Bonfiglioli BTD-BCR synchronous servo motor

Bonfiglioli BTD-BCR synchronous servo motor

Company background, application and basic explanation

Background: Bonfiglioli was founded in Bologna, Italy in 1956, and acquired the Vectron brand to expand its industrial servo drive business; The business is divided into three major sectors: industrial, mobile machinery, and wind power, with an annual output of 1.6 million units, certified by T Ü V and DNV quality systems.

Applicable scenarios: robots, plastic/metal processing, packaging, food and beverage, winding, textile and other high dynamic equipment; The motor must be used in conjunction with the corresponding servo driver, which is an integral part of the entire actuator system; Paired with the ACTION CUBE frequency converter, the self-learning function can be used to optimize the motor control model.

Standard compliance

Meets the Low Voltage Directive 73/23/EEC, EMC Electromagnetic Compatibility Directive 89/336/EEC, and complies with EN 60034-1, EN60204-1, EN61000-6-2/4;

The North American market meets UL1004 (file E321737);

The manufacturer of the complete machine equipment needs to ensure that the entire machine complies with regulations, and the motor is only used as a component of the equipment.

All motors come standard with PTC thermistor winding overheat protection (F-class insulation); Free air cooling; 2-pole rotary transformer as standard feedback. Optional accessories: 24VDC electromagnetic holding brake, multiple absolute encoders, changing connector direction, higher protection level IP67.

The power supply specification is three-phase AC input, with two voltage levels of 230VAC (driver bus 320V) and 330VAC (driver bus 560V). The mechanical dimensions of the 230V/400V version are exactly the same as the mechanical model, with only different electrical parameters.

Parameter symbol table: Define all selection symbol units such as rated speed nn, rated torque Mn, locked rotor torque Mo, peak torque Mmax, torque constant KT, back electromotive force constant KE, stator resistance Rpp, stator inductance Lpp, electromechanical/electrical thermal time constant, rotor inertia JM, brake parameters, etc.

Core differences between BTD and BCR series

Project BTD series (Brushless Torque Density) BCR series (Brushless Classic Range)

Advanced pole winding technology, traditional stator winding technology

Positioning high torque density, compact size, high efficiency, wide torque speed range, high instantaneous overload

Machine base specifications Size2-5 (flange 55~142mm) Size2-8 (flange 55~240mm)

Locking torque range BTD2: 0.26-0.95Nm; BTD3：0.95‑4.2Nm； BTD4：4.1‑8.6Nm； BTD5：11.6‑27.3Nm； The maximum torque density can reach 5.6Nm/dm ³ BCR2-8, with a locked rotor torque of 0.2-115Nm; the maximum overload for small machine bases is 400%, and for large machine bases it is 300%

Typical rated speed BTD: 4500rpm; BTD3‑5：3000rpm BCR2‑3：4500rpm； BCR4‑7：3000rpm； BCR8：2000/3000rpm

Medium overload capacity, high overload, some specifications have a short-term peak torque of 400%

Selection logic: BTD is preferred due to limited space; BCR is preferred for large and short duration impact and wide speed range.

By changing the length K of the motor body, the same flange base can achieve multiple levels of torque; The flange size remains unchanged, and the body is lengthened to increase torque.

Provide a complete electrical meter for each model (400V version and 230V version separated); Contains torque speed curves for S1 continuous operation and S3 intermittent operation; The maximum allowable radial load FR and axial load FA for the shaft; the length, weight, and rotor inertia of the entire machine with/without brakes.

Model Naming Rules

Naming is divided into basic segment (required) and optional configuration segment (optional).

1) Basic segment example

BTD 2‑0026‑45‑230 / BCR 8‑1150‑20‑400

Series: BTD/BCR

Machine base size: 2-8

Locking torque code: 0026 represents 0.26Nm, 1150 represents 115Nm

Rated speed: 20=2000rpm; 30=3000rpm； 45=4500rpm

Power supply voltage: 230=200VAC; 400=330VAC

2) Optional configuration segment

K: Output shaft with DIN6885 keyway; Default no keyway;

FD24: Add 24VDC electromagnetic power-off to maintain braking; The brake is not included in the factory and cannot be installed later after leaving the factory; Increase the total length of the motor;

Power connector: default vertical 8-pin; PA08/PB08/PT08: Flange forward, reverse, rotatable 8-pin power connector;

Signal connector: default vertical 12 pin; CA12/CB12/CT12；

Feedback encoder: default 2-pole rotary transformer; S1-S3 Heidenhain incremental sine and cosine; Absolute value of D1-D4 EnDat; H1-H8 Hiperface absolute value encoder;

Protection level: default IP65; Fill in 67=IP67; 67OV=IP67 fluororubber O-ring;

Mechanical interface: default IMB standard flange shaft, special interfaces need to apply for evaluation from Bangfeili Technology Center.

Standard factory configuration summary: IP65 protection; Keyless output shaft; No brakes; 2-pole rotary transformer; Vertically fixed 8-pin power connector+12 pin signal connector; CE/UL-CUL certification. To modify any item, you need to fill in the corresponding optional fields.

Mechanical interface and installation

Mechanical interface definition: flange+output shaft, defining flange H, centering diameter A, bolt distribution B, shaft diameter D, shaft extension E; each size has a fixed standard IMB size table; Support customized non-standard interfaces, requiring manufacturers to evaluate feasibility.

Output shaft load: The maximum radial FR and axial FA (N) are given for each model, and the selection must verify the shaft load to avoid bearing damage.

Dimensional drawings: Provide outline drawings for each machine base; Distinguish between total length K with and without brakes; brakes will lengthen the motor.

Brake (FD24 option): Permanent magnet power-off brake, powered by DC24V; Only used for parking maintenance and cannot be used as a working brake; List of brake torque, power consumption, inertia, and weight for different machine bases; The brake cable is integrated into the power connector. Attention: Models that do not come with brakes from the factory cannot have brake components installed on site later.

Feedback system

1. Standard configuration: 2-pole rotary transformer Resolver

Accuracy: Absolute accuracy ± 4 arcminutes, maximum ripple of 1 arcminute; The maximum speed is 20000rpm; Excellent shock and vibration resistance.

Electrical parameters: transformation ratio of 0.5, excitation of 7Vrms/5kHz; Temperature range -55~+155 ℃; Provide a complete specification table for all parameters.

Paired with the ACTION series drivers, it can reduce harmonic errors and further improve position accuracy.

2. Optional encoders (Heidenhain, Sick Stegmann)

Incremental sine and cosine: ERN1387, ERN185;

EnDat2.1 absolute values: ECI1319, EQI1331, ECN1113, EQN1125;

Hiperface Absolute Value: SRS50/SRM50/SKS36/SKM36/SEL/SEK Series;

All feedback device signals and PTC temperature signals are consolidated into a 12 pin signal connector.

Thermal protection system (standard for all models)

PTC positive temperature coefficient thermistor, compliant with DIN44081, F-class motor insulation; Connected in series with the winding, the resistance rises sharply when the temperature exceeds the threshold, and the driver alarms and stops after detection.

The pins are defined at pin 2 (PTC+) and pin 6 (PTC -) of the 12 pin signal connector; Double insulation, meeting the EN61800-5-1 safety standard.

Electrical connector

Two types of Intercontinental circular connectors, with all male connectors on the motor body and female connectors on the cable side:

Power connector (8-pin): U/V/W three-phase, PE grounded; Reserve brake power pins (even without brakes); BTD2-5 and BCR2-7 use size1; BCR8 uses size 1.5.

Signal connector (12 pins): Resolver/encoder all signals+PTC temperature measurement signal.

Connector orientation options:

Default: Vertical up;

PA/CA: Facing the output flange; PB/CB: Back to flange; PT/CT: rotatable angle.

Performance Chart Explanation

Each model of the sample (BTD2~5, BCR2~8) is provided with two complete data sheets of 400VAC and 230VAC, including:

Locking torque Mo, rated speed nn, rated torque Mn, rated/locked/peak current;

Back electromotive force constant KE, torque constant KT;

Phase stator resistance Rpp, inductance Lpp;

Rotor moment of inertia JM; electrical, thermal, and mechanical time constants;

Without brakes, with brake weight;

S1 (continuous working system blue area) and S3 (intermittent short-term gray area) torque speed curve chart, conditions: environment 40 ℃, winding temperature rise 105 ℃.

Key usage precautions

The servo motor must be paired with a Bangfeili matched servo drive; Cannot be directly connected to the power grid; Professional mechanical and electrical technicians are needed for debugging.

The brake is only used for stopping and holding, and cannot be used for dynamic braking; The braking voltage is strictly DC24V.

The radial and axial loads of the shaft must be less than the sample limit.

Standard protection IP65; IP67 must be ordered with the 67/67OV option specified.

Different torques on the same machine base are distinguished by the length K of the body; After installing the brake, the overall length of the machine increases.

Feedback device selection: Priority should be given to standard rotary transformers in harsh vibration and impact environments; Absolute value encoder can be used for high-precision positioning.