Bonfiglioli Vectron BTD-BCR servo motor

Bonfiglioli Vectron BTD-BCR servo motor

Enterprise and Product Overview

Corporate Background: Bonfly was founded in Bologna, Italy in 1956; Acquiring Vectron brand to expand industrial servo business; The three major business segments of the group are industrial, mobile engineering machinery, and wind power, with an annual output of 1.6 million equipment, certified by T Ü V and DNV quality. The product emphasizes the concepts of green, safety, and sustainability.

Application scenarios for high dynamic devices: robots, plastic/metal processing, packaging, food and beverage, winding, textile machinery. The motor must be equipped with a Bangfeili ACTION CUBE servo drive and cannot be directly connected to the power grid; Driver debugging software can achieve self-learning of motor models and achieve optimal control effects.

Compliance standards meet the EU Low Voltage Directive 73/23/EEC and EMC Electromagnetic Compatibility 89/336/EEC; Compliant with EN60034-1, EN60204-1, EN61000-6-2/-4; North American UL1004 certification (file E321737); CE marking. The manufacturer of the complete equipment is responsible for the compliance of the entire set of equipment.

Hardware standard configuration

The winding is equipped with PTC thermistor overheat protection and F-class insulation;

Free air cooling;

Standard feedback: 2-pole rotary transformer solver;

Optional: 24VDC power-off electromagnetic holding brake, multiple absolute/incremental encoders, connector multi angle steering, IP67 protection (including Viton fluororubber sealing ring version 67OV).

power supply level

230 version: Three phase 200VAC, driver DC bus 320V;

400 version: three-phase 330VAC, driver DC bus 560V;

The mechanical dimensions of the 230V/400V base are completely consistent, but the electrical parameters are different.

The parameter symbol definition sample begins with a complete definition of all selection symbols: rated speed, rated torque, locked rotor torque, peak torque, torque constant KT, back electromotive force KE, stator phase to phase resistance Rpp, inductance Lpp, thermal/electrical time constant, rotor inertia, brake parameters, axial radial FR/axial FA load, etc.

Comparison of BTD and BCR series positioning

Machine base size 2-8; Different torque levels can be obtained by changing the length K of the same flange base.

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

Advanced winding technology, optimized magnetic circuit, traditional stator winding process

Core advantages: extremely high torque density, high efficiency, compact structure, short-term large overload, wide torque speed range

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

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

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

Selection logic: BTD is selected due to limited installation space; Need frequent impact and prioritize BCR for large and short-term peak loads. The document includes a bar chart for a visual comparison of the two series' locked rotor torque, torque density, and overload capacity.

Model naming and coding rules

The model is divided into a basic segment (required) and an optional configuration segment (to be filled in only when deviating from the default).

Default factory benchmark configuration

IP65 protection, keyless output shaft, no brake, 2-pole rotary transformer, vertical 8-pin power connector, vertical 12 pin signal connector, CE-UL-cUL certification.

1) Basic segment example

BTD 2‑0026‑45‑230 / BCR 8‑1150‑20‑400

Series: BTD/BCR

Machine size: 2-8

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

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

Voltage level: 230=200VAC; 400=330VAC (BCR8 supports 350VAC)

2) Optional suffix

K: Output shaft DIN6885 standard flat key; Default no keyway;

FD24: DC24V loses power and maintains braking; The brake is pre installed at the factory and cannot be installed later on site, increasing the total length of the motor;

Power connector: PA08 facing flange, PB08 facing away from flange, PT08 rotatable; Default vertical;

Signal connector: CA12 facing flange, CB12 facing away from flange, CT12 rotatable; Default vertical;

Feedback device:

Default: 2-pole Resolver rotary transformer;

S1-S3: Heidenhain sine cosine incremental encoder;

D1-D4: Absolute value of EnDat;

H1-H8: Piperface absolute value encoder;

Protection level: 67=IP67; 67OV=IP67+Viton fluororubber O-ring;

Mechanical interface: default to standard IMB flange shaft; Non standard interfaces require a technical feasibility assessment from the manufacturer.

Mechanical interface and installation

Standard IMB mechanical interface: flange+output shaft; Key dimensions: flange H, centering diameter A, bolt circle B, shaft diameter D, shaft extension E; each machine base has a fixed standard size table.

Shaft load limit: Each model clearly specifies the maximum radial load FR and axial load FA of the output shaft, and the selection must be verified to prevent bearing damage.

Whole machine length K: Within the same machine base, the body length K increases with the increase of torque; After installing brakes, the overall length of the machine further increases; The sample provides length and weight with/without brakes.

Brake instruction (FD24): Used only for parking maintenance and strictly prohibited as a dynamic working brake; 24VDC power supply; The braking parameters (holding torque, power consumption, inertia, suction/release time) are all provided in the data sheet, and the brake cable is integrated into the power connector.

All machine bases come with 2D exterior drawings: flange, shaft, mounting holes, and overall length K view.

5、 Feedback system

Standard configuration: 2-pole rotary transformer Resolver

Absolute accuracy ± 4 arcminutes, maximum ripple of 1 arcminute; The maximum allowable speed is 20000 rpm; Excellent resistance to vibration and impact;

Motivate 7Vrms/5kHz; Working temperature -55~+155 ℃;

The document includes a schematic diagram of the working principle of the Resolver and an accuracy error curve.

Optional encoders: Heidenhain incremental sine and cosine, EnDat, Hiperface multi model absolute value encoder; The feedback signal and PTC temperature measurement are all consolidated into a 12 pin signal connector.

Electrical connector

Using Intercontinental circular aviation plug, the motor body is male and the cable side is female:

Power connector (8-pin): U/V/W three-phase, PE grounded; Reserve brake power pins (even if there are no brake pins physically present); BTD2-5 and BCR2-7 use size1; BCR8 uses size 1.5.

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

Connector orientation options: vertical (default), facing towards the flange, facing away from the flange, rotatable angle.

Complete technical data sheet (BTD2-5, BCR2-8)

Two complete electrical parameter tables, 400VAC and 230VAC, are provided separately for each motor specification. The testing conditions are: ambient temperature of 40 ° C and winding temperature rise of 105 ° C. The table contains:

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

Back electromotive force constant KE, torque constant KT;

Stator phase resistance Rpp, inductance Lpp;

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

Weight of the whole machine without brakes and with brakes;

Maximum radial FR and axial FA loads on the shaft;

S1 (continuous working system, blue area), S3 (intermittent short-term working system, gray area) torque speed curve chart.

BTD covers Size2-5; BCR covers Size2-8; BCR8 supports the 2000rpm low-speed high torque version.

Important usage constraints and precautions

The servo motor must be paired with an Active CUBE servo drive from Bangfeili and cannot be directly connected to the mains power supply; The operator must be a professionally trained technician.

Electromagnetic brakes are only used for stopping and holding, and cannot be used for dynamic braking; The power supply is strictly DC24V; Brakes cannot be installed on-site, please specify when placing an order.

The radial and axial working loads of the output shaft are not allowed to exceed the given FR and FA limits of the sample.

Standard protection IP65; IP67 must be ordered and specified as 67 or 67OV.

Priority should be given to selecting the standard rotary transformer solver for harsh and strong vibration impact conditions; Absolute value encoder is selected for high-precision positioning scenarios.

The winding PTC temperature protection is connected to the driver signal connector to achieve motor overheating alarm and shutdown.

Motor size K: Same flange, the larger the torque, the longer the body; Installing brakes will increase the axial length of the entire machine.