1 Linear Motor BMS04[edit | edit source]
This is a high temperature linear motor which is able to survive, for a short time, temperatures up to 250°C. The motors are mounted on the whole track system and they apply the stretching force to the clips.
1.1 Mechanical layout[edit | edit source]
There are different mechanical layouts for the motor. At first the width of the motor, the width is always related to the iron package of the motor. It can be 90mm or 135mm.
There are also different lengths, it can be 4 lambda, 6 lambda, 8 lambda or 14 lambda.
Also the end face of the motor can be different. Both sides planar (gg), both sides bevelled (ss) or one side bevelled and one planar (gs or sg). If a motor is "gs" or "sg", depends of the clip moving direction. When first comes a planar end face, the motor is called "gs". First a bevelled end face, the motor is called "sg".
1.2 Electrical layout[edit | edit source]
As it's written in the definitions, one motor consists of one or more segments with a defined length. The segment consists of an integer number of elementary motors, these elementary motors have a length of one lambda. There are two further dimensions which defines a motor, the wire diameter and the number of windings. These dimensions are for the checkup normally not necessary, because they are depending on the line speed. But in the seldom case when a motor is broken and you have no spare part it could be important. Because it's possible there is a spare part motor with the same mechanical and electrical layout and only the wire diameter is different (one motor for slow section of the line and one motor for fast section), then you can normally not exchange the motors. If this case happens, please contact Template:EEC-Support.
Of every motor type always exists a "L" (left) and a "R" (right) type. As you can see in the following picture, a left motor is always mounted on the right side bottom and on the left side top and a right motor is always mounted on the left side bottom and on the right side top. This fact is always based on the film direction which is marked in the picture with the green arrow. Generally it is not possible to exchange a left motor with a right motor and reverse. But if there are some requirements fulfilled, the change is possible. The case is detailed explained in point "9.5 Turn a motor"
The mechanical layout also influences the electrical layout. Generally spoken, if there is a bevelled end face then one coil is missing. If you have a "ss" Motor, the first U coil and the last W coil is missing.
1.3 Different connections[edit | edit source]
The mainly used wiring method is "double" (top and bottom zone is fed parallel by one inverter), but there are different wiring methods depending on the line layout and also on the motor layout. Following the different wirings are explained in detail.
1.3.1 Preheat[edit | edit source]
Inside the preheat zone all clips are in stack an there is a smooth clip movement very important. To reach this target the clip moving force has to be constant. Therefore all disturbing forces should be compensated. The compensation will be successful if there is a shift between the top and bottom motors.
Tests have shown that a shift of 1/6 lambda leads to the best result. But if there is a shift, the parallel feeding top-bottom is not possible anymore, because the induced voltages in each zone are different which leads to an asymmetric current and the effective phase angles have also the1/6 lambda shift. So the top and bottom motors have to be fed by different inverters to apply different phase angles in the top and bottom motor.
But one inverter is able to feed two zones (same MDX in both zones), thus the two zones of a one preheat motor are connected parallel to one inverter. In a preheat motor all Pt100 are connected. The wiring is shown in the following electrical drawing.
1.3.2 Single[edit | edit source]
At some parts of the LISIM track only a low force is necessary, at this sections only a single level motor is mounted, usually on the bottom of the track. The single level motors are normally at the turn around of the LISIM outlet.
1.3.3 Double[edit | edit source]
A motor on top and one on bottom is the "normal" situation at the film side. In this case the top and bottom zone is connected parallel to one inverter. In some lines there is a serial connection (e.g. 1608 EOC).
1.3.4 Split[edit | edit source]
At the area of the clip opener on the top level is only the mounting of 90mm motors possible. But in this area a high force is needed, so on the bottom level a 135mm motor is mounted. If a 90mm motor and a 135mm are connected parallel, the induced voltage in each motor is not at the same level. This would lead again to an asymmetric current. To avoid this, each segment (top and bottom) is connected to one inverter (single zone).
The zone counting in this area is a little bit different. The easiest way to understand the counting is to take a look at the "Zonenplan". The wiring is the same like a single level motor.
1.3.5 Transport[edit | edit source]
The whole transport zone is running with the same MDX, so in this case the zones should be as long as possible to reduce the number of inverters. In the transport zone is also only a low force necessary, therefore only on the bottom level are motors mounted. To increase the length of the zones in the transport zone, more motors (a transport motor consists of a single segment) are connected serial. How many motors are connected serial is depending on the speed in the transport zone. To reduce the self induction e.m.f., the windings of these motors are reduced. This leads to a higher current in order to reach the same force level. The transport zone motors are equipped with two Pt100, one is connected and the other one is for spare.
1.3.6 Serial[edit | edit source]
In a 0 idler line the segments of top and bottom motor are connected serial to one zone. Because there is a shift of the permanent magnets and the serial wiring ensures that the current in the top and bottom segement is always at the same level.
1.3.7 Missing coil[edit | edit source]
It is possible that one coil in a zone is missing. In one elementary motor maximum one coil can be missing. If the zone consists of only one elementary motor and one coil is missing, the wiring is different. If the U coil is missing, the star point is connected to the U phase. If the W coil is missing, the star point is connected to the W phase. The same situation can happen at serial connected motors.
If the zone consists at least of two elementary motors, maximum in one of these elementary motors a coil can be missing. In this case all the wiring methods listed above are valid, because there is at least one coil in each phase.
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missing U coil
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missing W coil
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missing U coil - serial connection
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missing W coil - serial connection
1.4 Wire marks[edit | edit source]
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wire marks
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wire marks - new
Every wire of a linear motor is marked with its own code. The marks consist of a PTFE shrinking tube. If there is a left motor the code starts with two tubes, a right motor starts with only one tube. The colour of these tubes also indicates the phase, black for U phase, blue for V phase and red for W phase. After these tubes there is a gap and the gap is followed by four other tubes. These four tubes are showing a binary code which indicates the segment number and the colour of them indicates if it is the beginning (blue) or end (red) of a coil. For example in the drawings is written "1LUB – BK1 1000", "1LUB" indicates segment number 1, left motor, phase U, beginning of coil. This is enough to define the correct wire. To make it easier, there is an additional expression "BK1 1000" which describes the code, black for phase U, segment number 1 and the binary code. The expression "1LUB – BK1 1000" is shown in the first line of the table in picture 22.
In future the binary code will be replaced by a yellow mark on which the segment number is written in decimal numbers.
1.5 Turn a motor[edit | edit source]
With the spare part package of linear motors, which is delivered with every line, it is possible to replace every motor in the whole line. But not every type of motor is in the spare part package, because if a left motor is mechanical and electrical symmetric to a right motor, they can be exchanged. It is also possible reverse. This procedure is called "turn a motor", because the projected end faces of the motor will be exchanged. If it is possible to turn a motor can be easily checked with the spare parts list. When of a motor his left or right counterpart does not exist, it can be turned. When you reconnect a turned motor three points need to be observed:
- The beginning and the end wire of a coil must be turned.
- The phases U and W must be turned.
- The sequence of the segment numbers must be turned.
When the motor is reconnected a function test is mandatory. If the function test is successful, then the connections can be soldered. Followed you can compare the wiring of an original motor and a turned preheat motor.
