KALWERK motor Germany KALWERK model KALWERK price

KALWERK motor refers to the engine that controls the operation of mechanical components in a servo system; it is an auxiliary motor for indirect speed variation. Servo motors can control speed with very high positional accuracy, converting voltage signals into torque and rotational speed to drive controlled objects. The rotor speed of a servo motor is controlled by the input signal and responds quickly. In automatic control systems, it serves as an actuator, featuring small electromechanical time constants and high linearity, converting received electrical signals into angular displacement or angular velocity output on the motor shaft. It is divided into two main categories: DC and AC servo motors. Its main characteristics are that there is no self-rotation when the signal voltage is zero, and the speed decreases uniformly as torque increases.

KALWERK motor mechanical characteristics

Motor features: low moment of inertia, low starting voltage, low no-load current; eliminates the contact commutation system, greatly increasing motor speed, with a maximum speed up to 100 000rpm; brushless servo motors can achieve control of speed, position, torque, etc., without an encoder during servo control; there is no brush wear, and in addition to high speed, it features long life, low noise, and no electromagnetic interference. Features of DC brushed servo motors: 1. Small size, fast action and response, high overload capacity, wide speed regulation range. 2. High low-speed torque, small fluctuation, smooth operation. 3. Low noise, high efficiency, 4. Rear-end encoder feedback (optional) constitutes advantages such as DC servo, 5. Wide voltage transformation range, adjustable frequency. DC servo motors can be applied in spark erosion machines, robotic arms, precision machinery, etc. They can be configured with 2500P/R high-resolution standard encoders and tachometers, and can be equipped with gearboxes to bring reliable accuracy and high torque to mechanical equipment. Good speed regulation, highest output power per unit weight and volume, greater than AC motors, and far exceeding stepper motors. Multi-stage structure has small torque fluctuations. Servo motors are used in closed loops. That is, they constantly transmit signals to the system and correct their operation based on signals from the system. Servo motors can also be controlled by microcontrollers.

KALWERK motor structure

The motor consists of stator poles, rotor, brushes, housing, etc. Stator poles use permanent magnets (permanent steel), including materials such as ferrite, AlNiCo, and NdFeB. According to their structural form, they can be divided into cylindrical and tile types, among others. The rotor is generally made of laminated silicon steel sheets, with enameled wire wound between the two slots of the rotor core (three slots mean three windings), and each joint is soldered to the metal segments of the commutator. Brushes are conductive components connecting the power supply to the rotor windings, possessing both conductivity and wear resistance. Permanent magnet motor brushes use single-metal strips, metal graphite brushes, or electrochemical graphite brushes. 2. Brushless DC motor: consists of a permanent magnet rotor, multi-pole winding stator, position sensors, etc. The characteristic of brushless DC motors is being brushless, using semiconductor switching devices (such as Hall elements) to achieve electronic commutation, i.e., replacing traditional contact commutators and brushes with electronic switching devices. It has advantages such as high reliability, no commutation sparks, and low mechanical noise. Position sensors commutate the current in the stator windings in a certain order according to changes in rotor position (i.e., detecting the position of rotor poles relative to stator windings, generating position sensor signals at determined positions, which are processed by signal conversion circuits to control the power switch circuit, switching winding current according to a certain logical relationship). There are three types of position sensors: magnetic, photoelectric, and electromagnetic. For brushless DC motors using magnetic position sensors, their magnetic sensing devices (such as Hall elements, magnetic diodes, magnetic transistors, magnetic resistors, or dedicated integrated circuits) are installed on the stator assembly to detect changes in the magnetic field generated by the rotation of the permanent magnet rotor. Hall elements are commonly used in electric vehicles. For brushless DC motors using photoelectric position sensors, photoelectric sensing devices are configured at specific positions on the stator assembly, and a light-blocking plate is installed on the rotor, with the light source being an LED or a small bulb. When the rotor rotates, due to the action of the light-blocking plate, the photosensitive components on the stator will intermittently generate pulse signals at a certain frequency. For brushless DC motors using electromagnetic position sensors, electromagnetic sensor components (such as coupling transformers, proximity switches, LC resonant circuits, etc.) are installed on the stator assembly. When the position of the permanent magnet rotor changes, the electromagnetic effect causes the electromagnetic sensor to generate high-frequency modulated signals (whose amplitude varies with rotor position). The operating voltage of the stator windings is provided by an electronic switch circuit controlled by the position sensor output.

KALWERK motor structure

The motor electronic commutation circuit consists of two main parts: the power conversion circuit and the control circuit. Working in conjunction with the position sensor, it controls the energization sequence and timing of each phase winding of the motor stator, playing a role similar to mechanical commutation. When the system is running, the power converter accepts control information from the control circuit, distributing the power of the system's working power supply to each phase winding on the stator of the brushless DC motor according to a certain logical relationship, so that the motor produces continuous torque. The inverter converts DC current into AC current to supply the motor. Unlike general inverters, its output frequency is not independently adjusted but is controlled by the rotor position signal, making it a "self-controlled inverter." Permanent magnet brushless motors BLDCM, due to the use of self-controlled inverters, keep the frequency of the motor input current and the motor speed always synchronized; the motor and inverter will not oscillate or lose step, which is also one of the significant advantages of permanent magnet brushless motors BLDCM. The sequence and timing of conduction for each motor winding primarily depend on signals from the position sensor, but the signals generated by the position generally cannot directly drive the power switching elements of the power converter. They often require logical processing and isolation via the control circuit before driving the switching elements of the power converter. The function of the driver box circuit is to process the rotor position signal detected by the position sensor, output it according to a certain logic code, and trigger the power switching transistors.

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