When to Use custom high voltage motor manufacturer？

Why high power motor is suitable for high voltage and medium voltage?

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Reduce the cost of power supply.

Higher voltages allow for the use of smaller cables to reduce distribution cable cost,that means reducing the current by increasing the voltage. So medium (3kV~11kV) and high voltage are more prefer for heavy duty applications.

When the power factor of the motor is fixed, the same power of motor voltage and current is inversely proportional,

High voltage=small current, low voltage=large current

Low voltage high output motors can only achieve higher power through higher currents, so that electromagnetic wires and motor leads with a sufficiently large cross-section are required to meet high currents, the iron slot needs to be enlarged, and the control equipment of the motor must be able to withstand the impact of high currents.

If the high voltage or medium voltage motor is used,the current becomes smaller,only the electromagnetic wire and the insulation structure of winding, the wiring system must meet the special requirements of high and medium voltage.

From the electrical perspective, low-voltage motors have to go through a transformer, while high-voltage motors are directly connected to the power supply line, it’s reducing the cost of electricity.

From the power and winding perspective, high voltage motors have greater advantages, but there are also limitations in terms of manufacturing and use: high-voltage motor windings are more expensive, such as the cost of magnet wires, mica materials, high and low resistance bands, magnetic slot wedges,etc; Each coil of the high voltage motor must go through the external insulation wrapping test and insulation treatment process.

From the usage perspective, the requirement of environment for high-voltage motor is higher than for low-voltage motors, including ventilation and heat dissipation devices, bearing system shaft current prevention measures, etc.

End-users should consider the reliability needs of their specific application, and our engineers will assist you if you have problems with selection or others.

Instrumentation equipment and precision automation systems manufacturers rely on motion components in applications from optical scanning to micro-mechanical assembly. PI supports these applications with a large variety of standard and custom motion and positioning solutions. A combination of in-house-developed and off-the-shelf mechanical and electronic components, including actuators, guiding systems, position sensors, and motion controllers, allows for great flexibility and performance at reasonable cost.

While gearbox / screw-driven positioning elements provide advantages for vertical and high force applications, direct drive electrodynamic motors are higher speed, zero-wear, and friction-free transmission devices that are preferable in positioning and scanning systems that require high dynamics & repeatability along with reliability over millions of cycles. 

In addition to designing piezo-ceramic direct drive linear and rotary motors, engineers at PI have a long history of developing custom motion systems with electrodynamic motors, especially for high-precision and/or high-dynamics applications. The main goal is to achieve specific performance targets that cannot be reached by off-the-shelf products sourced from the market. Here’s a link to a paper dating back to , describing a novel  momentum compensated high-speed voice coil linear scanner; other examples include multi-axis Maglev systems, high-speed hexapods, and compact voice coil motors with force and position control. 

This blog explains the functional principle and properties of voice coil, 3-phase linear, and torque motors, and provides examples on how performance characteristics of the various motor types can be adapted to the specific requirements of the positioning solution through an individual design, e.g., to achieve a high force density or a compact design.

The company is the world’s best custom high voltage motor manufacturer supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

Simulation tools allow customization and optimization for voice coil motors for different parameters, such as force and motor constant. The motor constant denotes the ratio of force to power loss, or the efficiency of the motor in regard to converting electrical into kinetic energy. The higher the motor constant, the less heat is produced when a certain force is generated. The motor constant is temperature-dependent; with a rise in temperature comes a rise in the winding resistance leading to increased power loss.

PI has developed cylindrical motors, as shown in Figure 4, to maximize the motor constant.

They are characterized by a maximized ratio of motor constant to installation space and can be manufactured in various sizes. Cylindrical motors can be used in fast focusing applications, for moving a measuring head in a metrology system vertically. In combination with a flexure guiding system, especially compact units can be built.

Table 1 shows the performance characteristics of three examples in different sizes.

Custom encapsulated linear motors for vacuum applications are also available from PI. This results in improved heat dissipation, allowing for higher nominal forces. In addition, the sealing compound ensures that the motor is protected from external damage, e.g., during assembly.

For special applications that require high velocities or fast current rise times, PI can design motors for very high operating voltages up to 600 VDC. In this regard, linear motors benefit from the same effect that was previously described for voice coil motors. Standard industrial high-voltage servo amplifiers are available to drive these motors.

Halbach Arrays

PI can customize the length of the magnetic tracks for OEM positioning systems. Single-sided or U-shaped magnetic tracks are available. U-shaped magnetic tracks achieve higher magnetic field strengths and higher forces than single-sided magnetic tracks. If the magnets are arranged in a Halbach array, the magnetic field strength can be increased by about 10% compared to a North / South Pole arrangement. In addition, the iron counter plate can be omitted in a Halbach array, making these magnetic tracks significantly lighter (Fig 8). The advantages of using a Halbach array also apply to single-sided magnetic tracks. In this case, the use of Halbach arrays avoids the generation of high stray fields on the back of the single-sided magnetic track. PI can provide carbon supports for applications that require ultra-light magnetic tracks.

Iron-core linear motors are suitable for applications requiring high forces and accelerations with limited installation space. The iron maximizes the magnetic forces and contributes to high thermal stability. To reduce eddy current losses, the iron is laminated and it is mostly made of stacked and insulated transformer plates. The disadvantage of iron-core motors is the attraction force that arises between the iron and the magnets arranged on the opposite side. This is increased further still if a steel linear guide is used. “Cogging” is also a problem since the displacement force varies over the travel range – while this can be minimized by means of special geometries, it cannot be completely eliminated but advanced control algorithms can make it negligible for most applications. An example of an iron-core linear motor is shown in Figure 9.

Ironless and iron-core linear motors are available. For example, motors of both types are used in the V-508 linear stage series. An example of a linear stage of this series is shown in Figure 8.

The sealed motor shown in Figure 10 is an example of a proprietary linear iron-core motor developed by PI.

Ironless linear motors are suitable for positioning tasks with the highest demands on precision, linearity, and speed stability because they are not affected by cogging. They are also suitable for the smallest installation spaces thanks to their particularly flat design. Power and dynamics requirements can be met by increasing the number or dimension of the motor coils. 

In most cases, ironless motors achieve lower nominal and peak forces than iron-core motors. This is due to the lack of thermally conductive metals in the design and the resulting limited heat dissipation from the coils. However, the motors can be protected against overload by means of additional temperature sensors. An example of an ironless linear motor is shown in Figure 12.

The flat motor with a U-shaped magnetic track, shown in Figure 13, is an example of a proprietary ironless linear motor developed by PI.

Torque motors are often used in rotation stages for precision positioning and automation applications. Rotation stages based on direct drive torque motors exhibit zero play and backlash unlike worm-gear driven stages. When combined with frictionless air bearings, they provide virtually unlimited service life (Figure 14a). A torque motor is basically a radially designed 3-phase linear motor. In an alternative design, the rotor can also be represented as a rolled-up, single-sided magnetic track, while the stator houses the coils which are embedded in an iron matrix. An example of a custom torque motor developed by PI is shown in Figure 14b.

With the in-house expertise to develop proprietary motors and with the core technologies needed for a complete positioning solution, such as sensors, guides, and motion controllers, PI offers its customers competitive solutions with performance characteristics that are optimally adapted to the requirements of the application. Figure 17, for example, shows an application that combines different motor types. The multi-axis setup for autofocus applications shown consists of an X and a Z axis. The X axis, for example, holds a workpiece that is to be machined on a V-508 linear stage. As a supplement to the commonly used piezoceramic drives, the voice coil Z axis enables long travel ranges up to several millimeters. This is important, among other things, for laser material processing. Travel ranges of 1 to 7 mm are typically also required for multiphoton fluorescence microscopy and deep tissue microscopy. Furthermore, voice coils offer particularly high maximum speeds which can, for example, be used to increase throughput when using “scanning-on-the-fly mode” in digital slide scanning processes.  

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