
Gearhead
Shaft Option
R = Round
F = Flat
D = 2 fiats
spaced 180°
(*) not used if motor only
Slotless
22
BH
Diameter (in mm)
13
16
18
22
26
30
32
-
Brushless
m
Body Length
S = Short
M = Medium
L = Long
C = Short
F = Flat
8B
P
01
8B: Hall Sensor
(8 wires)
3C: sensorless
(3 wires)
6A: On board electronic
(6 wires)
2A: On board electronic
(2 wires)
Winding
C-E-H-K...
Execution
01, 05...
Explanation of Specifications
MOTOR PART SPECIFICATION
ExpLanation
BACK-EMF CONSTANT Ke [V/krpm] +/-8%
Voltage induced at a motor speed of 1’000 rpm
ELECTRICAL TIME CONSTANT te [ms]
The time required for current to reach 63% of its nal value for a xed voltage level
INDUCTANCE L [mH]
Measured with a frequency of 1 kHz between 2 phases of the stalled motor. The value gives an order of magnitude
MAX CONTINUOUS POWER AT 10krpm [W]
Power developed at 10krpm so the motor doesn’t exceed its thermal rating
MAX CONTINUOUS POWER DISSIPATION [W]
The maximum power the motor can dissipate without exceeding its thermal rating
MAX CONTINUOUS STALL CURRENT OR MAX CONTINUOUS
CURRENT Ics [A]
Current drawn by the motor at zero speed (locked condition) so the motor doesn’t exceed its thermal rating.
MAX CONTINUOUS STALL TORQUE Tcs [mNm OR oz-in]
The amount of torque at zero speed, which a motor can continuously deliver without exceeding its thermal rating
MAX CONTINUOUS TORQUE AT 10krpm [mNm OR oz-in]
Torque developed at 10krpm so the motor temperature doesn’t exceed its thermal rating
MOTOR CONSTANT 10krpm [mNm/watt OR oz-in/watt ]
Figure of merit to evaluate motor
NO-LOAD CURRENT I0 [mA] +/-50%
Current of the unloaded motor at no-load speed. It represents the friction losses of the standard motor at that speed.
NO-LOAD SPEED Wnl or n0 [rpm] +/-10%
Speed of the unloaded motor, it is proportional to the supply voltage.
1/2
1/2
MEASURING OR RATED VOLTAGE U OR Vr [V]
Supply voltage at which the characteristics have been measured (at 20/25°C).
MECHANICAL TIME CONSTANT tm [ms]
It is the product of motor regulation (R/k2) and rotor inertia J. It describes the motor physically taking into account
electrical (R), magnetic (Kt) and mechanical (Jm) parameters. It is the time needed by the motor to
reach 63% of its no-load speed or of its nal speed in view of the voltage and load conditions.
PEAK CURRENT Ipk [A]
The current drawn by the motor when delivering peak torque
PEAK TORQUE [mNm OR oz-in]
The maximum torque a brushless motor can deliver for short periods of time.
RESISTANCE R [Ohm] +/-10%
Terminal resistance phase to phase at 25°C
ROTOR INERTIA Jm [kg-m or oz-in-sec ]
Rotor (magnet and shaft) inertia
STATIC FRICTION TORQUE Tf [mNm OR oz-in]
Torque required to turn the motor shaft with out powering the motor
THERMAL RESISTANCE [°C/Watt]
Gives the motor temperature rise for a power dissipation of 1 W.
For slotted motor the value is measured with motor mounted on a 6.0” x 6.0” x 0.25” aluminum heat sink
For slotless motor the value is measured under unfavorable conditions (motor alone). With measuring methods
refiecting more common operating conditions, values which are 10 to 50% lower may be obtained.
TORQUE CONSTANT Kt [mNm/A OR oz-in/A] +/-10%
Indicates the torque developed for a current of 1 Amp
VISCOUS TORQUE (LOSSES) [mNm/krpm OR oz-in/krpm]
Inherent losses such as friction in the ball bearings and Foucault current. Those are proportional to speed.
WEIGHT W [g OR oz]
Average weight of the standard motor
2
2
Where to apply your
Portescap Brushless motor
SURGICAL HAND tooL
When you’re an orthopedic surgeon performing multiple operations in a day,
hand tools that are powerful and precise are a must. However, a smaller, more
lightweight version of the tool would be a welcome relief. Portescap supplies
customized solutions that are exceptionally lightweight but do not
compromise performance. Its lightweight feel and low-heat feature reduce
hand fatigue in surgeons.
Suitable sealing and optimized design assure adequate autoclaving and
prevent contamination. So surgeons, and their patients,
have a lot to feel comfortable about.
mEDICAL
• High speed surgical hand tools
• Respirators & ventilators
• Small bone surgical hand tools
• Infusion & insulin pumps
• Large bone surgical hand tools
• Dental imaging
• Dental hand tools
• Analyzers
INDUStRIAL AUtomAtIoN
• Industrial nut runners
• Conveyors
• Industrial screwdrivers
• Electronic assembly
• Air pumps
AERoSPACE & DEFENSE
• Aircraft on board instrumentation
• Valves
• Gyroscope
• Fuel metering system
• Satellites
• Electric actuator
SECURItY & ACCESS
• Barcode readers
• Locks
• Camera
• Ticket printer & dispenser
otHER
• Robotic
• Precision instrumentation
• Engraving
Timing Relationship
B0504, B0508, B0512, 13BC, 16BHS, 16BHL, 22BHS, 22BHM, 22BHL
Timing relationships between the motor phases and the hall sensors that
support cummutation (four pole motor). CW rotation from shaft end.
Motor is supplied with connector AMP #640430-8 which may be removed.
16
www.portescap.com
Miniature Motors
B0610, B0614, B906, B909, B912, B1106, B1112, B1118, B1505, B1515, B1525, nuvoDisc series
Timing relationships between the motor phases and the hall sensors that
support cummutation (four pole motor). CW rotation from shaft end.
Motor is supplied with connector AMP #640430-8 which may be removed.
www.portescap.com
17
Slotted BLDC
Timing Relationship
tURBoDISC™ StEPPER motoRS
P430
P532
P310
P110
P010
The TurboDisc provides exceptional dynamic performance
Why a TurboDisc motor
98
unparalleled by any other stepper on the market. The unique
TurboDisc Motor Basics 99
thin disc magnet enables finer step resolutions in the same
diameter, significantly higher acceleration and greater top
end speed than conventional steppers. TurboDisc excels in
applications that require the precision of a stepper and the
speed/acceleration of a DC motor.
How to select your
TurboDisc motor
100
TurboDisc Specifications
101
Where to apply
TurboDisc motors
103
Why a turboDisc motor
Stator w/windings
Bearings
Disc magnet
End Bells
Innovation & Performance
A technology providing unique results. At its heart there is the
rotor, a thin disc or rare earth magnet material. Portescap’s unique
design allows for axial magnetizing with a high number of poles,
Your custom motion
solution
• Sintered or ball bearings
and for optimizing the magnetic circuit with a corresponding
• Various windings
reduction of losses. The quantum leap of this state-of-the-art
• Shaft modiflcations – increase/decrease length, knurling
technology developed by Portescap is extremely high dynamic
performance comparable to DC servo motors but obtained from a
simple stepper motor.
• Longer leads, connectors
• Gearheads for increased torque
• Encoders for position veriflcation
The TurboDisc is well suited to be tailored to your application
requirements. Our design engineers can integrate our motor into
your assembly. Our TurboDisc design assistance can range from
providing additional components to a fully customized motion
solution that optimizes the space and performance of your
machine. TurboDisc advantages include:
Standard Features
Frame sizes ranging from:
• Outer diameter - 10 mm to 52 mm
• Precise - Well suited for microstepping
• Output speed - up to 10,000 rpm
• Fast - Disc Magnet enables fastest acceleration and highest top speed
of any step motor while maintaining accurate positioning
• Step angle – 3.6º, 6°, 9º & 15º
• Unique - Low detent torque and highly customizable
• Adaptable - Higher steps per revolution than CanStack products; can
be increased through tooling
• Miniature - Down to 10 mm diameter with 24 steps per revolution
• Output torque - up to 350 mNm
turboDisc motor Basics
the High Performance Disc magnet technology
The exceptional possibilities offered by the Turbo Disc line of
Such a rotor design has a very low moment of inertia, resulting in
disc magnet stepper motors are unequalled by any other kind of
outstanding acceleration and dynamic behavior. These features,
stepper motor. The advanced technology, developed and patented
together with high peak speeds, mean that any incremental
by Portescap, allows for truly exceptional dynamic performance.
movement is carried out in the shortest possible time. Low
The rotor of these motors consists of a rare earth magnet having
inertia also means high start/stop frequencies allowing to save
the shape of a thin disc which is axially magnetized. A particular
time during the first step and to solve certain motion problems
magnetization method allows for a high number of magnetic
without applying a ramp. Those motors, specially designed for
poles, giving much smaller step angles than conventional two-
microstepping, feature a sinusoidal torque function with very low
phase permanent magnet stepper motors.
harmonic distortion and low detent torque. Excellent static and
dynamic accuracy is obtained for any position and under any load
or speed conditions.
Short magnetic circuit
using high quality
laminations
No magnetic coupling
Rotor with very low inertia
Concept Detail
Motor Characteristics
Advantages for the application
Thin multipolar rare earth disc magnet
Very low motor inertia
Very high acceleration, high start/stop frequencies
Very short iron circuit made of SiFe / NdFeB
laminations, Coils placed near to the airgap
No coupling between phases
Sinusoidal torque function
Low detent torque
Superior angular resolution in microstep mode
Optimally dimensioned iron circuit
Torque constant is linear up to 2 to 3 times nominal current
High peak torques
High energy magnet
High power to weight ratio
For motors in mobile applications
For size limitations
How to select your
turboDisc stepper
turboDisc motor torque Range
P010
P110
Continuous torque
P310
Peak torque
P430
PP520
P520
P530
P532
Torque in mNm 1
10
50
100
200
300
500
800 1000
1500 1750 2000
Torque in oz-in 0.14
1.4
7
14
28
42
71
113 142
212 248
283
turboDisc motor Designation
P
X
5
3
2
-25
8
012
TurboDisc
Internal
Code
Resistance
per winding
Code of
length
Number of rotor
pole pairs
Code of diameter
Motor version of full/
half-step = 2
Motor version of
microstep = 0
14
V
Motor
execution
code
Particular option
Number of connections
or terminal wires
Explanation of Specifications
MOTOR PART NUMBER
P110 064 068 08/12
ExpLanatIon
RATED VOLTAGE
vdc
12.00
Voltage rating of motor - motor can be run continuously at this
voltage
RESISTANCE PER PHASE, ± 10%
ohms
62.00
Winding resistance dictated by magnet wire diameter and # of
turns
INDUCTANCE PER PHASE, TYP
mH
46.00
Winding inductance dictated by magnet wire diameter and # of
turns
RATED CURRENT PER PHASE *
amps
0.12
Current rating of motor - motor can be run continuously at this
current
BACK-EMP AMPLITUDE
V/kst/s
10.80
The torque constant of the motor - the back EMF generated by
the motor when externally spun at 1000 steps per second
HOLDING TORQUE, TYPICAL *
oz-in /
mNm
1.0 / 7
When energized, the amount of torque to move from one
mechanical step to the next
DETENT TORQUE, TYPICAL
oz-in /
mNm
0.1 / 1
When un-energized, the amount of torque to move from one
mechanical step to the next
STEP ANGLE, ± 10% *
degrees
15.00
360 deg / number of mechanical steps of the motor
STEPS PER REVOLUTION *
-
24.00
Number of mechanical steps of the motor
NATURAL RESONANCE FREQUENCY
(NOMINAL CURRENT)
Hz
160.00
The frequency at which the motor vibrates at maximum
amplitude
ELECTRICAL TIME CONSTANT
ms
0.80
Represents the time it takes for the input current to the motor
coil to reach approximately 63% of its final value
ANGULAR ACCELERATION (NOMINAL
CURRENT)
rad/s2
167000.00
The rotational acceleration of the motor when supplied with
nominal current
THERMAL RESISTANCE
ºC/watt
45.00
ROTOR MOMENT OF INERTIA
oz-in-s2/
g-cm2
0.057 x 10E-4 / 0.4
OPERATING
ºC
-20 ~ +50
Temperature range which the motor will operate
STORAGE
ºC
-40 ~ +85
Storage temperature where the motor will operate
BEARING TYPE
-
SINTERED BRONZE SLEEVE (Optional
Ball Bearing on request)
Bearings on front and rear of the motor
INSULATION RESISITANCE AT 500VDC
Mohms
100 MEGOHMS
DIELECTRIC WITHSTANDING VOLTAGE
vac
300 FOR 5 SECONDS
WEIGHT
lbs / g
0.05 / 23
Weight of the motor
RADIAL
lbs / N
0.12 / 0.5 (AT SHAFT CENTER)
Maximum load that can be applied against the shaft
AXIAL
lbs / N
0.12 / 0.5 (BOTH DIRECTIONS)
Maximum load that can be applied directly down the shaft
-
Insulated Cable, AWG 26
Rating of the lead wires
B (130°C)
Maximum temperature of the winding insulation
AMBIENT TEMPERATURE RANGE
SHAFT LOAD RATINGS, MAX AT 1500
RPM
LEADWIRES
TEMPERATURE CLASS, MAX
RoHS
-
COMPLIANT
Inertia of the rotor
P010 064 015 /P110 064 003
Pull-Out Torque vs Speed • Full step, bipolar voltage
0.9
6.0
0.8
Pull-Out Torque
0.7
5.0
0.6
4.0
3.0
0.4
Pull-In Torque
0.3
2.0
0.2
Torque
1.0
0.1
0
Speed
200.00
500.00
400.00
1000.00
800.00
2000.00
1200.00
3000.00
2000.00
5000.00
2800.0
7000.00
0.0
4000.0
pps
10000.00
P110 064 015 Pull-Out Torque @ 24V, 47 ohms Series Resistor
P110 064 2.5 Pull-Out Torque @ 0.9A, 24V
P110 064 015 Pull-In Torque @ 24V, 47 ohms Series Resistor
P110 064 2.5 Pull-In Torque @ 0.9A, 24V
Definitions
Pull-Out Torque The amount of torque that the motor can produce at speed without stalling
Pull-In Torque
The amount of torque that the motor can produce from zero speed without stalling
Speed
# of pulses per second provided to the motor, also stated in revolutions per minute
Voltage
Voltage applied to the drive
Current
Current applied to the drive
Drive
Chopper type drive - current controlled to the motor winding
rpm
mNm
oz-in
0.5
Where to apply your
turboDisc stepper
the turboDisc stepper provides the highest torque to
inertia ratio and is ideal for applications requiring, fast
and precise positioning.
Focus On: medical Analyzer
Portescap’s challenge for the application was to provide
maximum torque in a small diameter package. The higher
speed capability of the TurboDisc allowed a higher
gear ratio to be utilized, yielding an increase in
output torque at the desired speed. The disc
magnet design creates quick response time
for the motor, increasing the throughput
of the machine.
textile
• Yarn monitoring system
• Electronic wire winding
Factory Automation
• Pick & place machines
• Wafer handling
• Head positioning
• Feeders
• Die bonding
medical & Lab Automation
• Analyzers
• Milling machines
• Syringe pumps
• Prosthetics
• Pipettes
Other Industries & Applications
• Engraving
• Aircraft instrumentation
• Laser cutting
• Fiber optic splicers
• Bar code scanning
• Mail sorting
ENCoDeRS
Feedback mechanisms for gauging motor position and speed
Why an Encoder
250
are highly essential for a wide range of applications in medical,
Spotlight on MR2 Encoder
251
Encoder Specifications
254
industrial automation, security and access. Portescap’s encoder
technologies spanning from the simplest tachogenerators to
highly sophisticated MR encoders provide a bundle of solutions
for positioning and speed related feedback to facilitate the needs
of motion in a variety of applications.
Why an Encoder
Asic
LED
Codewheel
Feedback & Positioning
D.C. tACHOGENERAtORS
mAGNEtIC ENCODERS
The combination of an ironless rotor, a high grade permanent
The integrated Portescap type D magnetic encoder consists of
magnet, and a commutation system made of precious metals,
a multipolar magnet mounted directly on the motor shaft. As
results in Portescap DC tachogenerators having a truly linear
the motor shaft turns, magnetic flux variations are detected by
relationship between angular velocity and induced voltage, a
Hall sensors which generate two TTL-CMOS compatible output
very low moment of inertia and negligible friction.
signals having a 90° phase shift between both channels. The
OPtICAL ENCODERS
simple and robust design of this sensor makes it ideally suited
to applications with severe operating conditions, such as high
The incremental optical encoders from Portescap have three
temperature, dust, humidity, and vibration. Integrated into
output channels. It uses a dedicated ASIC having a matrix of
Portescap motors, these units are intended for applications
optoelectronic sensors which receives infrared light from an
requiring compact and reliable high performance systems for
LED after its passage through a metal codewheel. The mask
speed and position control.
determining the phase angle and index position is directly
integrated onto the circuit, ensuring very high precision. The
differential measure of the light modulated by the codewheel
generates digital output signals insensitive to temperature drift
with an electrical phase shift of 90° between channels A and B.
The standard version of the encoder provides CMOS
compatible complementary signals for improved signal
transmission and noise rejection. Besides the detection of the
direction of rotation and signal transitions in channel A and B for
direct control of a counter or a microprocessor, the integration
of this particular circuit offers additional functions such as a
stand-by mode for reduced current consumption in battery
powered equipment.
Spotlight on mR2 encoder
Magnetoresistance effect which was first discovered in 1857 can be seen in three different configurations: 1.R(M(T)) – Resistance changes due to indirect manipulation of magnetization through thermal changes
2.R(M) – Resistance changes due to direct manipulation of the magnetization.
3.R(ωM,I) – Resistance changes due to the angle between the magnetization and current
The third effect, also referred to as anisotropic magnetoresistance is exploited in Portescap’s high resolution MR encoders.
This resistance variation responds to the following equation:
γ(ωM,I) = γ 0 + γ fi cos2(ωM,I)
where γ 0 is the zero-field resistivity, γ fi is the minimal resistivity and ωM,I is the angle between the magnetic field and the
current. The relation between resistivity and magnetic angle governs the design of the MR encoder and as such the encoder
signals have negligible effect on variation in magnetic field strength.
Using interpolation techniques, several output lines per revolution are generated with only one period of analog signal coming
out from the sensor – magnet system, in incremental magnet encoders. The pulse signal from MR encoder as shown below is
proportional to speed and distance traveled by the shaft and can be used for effective feedback.
A
B
State:
0
0
1
0
1
1
0
1
0
0
1
0
1
1
0
1
0
0
1
0
1
1
0
1
0
0
0
2
3
1
0
2
3
1
0
2
3
1
0
Permanent
magnet
As the MR technology is not needed to have physically all the output lines
(poles in case of a magnetic encoder) on the encoder disc, the MR encoder
can be made very compact, even for high resolution. The magnetic field
inside the encoder can be maximized by having a low number of relatively
big magnetic poles. The strong field so obtained makes this encoder very
resistant against any unwanted external field.
Also, with this compact design the encoder disc magnet remains very small
thus sustaining the motor’s high dynamic performances.
Finally, as this encoder is made around a magnetic angle sensor, it is not
sensitive to vertical position changes and, hence, ball bearings in a motor are
not a prerequisite to achieve high resolution.
Motor
End cap
Encoder
Chip
Encoder
Chip
Concept Detail
Encoder Characteristics
Advantages for the Application
Interpolated lines
Physical line count on the encoder disc
is much lower than encoder resolution
Ultra compact design for high resolution
Field angle sensor
High magnet field obtained with simple
bipolar magnet
No sensitivity to axial movement of the
encoder magnet
Very low sensitivity to unwanted
external field
Ball bearing motor not required even
for high resolution
Low thickness high field density
magnet
Ultra low encoder inertia
High dynamic performance of the
motor stays intact
GEARHEADS
R16
R40
R32
M22
Portescap manufactures some of the highest performance
Why a Gearhead
224
miniature gearheads in the industry that are subjected to rigorous
Basic Gearhead Operation
225
quality tests during manufacturing.
With a range of planetary and spur gearheads from 8 mm to 40
mm in diameter, Portescap can offer an entire drive train based on
its motor gearbox solutions. Resident experts in gear technology
can assemble the gears at Portescap with metal or plastic gears
based on an application need.
How to select your Gearhead 226
Gearhead Specifications
228
Why a Gearhead
Gearhead
Designation
Efficient Performance
Every application has power requirements in terms of speciflc
values of speed and torque. With a load demanding high torque at
low speed, use of a large motor capable of developing the torque
would be uneconomic, and system efflciency would be very low. In
R
22
0
190
Gearbox
Type
Gearbox
diameter
in mm
Gearbox
execution
code
Reduction
ratio
such cases, a better solution is to introduce some gearing between
the motor and the load. Gearing adapts the motor to the load, be it
for speed, torque, or inertia. The motor-and-gearbox assembly will
provide greater efflciency and will be an economic solution.
Reduction Gearboxes using Spur
Gears
This gear technology offers advantages in current-limited
applications where lowest input friction and high efflciency are
essential. The broad range of Portescap spur gearboxes is well
adapted to our motor lines, and includes integrated gearmotors.
Planetary Gearboxes
High Speed Planetary Gearboxes
The main advantages of Portescap planetary gearboxes are their
This high performance product line was designed for use on BLDC
high rated torque and a high reduction ratio per gear train. Both
motors with iron core windings. The gearboxes tolerate input
types use high quality composite materials. The all-metal planetary
speeds in the range of 10,000 to 70,000 rpm and output speeds of
gearboxes, have a very compact design with excellent
several 1,000 rpm. This facilitates a motor-gearbox unit of very
performance and lifetime.
small dimensions that can provide extremely high values of speed
and torque.
Basic Spur and Planetary
Gearhead operation
Principle of the spur
gearhead:
The pinion of radius r1 and number of teeth
z1, drives the input wheel of radius r2 and
number of teeth z2.
The reduction ratio per train “i ” is z2:z1 which
is equal to r2:r1.
Concept Detail
Spur gear concept:
Only 1 transmission point per train
Principle of the
planetary gearhead:
The pinion S (= sun) having “s ” teeth is
driving the planets P (3 or 4 per train) which
have “p “ teeth and are fixed to the planet
carrier.
A = stationary annulus with “a “ teeth.
The reduction ratio per train is i = (a:s) +1.
Gearhead Characteristics
Advantages for the Application
Low friction per train
Good efficiency, about 0.9 per train
Arrangement of several trains as intended by Long gearhead of small diameter or short
the designer
gearhead of large diameter
Input and output shaft not necessarily in line Free choice for placing the motor relative to
Two output shafts possible
the output shaft
Mounting of a sensor, a potentiometer
Input wheel made of high grade
plastic generated at high motor
speeds
Reduction of mechanical noise
Silent operation
Planetary concept:
3 or 4 transmission points per train
Reduction ratio per train is higher but so is
friction
Can transmit higher torques
Input and output of a train have the same
direction of rotation
Less backlash
Less trains for a given reduction ratio
Efficiencies about 0.85 per train
Very compact gearbox for its performance
For any number of trains, the load always
rotates in the same direction as the
motor
Smaller shock in case of a paid reversal of
motor rotation
How to select your gearhead
In addition to the dynamic output torque, the factors that should be considered when selecting a gearhead to be operated
in conjunction with a Portescap motor are defined below:
Direction of rotation
It indicates the direction of the output shaft relative to the motor (= or fi). In planetary gearboxes, the direction is always
the same at input and output, for any number of trains.
Efficiency
It depends mainly on the number of trains. It is an average value, measured at an ambient temperature of 20 to 25°C. A
new gearbox has lower values which will reach the normal value after the run-in period.
max. static torque
It is the peak torque supported at stall; beyond this limit value the gearbox may be destroyed.
Max. recommended input speed
It has a large influence on the noise level and life time of the gearbox and, depending on the application, should be
considered when selecting the reduction ratio.
Backlash
This is the angle a gearbox output shaft can rotate freely with the input blocked. It is mainly due to gear play necessary to
avoid jamming, plus shaft play and the elastic deformation of teeth and shafts under load.
As it is load-dependent, two values are given, with and without a load torque. In fact, backlash of the preceding gear trains
appears at the output shaft diminished by the reduction ratio. Contrary to this, output shaft backlash appears at the input
multiplied by the ratio. With a 100: 1 ratio, a backlash of 1° represents a rotation of 100° at the input, and at each reversal of
the motor, the output only starts rotating once these 100° are caught up.
Standard features of a range of Portescap gear heads are given below. Detailed
specifications can be found in the catalog page for each of the gearbox.
GEARBOX
R10
R13
B16
BA16
Diameter
mm
10
13
16
16
Length (range)
mm
9 - 26.5
14.5 - 26.8
10.5 - 23
26.7 - 36.7
Ratio (range)
-
4 - 4096
5.5 - 915
5 - 2187
22.5 - 3280.5
Nominal Torque
Nm
0.1
0.25
0.12
0.2
Ef⁄ciency
(ratio dependent)
-
0.9 - 0.5
0.85 - 0.55
0.81 - 1.48
0.72 - 0.48
PRODUCT RANGE CHART
GEARBOX
R16
R22
M22
K24
K27
Diameter
mm
16
22
22
24
27
Length (range)
mm
16 - 28.3
25 - 40
22.6 - 50.2
15 - 21
28.5
Ratio (range)
-
5.5 - 915
5.75 - 1090 3.67 - 903.8
5 - 2048
6.2 - 2970
Nominal Torque
Nm
0.3
0.6
1.5
0.17
0.4
Ef⁄ciency
(ratio dependent)
-
0.85 0.55
0.8 - 0.5
0.8 - 0.5
0.85 0.65
0.65 - 0.4
R32
RG1/8
RG1/9
K40
R40
GEARBOX
Diameter
mm
32
26.2
26.2
40
40
Length (range)
mm
32 - 50
16.5
17.3
40 - 50
38.3 - 63.8
Ratio (range)
-
5 - 405
3.56 - 753
Nominal Torque
Nm
4.5
0.6
1.2
3
10
Ef⁄ciency
(ratio dependent)
-
0.8 - 0.55
0.8 - 0.55
0.8 - 0.45
0.8 - 0.55
0.85 - 0.5
5.75 - 1090 5.5 - 3000 4.25 - 1620