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Harowe Resolvers

Harowe Resolvers. For ?? Date ??. Harowe Feedback Mike Prentice 2006. Harowe Feedback Product Manager Phone 610/429-3502 Cell 610/331-7911 Mike.Prentice@dancon.com FEEDBACKDEVICES.COM. Presentation Outline. Harowe Background, Sales & Customers Harowe Product Line Overview

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Harowe Resolvers

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  1. Harowe Resolvers For ?? Date ??

  2. Harowe Feedback Mike Prentice 2006 Harowe Feedback Product Manager Phone 610/429-3502 Cell 610/331-7911 Mike.Prentice@dancon.com FEEDBACKDEVICES.COM Confidential

  3. Presentation Outline • Harowe Background, Sales & Customers • Harowe Product Line Overview • New HaroMax Resolver & Accuracy • Harowe Literature Support • Technical Section – Resolver Terms Confidential

  4. Harowe Background Over 50 Years of Experience in Resolvers/Synchros Large Installed Base & Brand Name Recognization Over last 15 years owned by Bowmar Instruments, BTR, API and Danaher. Manufacturing facilities in ST. Kitts, WI and Amherst N.Y. Currently supply greater than 400 customers with greater than 500 different products/part numbers. Current shipments approx 20,000 resolvers/month Over last 20 years – approx 5 million resolvers Confidential

  5. Harowe Strengths Short Prototype Lead Times Product Reliability & Ruggedness Custom Design Capabilities & Flexibility Continuous Improvement Philosophy Low Cost Manufacturing High Quality/Reliability Manufacturing Low Volume/High Mix Manufacturing Confidential

  6. Harowe Customers 1/4 of Harowe business is military/commercial aircraft (Woodward Governor, Jet engine fuel systems for GE, Rolls-Royce, Pratt & Whitney) – These applications require the highest degree of quality and reliability. We have supplied 100% of their requirements for this product for almost 8 years. We value long term relationships and understand the responsibilities of a single source. Confidential

  7. Harowe Customers 3/4 of Harowe business supplying industrial servo motor manufacturers and industrial control manufacturers Kollmorgen - Pac Sci - MTS - Allen Bradley – Reliance Leeson - Parker – Control Techniques - Baldor Glentek – North Atlantic – Ametek Patriot Sensors With the major customers we have developed a long term partnerships where we supply 100% of their resolver requirements on a e-kanban basis. Confidential

  8. Harowe Product Line The frameless, brushless product line was also then created to provide customers high degree of customization and optimization as we worked to provide an optimum solution. Originally was small Size 8 and Size 11 housed resolvers/synchros with hairspring brushes with many aerospace applications Over 26 years ago, the brushless synchros were introduced to solve slip ring wear, brush bounce due to vibration, reduced RFI emissions and explosion hazards. About 7 years ago, the Size 15 and 21 were upgraded to current (600 series) level. These shed-wound products were lighter, lower cost and included the Harowe patented flux shield. Confidential

  9. Harowe Product Line Haromax development was started about 3 years ago as an evolution to the current production Size 15 and Size 21. The stator laminations and winding process was automated to reduce cost and improve accuracy. In all of our products we have worked with specific customers to provide an optimum solution for the specific customers requirements such as Low temperature applications, High Temperature applications, Radiation hardened, RFI shielding, High Speed solutions, etc etc Confidential

  10. Harowe Product Line Overview • Housed Resolvers • Low Cost R11 • Size 11 • HD R25 Frameless Resolvers • Size 10 • Size 15 • Size 21 • Size 31 • Size 55 Confidential

  11. Small Housed Resolvers Brushless Construction Stainless Steel Housings Stainless Steel Shafts ABEC 3 Bearings Standard Frame Size 11 Multi-speed in Size 11 (2X, 4X, & 5X) Standard Accuracy = +/- 7 arcmin (single) Low Cost R11 version now available Confidential

  12. Small Housed Part Numbers • 11BRCX - 300 - A1A / 5 Accuracy Term. Mtg. Frame Size OD of unit to next highest tenth of inch. Minor Electrical Minor Design .120 dia Shaft Desc. 1 = .375 in long 10 = .562 in long 58 = .375 in long w/flat 95 = .562 in long w/flat Major Design Unit Function BRW=Control Transformer, SS BRCT= Control Transformer, MS BRCX=Transmitter Electrical Specification Input Voltage & Frequency Input Current Transformation Ratio Confidential

  13. R25 Heavy Duty Resolvers Standard Accuracy to +/- 5 arcmin. 3 Standard Speeds (1X, 2X, & 3X) 6 Standard Windings Available 2 Standard Mountings (Flange or Servo) IP65 Packaging w/ Shaft Seals Available MS Connector or Flying Leads with Side or Rear Exit Confidential

  14. Heavy Duty Part Numbers R25-F-B-S-R-N-1B-10-00 R25 – Heavy duty resolver F – Flange mount or S - Servo mount B – MS 16S connector or C – MS 18 Connector or F – Flying Leads S – Side exit or R – Rear exit R – Round 3/8 in Shaft or F – Flat on shaft N – No shaft seal or Y – with shaft seal 1B – Electrical Kit (1 speed w/4Vrms & 5 KHz input) or 1A or 1C or 1D or 1E or 1F or 2A or 3A etc. 10 – Accuracy (+/- 10 arcmin) or 02 or 03 or 04 or 05 or 07 or 15 etc 00 – Special factory designator Confidential

  15. Frameless Resolvers • Machined Extruded Aluminum Housing • 12L14 Plated Hub or Sleeve • Simplified Assembly • Flux Shielding Technology • Multiple Speeds Available • Max Bore Size .237 in (6mm) with Size 10 • Max Bore Size .472 in (12mm) with Size15 • Max Bore Size .80 in (20mm) with Size 21 • New HaroMax Size 15 & 21 available with 50% less error • Max Bore Size 1.57 in (40mm) with Size 31 • Max Bore Size 3.65 in (93mm with Size 55 Confidential

  16. Frameless Part Numbers • 21BRCX - 601 - H42/10 Accuracy Mtg. Frame Size OD of unit to next highest tenth of inch. Minor Design Bore Size Major Design Unit Function BRW=Control Transformer, SS BRCT= Control Transformer, MS BRCX=Transmitter Electrical Specification Input Voltage & Frequency Input Current Transformation Ratio Confidential

  17. HAROMAX Mmmmm Mmmmm Mmmm Mmmm Mmm Confidential

  18. HAROMAX • New toothwound design incorporates windings that are manufactured and installed completely automatically for least amount of part to part variation for greatest consistency Confidential

  19. HAROMAX • 700 Series will provide • Maximum Accuracy and • Minimum Error for • Demanding Position and • Velocity Feedback Electrical Error is 50% less than standard resolver Confidential

  20. Resolver Input Confidential

  21. Angular Error Definition • Accuracy same as Angular error – Difference between mechanical angular position indicated by electrical output signals and the true or actual mechanical angular position of the rotor with respect to the stator. Confidential

  22. Angular Error Sources • Design Limitations and Constraints a) Limitations in the distribution of the stator and rotor windings generate odd- order (3, 5, 7,….cycles/rev) harmonics. These are fairly well minimized by conventional design techniques. - Variable pitch – Variable turn – St.Kitts - Constant pitch – Variable turn - Haromax Confidential

  23. Angular Error Sources • Design Limitations and Constraints b) Inconsistency in the winding placement in the lamination slots and uniformity of end turn arrangements also affect accuracy and part to part issues. - HaroMax is solution – utilizes tooth winding Confidential

  24. Angular Error Sources • Design Limitations and Constraints c) Number of Slots in rotor & stator. In certain cases, Harmonic components of the stator slots or rotor slots are observed in the error characteristic. Slot error can be attenuated by skew of lam stack slots. Slot errors can be enhanced by radial misalignment. - HaroMax has 13 slot stator and 20 slot rotor – Can see harmonics at 13, 20, 26, 40 cycles/rev Confidential

  25. Angular Error Sources 2) Mechanical imperfections, manufacturing errors and material variations. Must have radial uniformity (constant air gap). - Results in harmonic components of error with spatial periods of 1 or 2 cycles/rev. - For Multiple speeds error is 1 - 2 spatial periods multiplied by speed. 3 speed harmonics 3rd and 6th order Confidential

  26. Angular Error Sources 3) Mounting Inaccuracy 4) Resolver-to-Digital Decoding error - These will not be discussed here since these items are the responsibility of the customer. Confidential

  27. Angular Error Sources • In summary, the resolver error curve represents the sum of all of the above issues. The resolver error curve can be represented as a series of Fourier Series of Harmonic components with the above discussed issues being the components with the largest magnitude. Confidential

  28. Size 21 Error Curve Confidential

  29. Size 21 FFT (Fourier series of the resolver error curve’s harmonic components) Confidential

  30. Velocity Ripple • In robots or servo applications the resolver reports position and velocity (derived) of motor to controller. At constant speed, each harmonic contributes to instantaneous speed of motor in proportion to the product of harmonic order, magnitude of harmonic and speed. Harmonics of static error show up as time harmonics in the Velocity error or ripple. Frequency of ripple is product of harmonic order and rotational angular frequency. Confidential

  31. Velocity Ripple Conclusions • Higher order harmonics (slotting) would contribute more to ripple if equal magnitude – But frequency higher. • Increased motor speed increases amplitude of ripple and frequency But higher order harmonics are normally smaller and velocity ripple components are filtered by the closed-loop bandwidth of the controller. So as speed increases slot harmonics will move beyond the system response. Confidential

  32. Velocity Ripple Conclusions 3) Assessing the harmonic components of static error to investigate ripple requires: a) detailed knowledge of application b) critical operating speeds c) system bandwidth d) potential influence of neighboring electromagnetic brake – location of rotary transformer, magnetic/non-magnetic components in resolver, flux shielding, etc Confidential

  33. Harowe Literature • Limited copies • PDF only Confidential

  34. Harowe Literature Size 11 Basic Info Confidential

  35. Harowe Literature R25 Configuration info Confidential

  36. Harowe Literature Frameless only Basic Mechanical info Confidential

  37. Harowe Engineering Prints General Text Pages Confidential

  38. The 3 R’s Advantages of Harowe Feedback • Reputation To successfully compete in the feedback industry, a reputation for excellence is a must and it must be guarded. • Reliability The feedback customer expects every product to function right out of the box and never fail. • Response The feedback customer expects every individual in the company to react immediately every time with full support. Confidential

  39. Precision Laminations Help Assure High Accuracy 155ºC Rated Winding (Optional 220ºC) for High Temp Environments Flux Shield Eliminates Crosstalk (pat. pend.) No On-Board Electronics Means Resolvers Can Be Used Where Encoders Cannot. Multi-Pole Versions in Both Housed and Frameless Models to Size 55 Available Housed Version Resolver Advantages Confidential

  40. Technical Section Additional slides to discuss Feedback Language (accuracy, precision, resolution, incremental vs absolute, analog vs digital, open vs closed systems, signal types, electrical specifications, mechanical specifications and environmental issues. Confidential

  41. Language Precision Accuracy Resolution Repeatability Confidential

  42. Measuring Systems • Incremental The measured value is the result of an increase or decrease in incremental steps. For example, measuring yards using a yardstick and counting the number of times the yardstick is moved to the next interval. • Absolute The measured value is given as a code that represents an absolute position. A 12 inch ruler has a number at each one inch interval designating the absolute position of that interval with respect to the end of the ruler. 12:52 Confidential

  43. Measuring Systems • Linear The measured value is a length or distance. Linear scales are used to measure inches or meters. Millimeter = Meter / 1000 Micron = Millimeter / 1000 = .00003937 inches Inch = 25.4 millimeters • Rotary The measured value is an angle. Circular scales are used to measure degrees or radians. Arc minute = Degree / 60 Arc second = Arc minute / 60 = Degree / 3600 Radian = 360 / 2p = 57.3º Confidential

  44. Measuring Systems • Analog The measured value is determined from a continuously changing detected value. 12:52 • Digital The measured value is counted from a two state detected value. Confidential

  45. Closed Loop Control System Motor Controller Drive Feedback Host Power Transmission Controlled Device . . . Precisely Monitored by Harowe’s Feedback Devices. . . Confidential

  46. Signal Types Signal Period Channel A Channel B Analog Reference Pulse Digital Interpolation Confidential

  47. Signal Types Resolver Input Confidential

  48. Resolver RESOLVER R4 S4 Rotor Stator S2 R2 S1 Stator S3 • Resolvers have two stator coils oriented at 90 degrees. The output signal amplitudes vary with the sine and cosine of the rotation angle. A two-pole resolver gives the absolute position of the rotor since one mechanical revolution is one complete electrical cycle. 360m = 360e Additional poles can be added to increase resolution. A 2 pole and a multi-pole may be combined for a Two Speed resolver. 2 phase output 90 degrees apart on 4 wires Confidential

  49. Synchro SYNCHRO S1 S3 R1 Stator Rotor R2 S2 • Construction resembles a 3 phase motor with windings at 120 degrees. A torque transmitter (TX) is capable of driving enough current to do work. When the output of the transmitter is applied to the stator windings of a Torque receiver (TR) the receiver rotor will rotate. The TR rotor will take a position approximating the position of the TX rotor. 3 phase output 120 degrees apart on 3 wires Confidential

  50. Resolver • Speed Number of electrical cycles per mechanical revolution. • Transformation Ratio (TR) Ratio of output voltage to input voltage. • Primary Input winding - Rotor or Stator • Secondary Output winding Confidential

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