αSTEP
Un motore stepper ibrido che combina i vantaggi del controllo "ad anello aperto" e "ad anello chiuso". Ideale per applicazioni in cui è richiesto un controllo preciso di posizione, velocità e coppia.
Suggestions on Solving Problem With Stepper Motors and Servo Motors
αSTEP
Overview and Related Information
What is αSTEP?
What is αSTEP (Alpha step)?
αSTEP is a stepper motor based motor with a unique control that hybridizes open loop control and closed loop control.
Stepper motors are motors capable of accurately controlling rotation angle and speed in an open loop and are widely used in industrial fields such as semiconductor manufacturing equipment and medical analyzers. αSTEP was developed with the idea of increasing the reliability of stepper motors with open loop control. As with servo motors, αSTEP can provide high-precision positioning and speed control, as well as control to limit the torque generated by the motor to any desired value. Its high torque in the mid to low speed range makes it good for short-range positioning. Another attractive feature is its extensive product line which includes DC input and compact sizes.
- *The output power (W) of a servo motor is indicated as "rated output power" when it is running at "rated speed." On the other hand, since stepper motors, with their characteristic high precision positioning and high torque at medium and low speeds, have no "rated speed," no "rated output power" is given. Since the output power (W) calculated by the "rotation speed" also changes, the torque of a standard type motor is shown here as a reference to determine how many W corresponds to the rated torque of a servo motor.
αSTEP automatically switches between open loop control and closed loop control depending on the situation, while constantly monitoring the position and other factors. Normally, as with stepper motors, the movement is synchronized with the command by open loop control. If the position deviation exceeds ±1.8 ° due to overload, it switches to closed loop control like a servo motor to compensate.
History of αSTEP
The AS Series of the first αSTEP was launched in 1998. In 2007, the AR Series was launched to meet the needs of power saving and low heat generation of motors and industrial network compatibility. It was recognized as an energy-saving product and received the 29th Minister of Economy, Trade and Industry Award for Excellent Energy-Saving Equipment in 2008. Then in 2013, the AZ Series with a battery-free multi-rotation absolute encoder was launched. Absolute systems could now be built without batteries. Thus, over the past 20 years, αSTEP has continued to evolve in response to the changing times. Today, our products have been well-received by many customers and are used in a wide range of applications including factory automation (FA), semiconductors, electronic component manufacturing equipment, and medical equipment.
αSTEP’s Strengths
Design
High Response
Short distances can be moved in a short period of time by utilizing the stepper motor’s high response. The motors can execute commands without lagging.
Continues Operation Even With Sudden Load Fluctuation and Sudden Acceleration
The responsiveness of open loop control, which has no time lag with commands, creates agile movements. Sudden load fluctuations are handled by closed loop control. In the unlikely event of an abnormality, an alarm signal is output.
Holding the Stop Position Without Hunting
During positioning, the motor stops with its own holding force without hunting. Because of this, it is ideal for applications where the low rigidity of the mechanism requires absence of vibration upon stopping.
Tuning-Free
Because it is normally operated with open loop control, positioning is still possible without gain adjustment even when the load fluctuates due to the use of a belt mechanism, cam, or chain drive, etc.
Power Saving
Motor Loss Reduction
We reviewed the iron core materials used in the motor and optimized the magnetic circuit and stator windings. In the vicinity of 1000 r/min, where the loss peaks, the loss at no load is reduced by approximately 90 W, from 120 W to 30 W, in the conventional product. The loss at maximum load (100 % load factor) is also reduced from 80 W to 25 W, a reduction of approximately 55 W.
Reduced Driver Power Consumption
The PWM control of the driver has been improved to significantly reduce losses. The power consumption of the motor and driver as a combined unit is also greatly reduced. The table on the right shows a comparison of power consumption at 1000 r/min, and indicates that at a load factor of 50 % achieves energy savings of 45 % compared to conventional models.
Lower Motor Heat Generation
Reducing power consumption simultaneously lowers the heat generation of the motor. In conventional products, with an ambient temperature of 25 °C and a rotation speed of 1600 r/min, the outer coating temperature reaches about 100 °C under the operating conditions of 2-second operation and 3-second stop, while the ARM66AC has an outer coating temperature of about 50 °C under the same conditions, reducing the temperature rise to 1/3.
Product Line
In addition to standard type motors, we also have geared motors and electric actuators that combine motors with mechanical components. Drivers are available with AC input (100 V-240 V) and DC input (24 VDC/48 VDC). Many products compatible with various industrial networks are also available. Selecting motors and drivers from the same series within the same device makes it possible to consolidate the components used for wiring, control, and maintenance, thereby reducing the time and effort required for start-up.
Availability
Global Support Overseas Standards
Products are available in voltage specifications of single-phase 100 VAC/200 VAC system, three-phase 200 VAC system and DC input, allowing use in major countries around the world. Each Series is UL/CSA Standards certified, EN Standards compliant, and has the CE Marking.
Adoption Results
αSTEP can control not only high-precision positioning and speed control, but also limit the torque generated by the motor to a given value. Its high torque in the mid to low speed range makes it good for short-range positioning. Another attractive feature is its extensive product line which includes DC input and compact sizes. It has been employed in a wide range of applications where these characteristics can be utilized. Here are some actual adoption results, along with the main reasons why they were adopted.
FA (Factory automation)
The machine is used for automation in factories that require many movements such as carrying, pushing, pulling, and grabbing. We support the movement you are seeking with various industrial networks and electric actuators.
Semiconductor Manufacturing Equipment
It has been used for many years in semiconductor manufacturing equipment that require micron-level accuracy. Vibration be suppressed not only during transport, but during standstill as well.
Precision Stages
αSTEP is used for precision stages that need to move precisely to a given position. High-precision positioning is achieved in a variety of equipment such as analyzers and inspection devices.
Medical Dispensing Equipment and Analyzers
Our products have been trusted and used for many years in the field of medical equipment, where more reliable characteristics and quality are required.
Closed-loop control outputs an alarm in case of emergency and notifies the user of motor rotation abnormalities.
Food Weighing and Packaging Machines
Our products are used in weighing and packaging machines that require equipment with high processing speed. Their power is demonstrated via repetitive positioning with short strokes, such as label pasting, and contributes to shorter equipment takt time.
In-House Robots
In recent years, the employment of our products for in-house robots has been increasing. It contributes to the compactness and light weight as well as the condition monitoring and torque limitation required for robots.
Examples of In-House Production of Equipment
We also use αSTEP in in-house equipment at our manufacturing sites. In addition to the structure and system configuration of the equipment, important points for product selection in each axis are explained.
We have a page that provides information on our support from equipment design to start-up.
Responding to Robot Needs
Against the backdrop of a shortage of human resources, there has recently been a growing demand for "robots that can replace human labor." There are also an increasing number of situations where companies are starting to consider building robots in-house that are smaller and can carry out the required line work. The αSTEP AZ Series is equipped with an absolute system that eliminates the need for a battery, as well as a compact control motor to meet the needs of robot miniaturization and self-production.
Mechanical Multi-Rotation Absolute Encoders Reduce Sensor Use and Eliminate Batteries
With the αSTEP AZ Series, external sensors such as home can be reduced, contributing to a compact configuration with less wiring. The [ABZO] mechanical multi-rotation absolute encoder retains position information even if the power supply is interrupted during positioning operation due to an emergency stop or power failure. Since it is mechanical, it does not require a battery for data retention. There is no need to worry about the cost of purchasing batteries, problems occurring during operation, or maintenance periods. In addition, the AZ Series motors themselves can take the place of sensors and convert the robot's status into numerical values.
Monitoring Robot Status for Optimal Control
Not Too Much Torque
Output torque can be restricted to prevent damage to the mechanism and motor. A TLC signal is also output when the setting limiting value is reached, which can be detected and used on the PLC side.
Abnormality Detection and Stopping Before Alarms
Using information on torque and position, it is possible to detect predictable abnormalities before alarms register. The system can also be configured to take output signals to the host controller for immediate stoppages.
Speed and Torque Restrictions for Each Operation Area
Signals can be input based on information from external sources like area sensors and operations can switch to preset torque and speed levels.
Capable of Monitoring and Collecting a Range of Motor Statuses
Some statuses inside feedback can output a signal when a preset threshold value is reached. This can be used for preventive maintenance and to improve equipment safety.
Motor Temperature Monitoring
Real-time monitoring of robot motor temperature is possible.
Cumulative Load Monitor
The motor's load factor can be ascertained by area and detected as a value. This is useful when you want to know changes in long-term loads such as deterioration over time.
ODO/TRIP Monitor
Allows you to monitor the total number of rotations of the motor. This can be used for maintenance, etc.
Product Line of Compact and Lightweight Motors That Reduce Load on Robot Mechanism Tips
A wide range of compact and lightweight motors and actuators are available. It also contributes to downsizing the robot and reducing the load on each arm axis when used for end effectors.
Related Products
We also offer a robot controller that allows you to easily set up, program, and run the robot you have created with the αSTEP AZ Series.
Product Line
αSTEP Product Line
αSTEP AZ Series
-
Mechanical Multi-Rotation Absolute Encoder
Absolute position detection is possible with ±900 revolutions (1800 revolutions)* of the motor shaft from the reference home position.- *±450 revolutions (900 revolutions) for products with 20 mm, 28 mm (30 mm) frame size.
- Battery-Free
Because positioning information is managed mechanically by the ABZO Sensor, the positioning information can be preserved, even if the power turns off, or if the cable between the motor and the driver is disconnected.
Product Line
| Series | AZ Series | |
|---|---|---|
| Features |
|
|
| Position Sensor |
ABZO (Battery-free multi-rotation absolute encoder) 
|
|
| Motor Resolution | 3.6˚~0.036˚ | |
| Homing Method | Pushing | ○ |
| External Sensor | ○ | |
| Absolute System | No battery required | |
| Continuous Operation | △ (Possible up to motor sensor temperature of 85 °C) |
|
| Motor Type |
Standard Type |
|
| Actuator Type |
Electric Linear Slides |
|
| Driver Type |
Pulse Input |
|
| Compatible Network Type |
EtherNet/IP™ |
|
| Sequence Function | ○ | |
| Power Removal Function | ○ | |
| Data Collection Function | ○ | |
Motor/Actuator Types
Motor/Geared Motor Product Line
A wide range of motors from the industry's smallest motor with a frame size of 20 mm to various geared motors is available. The optimal type can be selected from the various geared motors based on torque, accuracy (backlash) and price.
Standard Type
Frame size 20 mm~85 mm
TS/TH geared(spur gear mechanism)
Frame size 42 mm~90 mm
Right-Angle FC Geared Type
(Face gear mechanism)
Frame sizes 42 mm, 60 mm
PS Geared Type
(Planetary gear mechanism)
Frame size 28 mm~90 mm
HPG Geared Type
(Harmonic Planetary®)
Frame size 40 mm~90 mm
Harmonic Geared Type
(Harmonic Drive®)
Frame size 30 mm~90 mm
αSTEP Equipped Electric Actuators Product Line
Oriental Motor has a range of electric actuators, consisting of motors and mechanical components, to meet the needs of various automated equipment. Motors and actuators have the same usability. By selecting products equipped with the AZ Series, it is possible to go without external sensors, reducing the burden on electricians and maintenance personnel.
Electric Linear Slides
Electric Cylinders
Compact Electric Cylinders
Hollow Rotary Actuators
Electric Grippers
Rack-and-Pinion System
Driver Types
Industrial Network Compatible Drivers
Products supporting EtherNet/IP, PROFINET, and EtherCAT respectively are available.
A single communication cable is used to connect the driver to the host control device, thus saving wiring.
- EtherNet/IP Compatible Drivers
- PROFINET Compatible Drivers
- EtherCAT Compatible Drivers
- EtherCAT Compatible Multi-axis Drivers
αSTEP AZ Series mini Driver
This compact driver can be controlled via RS-485 communication. The elimination of switch and I/O connector has resulted in a smaller and lighter driver. Compact design for installation in tight spaces. Weighing only 56 g, the lightweight design reduces load torque and inertia even when installed in moving parts, contributing to greater flexibility in mechanical and control cabinet design.
Built-In Controller Type Driver
With this type, operation data is set in the driver, then selected and executed from the host system. Host system connection and control are performed with any of the following: I/O, Modbus (RTU)/RS-485 communication, or an industrial network. Using the network converter (sold separately), CC-Link, MECHATROLINK, and EtherCAT communications are possible.
Pulse Input Driver
Operation is executed according to the pulse signal input to the driver. Motor control is performed from a positioning module (pulse generator) provided by the customer.
Support software (MEXE02) can also be used to check the alarm history and monitor status information.
For Those Who Have Not Decided on a Series
View More About the Selection Guide
Selection Guide
This selection guide will help you find the product series best suited for your equipment. Select an equipment application example and follow the guidance to select a product series.
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View More about the Problem Solving Case Studies
Problem Solving Case Studies
Here is the information on the solutions for your equipment issues. We introduce examples of in-house production of equipment used in actual manufacturing sites, as well as application examples of our recommended products to solve the issues with conventional equipment.
Learn More