Antriebssysteme

Technical EN

Information

WEWE
CREATE MOTION
CREATE MOTION DE

1
Imprint

As at:
2nd edition, 2010 – 2011

Copyright
by Dr. Fritz Faulhaber GmbH & Co. KG
Daimlerstr. 23 / 25 · 71101 Schönaich

All rights reserved, including translation rights. No part

of this description may be duplicated, reproduced, stored
in an information system or processed or transferred in any
other form without prior express written permission of
Dr. Fritz Faulhaber GmbH & Co. KG.

This document has been prepared with care.

Dr. Fritz Faulhaber GmbH & Co. KG cannot accept any
liability for any errors in this document or for the
consequences of such errors. Equally, no liability can be
accepted for direct or consequential damages resulting
from improper use of the products.

Subject to modifications.

The respective current version of this document is avail-

able on FAULHABER‘s website: www.faulhaber.com

2
Contents

DC-Micromotors DC-Micromotors 4 – 12
Flat DC-Micromotors & DC-Gearmotors

Brushless DC-Motors Brushless DC-Micromotors 13 – 23

Brushless DC-Servomotors
Brushless DC-Motors with integrated Speed Controller
Brushless Flat DC-Micromotors & DC-Gearmotors

Motion Control Systems Brushless DC-Servomotors 24 – 27

Stepper Motors Stepper Motors 28 – 33

Lead Screws

Linear DC-Servomotors Linear DC-Servomotors 34 – 39

Precision Gearheads Precision Gearheads 40 – 46

Encoders Encoders – 2 Channel 47 – 52

Encoders – 3 Channel

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3
DC-Micromotors

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4
DC-Micromotors
Technical Information

General information
The lifetime, depending on the application type, may DC-Micromotors
exceed the 10 000 hours. Higher speeds cause accelerated Precious Metal Commutation
mechanical wear, resulting in reduced lifetime.
Also excessively high current and temperature shortens
the lifetime. On the average, lifetime of up to 1 000 hours
for metal brushes, and more than 3 000 hours for graphite Series 0615 ... S
0615 N
brushes can be expected when the motors are operated 1 Nominal voltage UN
2 Terminal resistance R
within recommended values indicated on the data sheet. 3 Output power P2 max.
4 Efficiency  max.
These values do not influence each other. It is advisable
that the current under load in continuous operation 5 No-load speed no

should not be higher than one third of the stall current.

Notes on technical data
In motors with graphite brushes the relationship between
stall current and current under load depends on the All values at 22 °C.
All values at nominal voltage, motor only, without load.
delivered power and frame size. The motors should not
be operated at the stall torque MH, otherwise after a short Nominal voltage UN [Volt]
period of time, the commutation or the windings could be The nominal voltage at which all other characteristics
damaged. indicated are measured.
The motor develops its maximum power P2 max. at exactly Terminal resistance R [Ω] ±12%
half the stall torque MH which also corresponds to half the The resistance measured across the motor terminals.
speed. For reasons of life performance, this working point The value is directly affected by the coil temperature
should only be selected for intermittent periods. (temperature coefficient: α22 = 0,004 K-1).
For exceptional long life performance, brushless DC-Motors
are available. Output power P2 max. [W]
The maximum obtainable mechanical power achieved
Unspecified tolerances: at the nominal voltage.
Tolerances in accordance with ISO 2768 medium.
2
R –––U
≤ 6 = ± 0,1 mm P2 max. = –– · N – Io
4 R
≤ 30 = ± 0,2 mm
≤ 120 = ± 0,3 mm Efficiency ηmax. [%]
The max. ratio between the absorbed electrical power and
Motors with tighter tolerances and tolerances of values
the obtained mechanical power of the motor.
not specified are given on request.
It does not always correspond to the optimum working
Bearing options: point of the motor.
– Standard: Unless otherwise stated, vacuum impregnated
sintered bearings are used Io· R 2
= 1– ––––
max. · 100
UN
– Optional: Shielded ball bearings
No-load speed no [rpm] ±12%
Motor shaft:
Describes the maximum speed under no-load conditions
All dimensions with shaft pushed against motor.
at steady state and 22 °C ambient temperature. If not
Motor choice: otherwise defined the tolerance for the no-load speed is
The listed motor types represent standardised executions. assumed to be ±12%.
However, a variety of further coil possibilities are available.
no = (UN – Io · R) · kn

No-load current Io [A] ±50%

Describes the current consumption of the motor without
load at an ambient temperature of 22°C after reaching a
steady state condition. The tolerance is given at +/-50%.

5
The no-load current is speed and temperature dependent.
m = 100 ·R·J
–––––––––
Changes in ambient temperature or cooling conditions kM 2
will influence the value. In addition, modifications to the
Rotor inertia J [gcm2]
shaft, bearing, lubrication, and commutation system or
Rotor‘s mass dynamic inertia moment.
combinations with other components such as gearheads or
encoders will all result in a change to the no-load current Angular acceleration α max. [·103 rad/s2]
of the motor. The acceleration obtained from standstill under no-load-
conditions and at nominal voltage.
Stall torque MH [mNm]
The torque developed by the motor at zero speed max.
MH· 10
= –––––––
and nominal voltage. This value is greatly influenced J
by temperature. Thermal resistance Rth1/Rth2 [K/W]
UN – I Rth1 corresponds to the value between the rotor and
MH = kM · ––– o
R housing. Rth2 corresponds to the value between the
housing and the ambient air.
Friction torque MR [mNm]
Rth2 can be reduced by enabling exchange of heat between
Torque losses caused by the friction of brushes, bearings
the motor and the ambient air (for example using a heat
and commutators. This value is influenced by temperature.
sink or forced air cooling).
MR= kM · Io Thermal time constant τw1 / τw2 [s]
The thermal time constant specifies the time needed for
Speed constant kn [rpm/V] the rotor and housing to reach a temperature equal to
The speed variation per Volt applied to the motor 63% of final value.
terminals at constant load.
Qm
Final
no
kn = –––––––– =1 000
––––– temperature
UN – I o · R kE

Back-EMF constant kE [mV/rpm] 63,2 % of

Final (t) Thermal time constant
The constant corresponding to the relationship between temperature
the induced voltage in the rotor at the speed of rotation.
2
· kM
kE = –––––– T th
t
60

Torque constant kM [mNm/A] Operating temperature range [°C]

The constant corresponding to the relationship between Indicates the min. and max. motor operating temperature,
the torque developed by the motor and the current drawn. as well as the maximum permitted rotor temperature.
Current constant kI [A/mNm] Shaft bearings
The constant between the current in the motor and the The bearings used for the DC-Micromotors.
torque developed.
Shaft load max. [N]
1
kl = ––– The output shaft load at a specified shaft diameter for the
kM
primary output shaft. For motors with ball bearings the
Slope of n-M curve Δn/ΔM [rpm/mNm] load and lifetime are in accordance with the values given
The ratio of the speed variation to the torque variation. by the bearing manufacturers. This value does not apply to
The smaller the value, the more powerful the motor. second, or rear shaft ends.

n = –––––––
30 000 –––R Shaft play [mm]
––– · 2

M  kM The shaft play on the bearings, measured at the bearing
Rotor inductance L [μH] exit.
The inductance measured on the motor terminals at 1 kHz. Housing material
Mechanical time constant τm [ms] The housing material and the surface protection.
The time required for the motor to reach a speed of 63% Weight [g]
of its final no-load speed, from standstill. The average weight of the basic motor type.

6
DC-Micromotors
Technical Information

Direction of rotation Duty cycle δ = 100 %

Supply voltage U = 20 V DC
The direction of rotation is viewed from the front face. Current source, max. I = 0,5 A
Positive voltage to the + terminal gives clockwise rotation Space max. diameter = 25 mm
of the motor shaft. All motors are designed for clockwise length = 50 mm
Shaft load radial = 1,0 N
(CW) and counterclockwise (CCW) operation; the direction axial = 0,2 N
of rotation is reversible.

Recommended values Preselection

The maximum recommended values for continuous The first step is to calculate the power the motor is
operation to obtain optimum life performance are listed expected to deliver:
below. The values are independent of each other.


P2 = M · n ––––––––– [W]
The values will be reduced with thermal insulation and 30 · 1 000
elevated temperature but can be increased with forced
cooling.

P2 = 3 · 5 500 ––––––––– = 1,73 W
30 · 1 000
Speed ne max. [rpm]
The maximum recommended operating speed. A motor is then selected from the catalogue which will
Torque Me max. [mNm] give at least 1,5 to 2 times the output power [P2 max.] than
The maximum recommended torque rating. the one obtained by calculation, and where the nominal
voltage is equal to or higher than the one required in the
Current Ie max. [A] application data.
The maximum allowable current, based on the thermal
The physical dimensions (diameter and length) of the
limits of the max. permissible standard rotor temperature
motor selected from the data sheets should not exceed the
at 22 °C ambient.
available space in the application.
How to select a DC-Micromotor P2 max. ≥ P2 UN ≥ U
This section reviews a step-by-step procedure on how
to select a DC-Micromotor. The procedure allows calcula- The motor selected from the catalogue for this particular
tion of the parameters in order to produce a graph of application, is series 2233 T 024 S with the following
the characteristics and per-mitting the definition of the characteristics:
motor‘s behaviour. To simplify the calculation, in this Nominal voltage UN = 24 V DC
example continuous operation and optimum life perform- Output power, max. P2 max. = 2,47 W
Frame size: diameter Ø = 22 mm
ance are assumed and the influence of temperature and length L = 33 mm
tolerances has been omitted. Shaft load, max.: radial = 1,2 N
axial = 0,2 N
Application data: No-load current Io = 0,005 A
The basic data required for any given application are: No-load speed no = 8 800 rpm
Stall torque MH = 10,70 mNm
Required torque M [mNm]
Required speed n [rpm] Caution:
Duty cycle δ [%] Should the available supply voltage be lower than the
Available supply voltage, max. U [V DC]
Available current source, max. I [A] nominal voltage of the selected DC-Micromotor, it will be
Available space, max. diameter/length [mm] necessary to calculate [P2 max.] with the following equation:
Shaft load radial/axial [N]
2
R –––U
The assumed application data for the selected example are: P2 max. = –– · N – Io [W]
4 R
Output torque M =3 mNm
Speed n = 5 500 rpm
2
P2 max. (20 V) = ––– 20 – 0,005
57 ––– = 1,70 W
·
4 57

7
Optimizing the preselection
Graph 1
To optimize the motor‘s operation and life performance, Efficiency Output-
power Current Speed
the required speed [n] has to be higher than half the no- 
P2
I n

load speed [no] at nominal voltage, and the load torque [M] (%) (W) (A) (rpm)

has to be less than half the stall torque [MH]. 3,0 0,5 10 000

n o = 8 800 rpm

no
n ≥ ––– MH
M ≤ –––
9 000
P2 max = 2,47 W
2,5
2 2 100 0,4 8 000
I
IH = 0,421 A

nt
90 rre
7 000 cu

max = 80 %
From the data sheet for the DC-Micromotor, 2233 T 024 S 80
2,0

0,3 6 000
ef
the parameters meet the above requirements. 70 fic
ienc
y
1,5 5 000
60

out
is greater

put
no
n (5 500 rpm) ≥ ––– 8 800 = 4 400 rpm
–––––
50 0,2 4 000
sp

pow
2 than 2 40 1,0
3 000
ee
d
n

er
30
0,1 2 000
20 0,5
M
MH is less 10,70
M (3 mNm) ≤ ––– ––––– = 5,35 mNm 10
1 000 Torque
2 than 2 0 0 0 0
Io M Opt.= 1,18 mNm
MH = 10,70 mNm

0 1 2 3 4 5 6 7 8 9 10 11 (mNm)
MR= 0,13 mNm

This DC-Micromotor will be a good first choice to test in

this application. Should the required speed [n] be less than
Calculation of the main parameters
half the no-load speed [no], and the load torque [M] be
In this application the available supply voltage is lower
less than half the stall torque [MH], try the next voltage
than the nominal voltage of the selected motor.
motor up.
The calculation under load therefore is made at 20 V DC.
Should the required torque [M] be compliant but the
No-load speed no at 20 V DC
required speed [n] be less than half the no-load speed [no],
try a lower supply voltage or another smaller frame size U – (Io · R)
no = ––––––––– · 1 000 [rpm]
motor. kE

Should the required speed be well below half the no-load inserting the values
speed and or the load torque [M] be more than half the Supply voltage U = 20 V DC
Terminal resistance R = 57 Ω
stall torque [MH], a gearhead or a larger frame size motor No-load current IO = 0,005 A
has to be selected. Back-EMF constant kE = 2,690 mV/rpm

Performance characteristics at nominal voltage (24 V DC)

A graphic presentation of the motor‘s characteristics can 20 – (0,005 · 57)
no = –––––––––––––– · 1 000
be obtained by calculating the stall current [I] and the 2,690
torque [M] at its point of max. efficiency [Mopt.]. All other
Stall current IH
parameters are taken directly from the data sheet of the = 7 315 rpm
selected motor. U
IH = –––
R
Stall current

UN 20
IH = ––– [A]
I = ––– [A] 57
R

Stall torque MH
24 = 0,351 A
I = ––– = 0,421 A
57
MH = kM (IH – Io)
Torque at max. efficiency
inserting the value
[mNm]
Mopt. = MH · MR [mNm] Torque constant kM = 25,70 mNm/A

MH = 25,70 (0,351 – 0,005) = 8,91 mNm

Mopt. = 10,70 · 0,13 = 1,18 mNm

It is now possible to make a graphic presentation and

draw the motor diagram (see graph 1).

8
DC-Micromotors
Technical Information

Output power, max. P2 max. Efficiency at the operating point

R –––UN – I 2 P2 · 100
= –––– [%]
P2 max. = –– · o [W] U·I
4 R

2
–– · 20
P2 max.(20 V) = 57 –– – 0,005 = 1,70 W 1,52
= ––––––––– · 100 = 62,3 %
4 57 20 · 0,122

Efficiency, max. ηmax. In this example the calculated speed at the working point
is different to the required speed, therefore the supply
Io 2
max. = 1 – ––– · 100 [%] voltage has to be changed and the calculation repeated.
IH
Supply voltage at the operating point
2 The exact supply voltage at the operating point can now
0,005 · 100
= 1 – ––––––
max. = 77,6 % be obtained with the following equation:
0,351
U = R · I + kE · n · 10-3
At the point of max. efficiency, the torque delivered is:
U = 57 · 0,122 + 2,695 · 5 500 · 10-3 = 21,78 V DC
Mopt. = MH · MR [mNm] In this calculated example, the parameters at the operating
point are summarized as follows:
inserting the values
Supply voltage U = 21,78 V DC
Friction torque MR = 0,13 mNm Speed n = 5 500 rpm
and Output torque MN = 3 mNm
Stall torque at 20 V DC MH = 8,91 mNm Current I = 0,12 A
Output power P2 = 1,72 W
Efficiency η = 66 %
Mopt. = 8,91 · 0,13 = 1,08 mNm

Motor characteristic curves

Calculation of the operating point at 20 V DC For a specific torque, the various parameters can be read
When the torque (M = 3 mNm) at the working point is on graph 2.
taken into consideration I, n, P2 and η can be calculated:
To simplify the calculation, the influence of temperature
Current at the operating point and tolerances has deliberately been omitted.
In certain cases the influence of temperature should, how-
I = –M +MR
––––––– [A] ever, be taken into consideration.
kM

Graph 2
I = –3–––––––
+ 0,13 = 0,122 A Efficiency Output-
25,70 power Current Speed
P2

I n
Speed at the operating point (%) (W) (A) (rpm)

3,0 0,5 10 000

n =U –R·I
––––––– · 1 000 [rpm]
kE 9 000

2,5
100 0,4 8 000

90
20 – 57 · 0,122
n = –––––––––––––– = 4 841 rpm
7 000

· 1 000 80
2,0

2,690 0,3 6 000

1,72W

70 5 500 rpm

1,5 5 000

Output power at the operating point

60
66%

50 0,2 4 000
24
V
1,0
40
3 000










 30
0,1 2 000
0,12A
20
V
21
,7
8V
20 0,5

10
1 000 M
Torque


P2 = 3 · 4 841 · ––––––––– = 1,52 W 0 0 0 0

30 · 1 000 0 1 2 3 4 5 6 7 8 9 10 11 (mNm)

9
DC-Micromotors
Precious Metal Commutation
1

3
4

12

6
DC-Micromotor

7
1 End cap
2 Ball bearing
3 Brush cover 8
4 Brushes 9
5 Housing
6 Commutator
7 Coil 10
8 Shaft
9 Washer
10 Magnet
11 Retaining sleeve 2

12 Terminals 9

11

Features Benefits
The main difference between FAULHABER DC-Micromotors N Ideal for battery operated devices
and conventional DC motors is in the rotor. The winding N No cogging
does not have an iron core but consists of a self-supporting N Extremely low current consumption –
low starting voltage
skew-wound copper coil. This featherweight rotor has
N Highly dynamic performance due to
an extremely low moment of inertia, and it rotates with-
a low inertia, low inductance coil
out cogging. The result is the outstanding dynamics of
N Light and compact
FAULHABER motors. For low power motors, commutation
N Precise speed control
systems using precious metals are the optimum solution
N Simple to control due to the linear
because of their low contact resistance. performance characteristics

FAULHABER precious metal commutated motors range

in size from just 6 mm to 22 mm in diameter.
FAULHABER completes the drive system by providing Product Code
a variety of additional hightech standard components
including high resolution encoders, precision gearheads,
and drive electronics. FAULHABER specializes in the
modification of their drive systems to fit the customer’s
particular application requirements. Common modifica-
tions include vaccuum compatibility, extreme tempera-
ture compatibility, modified shaft geometry, additional 12 Motor diameter
19 Motor length [mm]
1219 N 012 G
voltage types, custom motor leads and connectors, and N Shaft type
much more. 012 Nominal voltage [V]
G Type of commutation (precious metal)

10
DC-Micromotors
Graphite Commutation
1
2
3

4
5
2

13
7

8
DC-Micromotor

1 Retaining ring
9
2 Spring washer
3 Ball bearing
10
4 Brush cover
5 Graphite brushes
6 Insulating ring 11

7 Commutator
8 Coil
9 Shaft
12
10 Magnet
11 Magnet cover
12 Housing
13 Terminals 3

Features Benefits
These motors feature brushes manufactured of a sintered N No cogging
metal graphite material and a copper commutator. N High power density
This ensures that the commutation system can withstand N Highly dynamic performance due to
more power and still deliver exceptionally long opera- a low inertia, low inductance coil

tional lifetimes. N Light and compact

N Precise speed control
A multitude of adaptations for customer specific require- N Simple to control due to the linear
ments and special executions are available. performance characteristics

FAULHABER motors with graphite brushes range in size

from just 13 mm to 38 mm in diameter.
FAULHABER completes the drive system by providing
a variety of additional high-tech standard components Product Code
including high resolution encoders, precision gearheads,
drive electronics, brakes and other servo componets.
FAULHABER specializes in the modification of their drive
systems to fit the customer‘s particular application require-
ments. Common modifications include vaccuum compat-
ibility, extreme temperature compatibility, modified shaft
geometry, additional voltage types, custom motor leads 23 Motor diameter [mm]
2342 S 024 CR
42 Motor length [mm]
and connectors, and much more. S Shaft type
024 Nominal voltage [V]
C Type of commutation (Graphite)
R Version (rare earth magnet)

11
Flat DC-Micromotors
Precious Metal Commutation
1

2
3

6
7

DC-Gearmotor with
integrated encoder 8

1 End cap with encoder PCB

9
2 Sintered bearing
3 Washer 10
4 Brush cover
5 Coils and collector 11

6 Sintered bearing 12
7 Washer 13
8 Housing with integrated gears
9 Intermediate plate 14
10 Sintered bearing
11 Output shaft
12 Washer
13 Sleeve bearing
14 Front cover

Features Benefits
The heart of these Flat DC-Micromotors is the ironless N No cogging
rotor made up of three flat self supporting coils. N Extremely low current consumption –
The rotor coil has exceptionally low inertia and inductance low starting voltage

and rotates in an axial magnetic field. N Highly dynamic performance due to

a low inertia, low inductance coil
Motor torque can be increased by the addition of an inte- N Light and compact
grated reduction gearhead. This also reduces the speed to N Precise speed control
fit the specifications in the application. N Simple to control due to the linear
FAULHABER specializes in the modification of their drive performance characteristics
systems to fit the customer‘s particular application require-
ments. Common modifications include vaccuum compat-
ibility, extreme temperature compatability, modified shaft
geometry, additional voltage types, custom motor leads Product Code
and connectors, and much more.

26 Motor diameter [mm]

2619 S 012 SR
19 Motor length [mm]
S Shaft type
012 Nominal voltage [V]
S Type of commutation (precious metal)
R Version (rare earth magnet)

12
Brushless DC-Motors

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13
Brushless DC-Servomotors
Technical Information

No-load current Io [A] ± 50 %

The current consumption of the motor at nominal voltage
Brushless DC-Servomotors and under no-load conditions. This value varies propor-
tionally to speed and is influenced by temperature.

Co + Cv · no
Io = ––––––––––
kM

Series 1628 ... B Stall torque MH [mNm]

1628 T
1 Nominal voltage UN The torque developed by the motor at zero speed and
2 Terminal resistance, phase-phase R nominal voltage.
3 Output power 1) P2 max.
4 Efficiency  max.
UN – C
MH = kM · ——
5 No-load speed no o
R
6 No-load current (with shaft ø 1,5 mm) Io

Friction torque CO [mNm]

Notes on technical data The sum of torque losses not depending from speed.
This torque is caused by static mechanical friction of the
The perfomance lifetime of Brushless DC-Servomotors is mainly influ- ball bearings and magnetic hysteresis of the stator.
enced by the ball bearings service life and the electronic components
used. On average, the lifetime may exceed 10 000 hours if the Viscous damping factor CV [·10-5 mNm/rpm]
motors are operated within the recommended values indicated on The multiplier factor defining the torque losses propor-
the data sheet.
tional to speed. This torque is due to the viscous friction
All values at 22 °C. of the ball bearings as well as to the Foucault currents in
All values at nominal voltage, motor only, without load.
the stator, originated by the rotating magnetic field of
Nominal voltage UN [Volt] the magnet.
The direct voltage applied on the motor phases corre- Speed constant kn [rpm/V]
spond to a bipolar supply with a 120° square-wave com- The speed variation per Volt applied to the motor phases
mutation logic. Definition of motor parameters η, no and at constant load.
Io are directly related to it. A higher or lower voltage may
be applied according to the application requirement. no
kn = ——–––– 1 000
= –––––
UN – I o · R kE
Terminal resistance, phase to phase R [ ] ±12 %
The resistance measured between two motor phases. Back-EMF constant kE [mV/rpm]
The value is directly affected by the coil temperature The constant corresponding to the relationship between
(temperature coefficient: α 22 = 0,004 K-1). the induced voltage in the motor phases and the rotation
speed.
Output power P2 max. [W]
The maximum obtainable mechanical power achieved by 2
· kM
kE = ——–––
the motor at continuous operation and at the thermal 60
limit. This power can only be obtained at high speeds.
Torque constant kM [mNm/A]

The constant corresponding to the relationship between
P2 max. = –––––– · n · (km · Ie max. – Co – Cv · n)
30 000 the torque developed and the current drawn.
Efficiency η max. [%] Current constant kI [A/mNm]
The max. ratio between the absorbed electrical power The constant corresponding to the relationship between
and the obtained mechanical power of the motor. the current drawn and torque developed.
It does not always correspond to the optimum working
kI = ——1
point of the motor. kM
No-load speed no [rpm] ±12 %
Slope of n-M curve Δn/ΔM [rpm/mNm]
The maximum speed the motor attains under no-load con-
The ratio of the speed to torque variations. The smaller
ditions at the nominal voltage. This value varies according
this value, the more powerful the motor.
to the voltage applied to the motor.

n = 30 000 –––
R
no = (Un – Io · R) · 1 000
––––– –––

M
––––––

· 2
kM
kE

14
Terminal inductance, phase to phase L [μH] Direction of rotation
The inductance measured between two phases at 1 kHz. The direction of rotation is given by the external servo
Mechanical time constant τ m [ms] amplifier. All motors are designed for clockwise (CW)
The time required by the motor to reach a speed of 63% and counter-clockwise (CCW) operation; the direction of
of its final no-load speed, from standstill. rotation is reversible.

100 · R · J Recommended values

m = –––––––––
kM2
The maximum recommended values for continuous
Rotor intertia J [gcm2] operation to obtain optimum life performance are listed
Rotor’s mass. dynamic inertia moment. below.
These values are independent each other.
Angular acceleration αmax. [·103 rad/s2]
No-load rotor acceleration, from standstill and at nominal The recommended torque (Me max.) and current (Ie max.) are
voltage. given with the Rth 2 value reduced by 55%.

(UN /R) · kM – Co · 10 Speed ne max. [rpm]

max. = –––––––––––––
J The max. operation speed limited by Foucault currents is
generated by the rotation of the magnet and the mag-
Thermal resistance Rth 1 / Rth 2 [K/W]
netic field in the stator. The values are calculated at 2/3 of
Rth 1 corresponds to the value between the coil and housing.
the max. permissible motor temperature, rounded off.
Rth 2 corresponds to the value between the housing and the
ambient air.
ne max. = Co2 + ––––––––––––––––
–––––– 30 000 · (T83 – T22) – –––––
Co
Rth 2 can be reduced by enabling exchange of heat bet- 4 · Cv2
· 0,45 · Rth 2 · Cv 2 · Cv
ween the motor and the ambient air (for example using
a heat sink or forced air cooling). Torque Me max. [mNm]
All parameters calculated at thermal limit are given with a The calculated torque for a motor at the thermal limit.
Rth 2 value reduced by 55%.
Thermal time constant τ w1 / τ w2 [s] Me max. = kM · le max. – Co – Cv · n
The thermal time constant specifies the time needed for
Current le max. [A]
the rotor and housing to reach a temperature equal to
The calculated current for a motor at the thermal limit.
63% of final value.
Operating temperature range [°C]

T125 – T22 – –––––– · n · 0,45 · Rth 2 · (Co + Cv · n)
The min. and max. permissible operating temperature Ie max. = 30 000
––––––––––––––––––––––––––––––––––––––––
of the motor. R · (1 + 22 · (T125 – T22 )) · (Rth 1 + 0,45 · Rth 2)

Shaft bearings
The standard bearings used for the Brushless DC-Servo-
motor.

Shaft load max. [N]

The max. load values allow a motor lifetime of 20 000
hours. This is in accordance with the values given by the
bearing manufacturer. The radial load is defined for a
force applied at the center of the standard shaft length.
Shaft play [mm]
The shaft play on the bearings, measured at the bearing
exit.
Housing material
The housing material and the surface protection.

Weight [g]
The average weight of the basic motor type.

15
Brushless DC-Micromotors
1

10
Brushless
Blind
8
DC-Micromotor 11

1 Blind 12 4
Micro Planetary
1
2 Housing
Blind Gearhead
13 9
2
3 Blindcover
Rear
3
4 Bearing
Blind support 10 Satellite carrier
4
5 Bearing
Blind 11 Satellite gear
5
6 Magnet
Blind 12 Sun gear 14
6
7 Washer
Blind 13 Planetary stage
7 Coil 14 Output shaft
8 Shaft 15 Housing
15
9 Cover / Bearing 16 Bearing / Cover
support 17 Retaining ring

16

17

Features Benefits
This smallest, brushless DC-Micromotor is based on the N Extremely light and compact
System FAULHABER skew wound coil technology.
® N Exceptional power to volume ratio
It is essentially comprised of a three phase coil, a stator N Brushless commutation for long life
housing, and a two-pole NdFeB magnet on the ouput N Low operating voltage
shaft as the rotor. N For combination with micro planetary gearheads

A Micro Planetary Gearhead of conventional design was

likewise developed for combination with the brushless
DC-Micromotor. The production employs LIGA-technology,
a method combining lithography, electroforming and
mold-copying. Special involute toothing with a module of
55 μm and a reduction ratio of 3,6 : 1 per gear stage is
used, providing the three stage gear motor combination Product Code
with 150 μNm torque. The microdrive is produced in series
under cleanroom conditions.

Brushless DC-Micromotors require an external electronic

controller. FAULHABER offers a wide variety of speed
control solutions for operation of the microdrive.

02 Motor diameter [mm]

0206 H 001 B
06 Motor length [mm]
H Shaft type
001 Nominal voltage [V]
B Type of commutation (brushless)

16
Brushless DC-Servomotors
1

7
Brushless 14
DC-Servomotor

1 Rear cover 8

2 PCB
3 Hall sensors
4 Bearing support 9
5 Ball bearing
6 Shaft
7 Magnet 10

8 PCB 11

9 Coil
10 Spring washer
12
11 Spacer
12 Stator laminations
13 Housing
14 Lead wires 13

Features Benefits
The FAULHABER Brushless DC-Servomotors are built N System FAULHABER®, ironless stator coil

for extreme operating conditions. They are precise, have N High reliability and operational lifetime

extreme long lifetimes and are highly reliable. Exceptio- N Wide range of linear torque / speed performance
nal qualities such as smooth running and especially low N No sparking
noise level are of particular note. The rare-earth magnet N No cogging
as rotor, and FAULHABER skew winding technology ensure N Dynamically balanced rotor
that these motors deliver top performance dynamics N Simple design
within minimum overall dimensions. N Standard with digital hall sensors with optional
analog hall sensors
This series is also available in an autoclavable version and
is ideally suited for application in laboratory and medical
equipment.
Product Code
Sterilizing conditions
N Temperature 134 °C ± 2 °C
N Water vapour pressure 2,1 bar
N Relative humidity 100 %
N Duration of cycle 20 min.
N Rated for a minimum of 100 cycles

24 Motor diameter [mm]

2444 S 024 B
44 Motor length [mm]
S Shaft type
024 Nominal voltage [V]
B Type of commutation (brushless)

17
Brushless DC-Servomotors
Sensorless, SMARTSHELL® Technology

4
1
8

9
10
11
12

13
Brushless DC-Servomotor,
sensorless
5

1 Cover / Bearing support

2 Ball bearing
3 Shaft
4 Magnet
7
5 Lead wires Hall sensor Module
6 Spring washer 6
7 Stator: 8 Flange
7.1 PCB 9 PCB
7.2 Coil 10 Hall sensors
7.1
7.3 Stator laminations 11 Lead wires
7.4 Cover / Bearing 12 Sensor magnet
7.2
support 13 Housing

7.3

7.4
Features Benefits
The skew-wound self-supporting coil, System FAULHABER®, N System FAULHABER®, ironless stator coil
the printed circuit board, the laminated stack and the N High reliability and operational lifetime
front-end bearing cover are all encapsulated and meshed N Wide range of linear torque / speed performance
together with a mould-injected LCP (Liquid Crystal N No sparking
Polymer), exhibiting outstanding mechanical and thermal N No cogging
features. N Dynamically balanced rotor
N Simple design
The modular design concept of the SMARTSHELL® motors
N Available with optional digital or analog hall sensors
offers two Hall sensor modules for precise speed and
position control. With these modules assembled to the
rear end of the motors, the BDS (Brushless Digital Sensors)
and BAS (Brushless Analog Sensors) options are available
for use with the appropriate drive electronics. Productt Code

22 Motor diameter [mm]

2232 S 048 BSL
32 Motor length [mm]
S Shaft type
048 Nominal voltage [V]
B Type of commutation (brushless)
SL Version (sensorless)

18
Brushless DC-Servomotors
4 Pole Technology 1

3
4
5

12
Brushless
DC-Servomotor
4 Pole Technology
7
1 Rear cover
2 PCB 8

3 Retaining ring
4 Spring washer
5 Ball bearing 9
6 Coil with Hall sensors
7 Housing
10
8 Stator laminations
9 Magnet 5
10 Shaft
11 Front flange
11
12 Flat cable
3

Features Benefits
The brushless servo motors in the FAULHABER BX4 N High torque 4 Pole Technology
series are characterised by their innovative design, which N Compact, robust design
comprises just a few individual components. N Modular concept
N Available with integrated encoders and
Despite their compact dimensions, the 4 pole magnet speed controllers
technology gives these drives a high continuous torque N High reliability and operational lifetime
with smooth running characteristics and a particularly N No sparking
low noise level. The modular rotor system makes it pos- N No cogging
sible to tune the performance of the motor to the higher N Dynamically balanced rotor
torque or higher speed needs of the application. N Simple design

Thanks to the electronic commutation of the drives, the

lifetime is much longer in comparison with mechanically Product Code
commutated motors. Alongside the basic version in which
the commutation is provided by an external control, the
highly flexible BX4 series also includes advanced speci-
fications with integrated speed controller or integrated
encoder.

The motors come standard with digital Hall sensors.

22 Motor diameter [mm]
2232 S 012 BX4
32 Motor length [mm]
S Shaft type
012 Nominal voltage [V]
BX4 Type of commutation
(brushless), 4 Pole Technology

19
Brushless DC-Motors
with integrated Drive Electronics
1

5
Brushless DC-Motor 3
with integrated Drive Electronics
6

1 Rear cover 7

2 Drive Electronics 8
3 Flat cable
4 Housing
9
5 Coil
6 Spring washer 10
7 Ball bearing
8 Washer 11
9 Magnet
10 Shaft
11 Rotor back-iron 7

12 Front flange
12

Features Benefits
These new brushless DC-Motors with integrated drive N System FAULHABER®, ironless stator coil
electronics combine the advantages of the System N High reliability and operational lifetime
FAULHABER skew wound coil technology with the lifetime
® N Wide range of linear torque / speed performance
benefits of electronic commutation. The motors are based N Programmable motor characteristics
on a three-phase ironless coil, a bipolar rare-earth perma- N No sparking
nent magnet and sensorless electronic commutation. N No cogging
N Dynamically balanced rotor
To define the position of the rotor in relation to the
N Integrated electronics
rotating field of the coil, the back-EMF is measured and
N Simple design
processed. The position detection of the rotor is sensorless.
N Available with optional digital or analog Hall sensors
The design features the basic linear characteristics over a
wide speed range and the absence of cogging torque just
like the traditional brush commutated DC-Motors in the Product Code
FAULHABER program. The rotating magnet and iron flux
path avoid iron losses and results in higher efficiency.

31 Motor diameter [mm]

3153 K 012 BRC
53 Motor length [mm]
K Shaft type
012 Nominal voltage [V]
BRC Type of commutation
(brushless), with integrated electronics

20
Brushless Flat DC-Micromotors
penny-motor® Technology

5
Brushless Flat
DC-Micromotor

1 PCB with coil 6

2 Bearing support
3 Ball bearing
4 Magnet
5 Rotor disc
6 Shaft

Features Benefits
The extremely flat design of the brushless penny-motor® N Ultra flat design
is made possible by innovative coil design. Instead of being N No cogging and precise speed control
mechanically wound, it is fabricated by means of photo- N Exceptional power to volume ratio
lithographic processes. High power neodymium magnets N Very low current consumption
(NdFeB) and a precise bearing system complete the motors N High operational lifetime
for exceptional torque and smooth performance despite
their extremely flat dimensions.

Motors with integrated spur gears are available with

coaxial or eccentric shafts for higher torque in a com-
pact form. The motors are electronically commutated for
extremely long operational lifetime. They are particularly
suited for applications where precise speed control and Product Code
continuous duty operation are a must; for example in high
precision optical filters, choppers or scanning devices.

12 Motor diameter [mm]

1202 H 004 BH
02 Motor height [mm]
H Shaft type
004 Nominal voltage [V]
B Type of commutation (brushless)
H Hall sensors

21
Brushless Flat DC-Micromotors
1

Brushless Flat
DC-Micromotor 8

1 End cap
2 Ball bearing
3 Hall Sensor PCB
4 Rotor and output shaft
5 Stator Coil
6 Rotor, Back-Iron
and Magnet
7 Ball bearing
8 Housing

Features Benefits
The heart of each brushless flat DC motor consists of the N No cogging torque
flat stator coils. The rotor is constructed of a high power N Electronic commutation using
three digital hall sensors
rare earth magnet and two rotating discs which provide
N Precise speed control
the back iron for an optimal use of the magnetic flux.
N Flat, light, and very compact
The rotating back iron also serves to eliminate any cog-
ging, or so-called detent torque which improves the in-
herent speed control properties of the motor drastically.

Thanks to the brushless commutation the motors can

reach much higher operational lifetimes than conventional
mechanically commutated DC motors.
Product Code
Motor torque can be increased and motor speed reduced
by the addition of an integrated reduction gearhead.
The revolutionary integrated design provides for a wide
variety of reduction ratios while maintaining a very flat
profile.

26 10 T 0 1 2 B
26 Motor diameter [mm]
10 Motor length [mm]
T Shaft type
012 Nominal voltage [V]
B Type of commutation (electronic)

22
Brushless DC-Motors
with integrated Speed Controller 1

2 3

Series 2232 ... BX4 5

with integrated
Speed Controller
Serie 2610 ... B
with integrated
1 Motor Speed Controller
2 Housing
3 Mounting flange 1 End cap
4 Electronics PCB 2 Electronics PCB
5 End cap 3 Motor (Front)

Features Benefits
These new brushless DC motors combine the advantages N Integrated drive electronics
of a slotless brushless motor with dedicated, high pre- N Extremely compact
cision, speed control electronics. N Very robust construction
N Easy to use
Speed control is achieved using the on board PI controller
N Integrated current limiting
with an external command voltage. The drives are pro-
N Control parameters can be tuned
tected from overload with the integrated current limiting. to the application

The control parameters of the drive electronics can

be modified to fit the application using our optional
programming adapter and the easy to use FAULHABER
Motion Manager software. Product Code
Many drives are also available in a simple 2 wire con-
figuration for ease of integration or replacement of
standard DC motors in some applications.

32 68 G 024 BX4 SC
32 Motor diameter [mm]
68 Motor length [mm]
G Shaft type
024 Nominal Voltage [V]
BX4 Type of commutation (electronic)
SC Integrated Speed Controller

23
Motion Control Systems

WE CREATE MOTION

24
Motion Control Systems
Technical Information

Brushless DC-Servomotor with

integrated Motion Controller

1 Heat sink/cover
2 Thermal conduction pad
3 Thermal protection
4 Motion Controller
5 Housing
6 Analog Hall sensors
7 Brushless DC-Servomotor
8 Interface cable

Features Benefits
With its incredibly compact design, this all-round package N Highly dynamic, compact drive system
with brushless motor and integrated
units a powerful brushless DC-Servomotor, a high-reso-
motion controller and encoder
lution encoder and a programmable position and speed
N Controlled either by means of a RS232
regulator. interface oder CAN interface
N Smallest integrated CANopen Motion Controller
Because of its brushless commutation, the service life of with CiA DS301 V4/ DSP402 V2 standard protocols
these powerful complete systems is only limited by the N Exact torque regulation through improved
servicelife of the bearings and the electronic components power monitoring
used. As well as the familiar RS232 interface, the system is N Very flexible motion control functionality
now available for the first time with a CAN interface and N Digital inputs for TTL and PLC can be configured compatibly
CANopen protocol. This means that up to 127 can be
linked and controlled with ease.
Product Code
The powerful motion controller, together with the valua-
tor, permits a whole host of positioning tasks and speed
regulations with a resolution of 1/3000 revolutions.
The integrated self-protection against overheating and
overvoltage ensures reliable operation. The use of the
latest DSP technology enables very high regular sensing
rates and PWM frequencies that make the dynamic power 3268 Motor series
G Shaft type
pack score extremely well in terms of regulation and 3268 G 024 BX4 CS
024 Nominal voltage [V]
effectiveness. BX4 Type of commutation
(brushless, integrated electronics)
CS Type of interface

25
Motion Manager
The high-performance “Motion Manager” software from
FAULHABER enables users to control and configure drive
systems with motion controllers.
The graphic user interface and commands use the same
menus and functions regardless if the CAN or RS232
interface is in use. This can dramatically simplify the first
steps into CAN applications.
Motion Manager for all Windows™ versions can be
downloaded free of charge in German or English from
www.faulhaber.com.

Startup and configuration

Motion Manager automatically searches for connected
drive nodes and displays these in the “Node Explorer”.
Transparent configuration dialogs and dynamic regulating
parameter setting, make entry easy.
Graphical online analysis of drive behavior (e.g. as step
responses) and possibility to change the regulating param-
eter continuious, provide invaluable help during to enter
commands. The program also supports the creation, trans-
mission and administration of sequential programs and
parameter files.
The program is rounded off with an online help and the
integrated Visual Basic Script language.

26
Motion Control Systems

Programming Integration in higher level control systems

The ASCII commands and CAN telegrams make it possible
Version with RS 232 Interface to integrate the drive into a higher level control system as
A complete ASCII command set is available for operation well as field bus based control environments.
and configuration of the drive. Visual Basic Script can be written and tested directly in the
Motion Manager.
Motion programs can be created in the Motion Manager
or other available terminal programs and then transmit- Furthermore, any high level language (Basic, C/C++,
ted to the drive where they are stored in the on-board Delphi, LabView...) can be used to develop applications
memory. The easy to use motion command library pro- on the PC which send commands via RS232 directly to the
vides all the necessary commands for programming. drive mechanism or to read messages sent from there.
Commands can also be used within a PLC program for
Version with CAN Interface
data exchange with the drive unit.
In addition to the standard CANopen profiles as defined
in the CiA DSP402 such as profile position mode and pro-
file velocity mode, the drive supports a special FAULHABER
Mode. With the help of the CAN command interpreter
implemented in the FAULHABER Motion Manager soft-
ware this mode allows the user to operate and configure
the drive with the same easy to use command set as with
the RS232 version.
The FAULHABER CANopen motion controller supports the
standard CiA DS301 / DSP402 / DSP305 protocols. The CAN
interface offers a wide range of functions. You will find
details of how to use and configure the controller in the
user‘s manual (available at www.faulhaber.com)
Alternatively, you can contact your local support engineer.

27
Stepper Motors

WE CREATE MOTION

28
Stepper Motors
Technical Information

phase winding is energized. Residual torque is useful to

hold a position without any current to save battery life or
Stepper Motors to reduce heat.
Two phase, 24 steps per revolution Rotor inertia [kgm2]
PRECIstep® Technology This value represents the inertia of the complete rotor.
Resonance frequency (at no load) [Hz]
AM1524-ww-ee Is the step rate at which the unload motor will show rotor
ww = V-6-35 resonance. It is recommended to start with a frequency
Voltage Curr
1 Nominal voltage 6 – above this frequency or to use half-, micro-step to operate
2 Nominal current per phase (both phases ON) – 0,1
outside this frequency. The resonance frequency changes
3 Phase resistance (at 20°C) 35
4 Phase inductance (1kHz) 15
with the addition of inertial loads.
5 Back-EMF amplitude 6
Electrical time constant [ms]
Is the time needed to establish 67% of the max. possible
Notes on technical
h i ld data phase current under a given operation point. It is one of
Nominal voltage [Volts] the factors which reduce the provided torque at higher
Is the voltage applied to both phase windings that will not speed.
overheat the motor. The motor develops nominal holding Ambient temperature range [°C]
torque using this voltage. Temperatures at which the motor can operate.
Nominal current per phase (both phases ON) [A] Winding temperature tolerated max. [°C]
Is the current level supplied to both phase windings Maximum temperature supported by the winding and the
that will not overheat the motor. The motor develops the magnets.
nominal holding torque when energized this way.
Thermal resistance winding-ambient air [°C/W]
Phase resistance 1) [6] The gradient at which the motor winding temperature
Phase winding resistance at 20 °C; tolerance is ±12%. increases per Watt of power losses generated in the motor.
Phase inductance [mH] Additional cooling surface is reducing it.
Inductance of the phase windings, measured at 1 kHz. Thermal time constant [s]
Back-EMF 1) [V/k 1000step/s] Time needed to reach 67% of the final winding tempera-
Amplitude of the back-EMF at 1000 steps/s. It is one of the ture. Adding cooling surfaces reduces the thermal resist-
factors which reduce the provided torque at higher speed. ance but will increase the thermal time constant.
Holding torque, at nominal current [mNm] Shaft bearings
Is the amplitude of the torque the motor generates with Offered are either self lubricating sintered bronze bearings
both phases energized in voltage or current mode. or 2 preloaded ball bearings. The ball bearing preload is
assured by a spring washer assembled at the rear bearing.
Holding torque, at 2 x nominal current [mNm]
Is the amplitude of the torque the motor generates with Shaft load, max. radial [N]
both phases energized with 2 x nominal current. The figure is representing for all bearing types the recom-
There is no risk of motor damage due to their magnetic mended maximally supported radial load.
design. However, to limit heat development the boost Shaft load, max. axial [N]
current should be applied only for short periods during The figure is representing for all bearing types the recom-
critical sections of the motion cycle. mended maximally supported axial load. The load handling
Step angle [degr.] capability of ball-bearings is higher than the set preload.
Number of angular degrees the motor moves per full-step. The rotor can be pulled without risk of damage to the
motor by about 0,2 mm.
Step angle accuracy [%]
Percentage of a full step by which the unloaded motor Shaft play max., radial [μm]
with identical currents in both phases will be off from any The clearance between shaft and bearing tested with the
calculated fullstep position. This error does not cumulate. indicated force to move the shaft.

Residual torque 1) [mNm] Shaft play max., axial [μm]

Torque needed to rotate rotor by outside torque when no Represents the axial play tested with the indicated force.

29
Isolation test voltage 1) [VDC]
Is the test voltage for isolation test between housing and
phase windings. Torque (mNm)
1.25
Motor dimensions [mm]
1
The values provide a rapid view about the motor
housing diameter and length as well as the standard shaft 0.75
diameter.
0.5
Weight [g]
0.25
Is the motor weight in grams.
0
1)
these parameters are measured during final inspection on 100 %
of the products delivered. 0 500 1000 1500 2000 2500 3000 3500
-0.25

-0.5
Stepper Motor Selection -0.75
T (ms)
The selection of a stepper motor requires the use of
published torque speed curves based on the load parameters.
It is not possible to verify the motor selection mathematically
without the use of the curves. Depending on the motor size suitable for the application
it is required to recompute the torque parameters with the
To select a motor the following parameters must be
motor inertia as well.
known:
In the present case it is assumed that a motor with an out-
N Motion profile side diameter of maximum 15 mm is suitable and the data
N Load friction and inertia has been computed with the inertia of the AM1524.
N Required resolution 2. Verification of the motor operation.
N Available space The highest torque/speed point for this application is
N Available power supply voltage found at the end of the acceleration phase. The top speed
is then n = 5000 rpm, the torque is M = 1 mNm.
1. Definition of the load parameters at the motor shaft
Using these parameters you can transfer the point into
The target of this step is to determine a motion profile
the torque speed curves of the motor as shown here with
needed to move the motion angle in the given time frame
the AM1524 curves for a current mode drive.
and to calculate the motor torque over the entire cycle
using the application load parameters such as friction and It is not possible to use the full torque of the motor:
load inertia. a safety factor of 30% is requested. The shown example
The motion and torque profiles of the movement used in assures that the motor will correctly fulfil the requested
this example are shown below: application conditions.

Torque Power
(mNm) (W)

Speed (rpm) AM1524-A-0,25-12,5-ee

2 Phasen ON, 0.25A, 12V
6000
3 1,5
5000

4000
2 1
3000

2000 1 0,5
1000

0 0
0 500 1000 1500 2000 2500 3000 3500 0 5000 10000 15000 20000 Speed (rpm)
T (ms) 2000 4000 6000 8000 (Step/s)

30
In case that no solution is found, it is possible to adapt N In full step mode (1 phase on) the phases are successive-
the load parameters seen by the motor by the use of a ly energised in the following way:
reduction gearhead. 1. A+ 2. B+ 3. A– 4. B–.
The demonstrated method does not specify the differences N Half step mode is obtained by alternating between
between the two published torque speed curves, one for 1-phase-on and 2-phases-on, resulting in 8 half steps
voltage mode and one for current mode (which was used per electrical cycle: 1. A+ 2. A+B+ 3. B+ 4. A–B+
as the solution for the application example). 5. A– 6. A–B– 7. B– 8. A+B–.

The difference is mainly linked to the performance one N If every half step should generate the same holding
may get from the motor. Whereas the voltage mode is torque, the current per phase is multiplied by √2 each
offering good performance at low speed the torque will time only 1 phase is energised.
decrease rapidly, the current mode allows higher speed The two major advantages provided by microstep opera-
performance as the constant current mode drive (the tion are lower running noise and higher resolution, both
current is controlled by a chip related control loop) which depending on the number of microsteps per full step
allows to apply a higher voltage to the motor phases. which can in fact be any number but is limited by the
Voltage mode is the best choice for application with system cost.
supply voltage below 10 V mainly due to the availability of As explained above, one electrical cycle or revolution of
suitable driver chips. In voltage mode, the motor winding the field vector (4 full steps) requires the driver to provide
must have a nominal voltage equal to the power supply to a number of distinct current values proportional to the
get the best performances. number of microsteps per full step.
The moment the voltage is higher than 10 V a current For example, 8 microsteps require 8 different values which
mode driver will be the better choice. It is recommended in phase A would drop from full current to zero following
to apply a supply voltage at least U = 5 x R x I of the the cosine function from 0° to 90°, and in phase B would
selected motor winding. rise from zero to full following the sine function.

3. Verification of the resolution These values are stored and called up by the program
It is assumed that the application requires a resolution controlling the chopper driver. The rotor target position is
of 9° angular. determined by the vector sum of the torques generated in
phase A and B:
The selected motor AM1524 has a step angle of 15° which
means that the motor is not suitable directly. It can be
operated either in half-step, which reduces the step angle MA = k · IA = k · Io · cos ϕ
to 7,5°, or in micro stepping. With micro stepping, the
resolution can be increased even higher whereas the pre- MB = k · IB = k · Io · sin ϕ
cision is reduced because the error angle without load of
the motor (expressed in % of a full-step) remains the same where M is the motor torque, k is the torque constant
independently from the number of micro-steps the motor and Io the nominal phase current.
is operated.
For the motor without load the position error is the same
For that reason the most common solution for adapting
in full, half or microstep mode and depends on distortions
the motor resolution to the application requirements is
of the sinusoidal motor torque function due to detent
the use of a gearhead or a lead-screw where linear motion
torque, saturation or construction details (hence on the
is required.
actual rotor position), as well as on the accuracy of the
phase current values.
General application notes
4. Verification in the application
In principle each stepper motor can be operated in
Any layout based on such considerations has to be verified
three modes: full step (one or two phases on), half step
in the final application under real conditions.
or microstep.
Please make sure that all load parameters are taken into
Holding torque is the same for each mode as long as dis- account during this test.
sipated power (I2R losses) is the same. The theory is best
presented on a basic motor model with two phases and
one pair of poles where mechanical and electrical angle
are equal.

31
Stepper Motors
Two phase

2 6

3
7
4

5
8
Stepper Motor

10
1 Retaining ring
2 Washer
3 PCB
4 Ball bearing
11
5 Rear cover / stator
6 Coil, Phase A
7 Inner stator 9
8 Rotor
9 Magnets 13

10 Shaft
4
11 Housing
12 Coil, Phase B
13 Front cover / stator

12

Features Benefits
2
PRECIstep® stepper motors are two phase multi-polar N Cost effective positioning drive without 1
an encoder
motors with permanent magnets. The use of rare-earth
N High power density
magnets provides an exceptionally high power to volume
N Long operational lifetimes
ratio. Precise, open-loop, speed control can be achieved
N Wide operational temperature range
with the application of full step, half step, or micro-
stepping electronics. N Speed range up to 16 000 rpm using a current
mode chopper driver
The rotor consists of an injection moulded plastic support N Possibility of full step, half step and microstep operation
and magnets which are assembled in a 10 or 12 pole
configuration depending on the motor type. The large
magnet volume helps to achieve a very high torque
density. The use of high power rare-earth magnets also
enhances the available temperature range of the motors Product Code
from extremely low temperatures up to 180 °C as a
special configuration. The stator consists of two discrete
phase coils which are positioned on either side of the
rotor. The inner and outer stator assemblies provide the
necessary radial magnetic field.

AM1524 Motor series

2R Bearing type A M 1 5 2 4 - 2 R- V- 1 2 - 1 5 0 - 5 7
V-12-150 Coil type
57 Motor version

32
Stepper Motors
Two phase with Disc Magnet

1
4
2

Stepper Motor
6

1 Retaining ring
2 PCB
3 Rear cover / stator
4 Coil
5 Housing 7
6 Sleeve
8
7 Disc Magnet
8 Shaft
9 Front cover
9
10 Sintered bearing

10

Features Benefits
The rotor consists of a thin magnetic disc. The low rotor N Extremely low rotor inertia
inertia allows for highly dynamic acceleration. The rotor N High power density
disc is precisely magnetized with 10 pole pairs which N Long operational lifetimes
helps the motor achieve a very high angular accuracy. N Wide operational temperature range
The stator consists of four coils, two per phase, which N Ideally suited for micro-stepping applications
are located on one side of the rotor disc and provide the
axial magnetic field.

Special executions with additional rotating back-iron

are available for exceptionally precise micro-stepping
performance.

Product Code

ADM1220 Motor series

ADM1220-2R-V2-01
2R Bearing type
V2 Coil type
01 Motor version

33
Linear DC-Servomotors

WE CREATE MOTION

34
Linear DC-Servomotors
Technical Information

Force constant kF [N/A]

The constant corresponding to the relationship between
Linear DC-Servomotors the motor force delivered and current consumption.
with Analog Hall Sensors
QUICKSHAFT® Technology Terminal resistance, phase-phase R [ ] ±12%
The resistance measured between two motor phases.
This value is directly influenced by the coil temperature
Series LM 1247 ... 01 (temperature coefficient: α 22 = 0,004 K-1).
LM 1247– 020–01 0
1 Continuous force 1) Fe max. 3,6 Terminal inductance, phase-phase L [μH]
2 Peak force 1) 2) Fp max. 10,7
3 Continuous current 1) Ie max. 0,55
The inductance measured between two phases at 1 kHz.
4 Peak current 1) 2) Ip max. 1,66
Stroke length smax. [mm]
5 Back-EMF constant kE 5,25
6 Force constant 3) kF 6,43 The maximum stroke length of the moving cylinder rod.
Repeatability [μm]
Notes
N t on ttechnical
h i ld data
t The maximum measured difference when repeating several
times the same movement under the same conditions.
All values at 22 °C.
Precision [μm]
Continuous force Fe max. [N] The maximum positioning error. This value corresponds to
The maximum force delivered by the motor at the thermal the maximum difference between the set position and the
limit in continuous duty operation. exact measured position of the system.
Acceleration ae max. [m/s2]
Fe max. = kF · Ie max.
The maximum no-load acceleration from standstill.
Peak force Fp max. [N] Fe max.
ae max. = –––––
The maximum force delivered by the motor at the mm
thermal limit in intermittent duty operation (max. 1 s,
20% duty cycle). Speed ve max. [m/s]
The maximum no-load speed from standstill, considering
Fp max. = kF · Ip max. a triangular speed profile and maximum stroke length.

Continuous current Ie max. [A] ve max. = ae max. · s max.

The maximum motor current consumption at the thermal
limit in continuous duty operation. Thermal resistance Rth 1 / Rth 2 [K/W]
Rth1 corresponds to the value between coil and housing.
T125 – T22 2 Rth2 corresponds to the value between housing and
Ie max. = ––––––––––––––––––––––––––––––––––––– · –––
R · (1 + 22 · (T125 – T22 )) · (Rth 1 + 0,45·R th 2 ) 3 ambient air.
The listed values refer to a motor totally surrounded by air.
Peak current Ip max. [A] Rth2 can be reduced with a heat sink and/or forced air cooling.
The maximum motor current consumption at the
thermal limit in intermittent duty operation (max. 1 s, Thermal time constant τ w1 / τ w2 [s]
20% duty cycle). The thermal time constant of the coil and housing,
respectively.
Back-EMF constant kE [V/m/s]
The constant corresponding to the relationship between Operating temperature range [°C]
the induced voltage in the motor phases and the linear The minimum and maximum permissible operating
motion speed. temperature values of the motors.

2 · kF Rod weight mm [g]

kE = ——––
6 The weight of the rod (cylinder with magnets).
Total weight mt [g]
The total weight of the linear DC-Servomotor.

35
Linear DC-Servomotors
Technical Information

Magnetic pitch τ m [mm] where:

The distance between two equal poles.
Fe : Continuous force delivered by motor [N]
Rod bearings
The material and type of bearings. Fext : External force [N]

Housing material Ff : Friction force Ff = m · g · ⋅ cos ( ) [N]

The material of the motor housing.
Fx : Parallel force Fx = m · g · sin ( ) [N]
Direction of movement m: Total mass [kg]
The direction of movement is reversible, determined by
the control electronics. g: Gravity acceleration [m/s2]

a: Acceleration [m/s2]
Force calculation
To move a mass on a slope, the motor needs to deliver
a force to accelerate the load and overcome all forces Speed profiles
opposing the movement. Shifting any load from point A to point B is subject to the
laws of kinematics.
Fext Equations of a uniform straight-line movement and
uniformly accelerated movement allow definition of the
various speed vs. time profiles.
Fe Prior to calculating the continuous duty force delivered by
m the motor, a speed profile representing the various load
movements needs to be defined.
Ff
Fy Triangular speed profile
Fg
The triangular speed profile simply consists of an accelera-
Fx tion and a deceleration time.

Speed (m/s)
The sum of forces shown in above figure has to be equal to:
t The shaded area equals
the movement length

F = m · a [N] during time t.

Entering the various forces in this equation it follows that:

t/2 t/2 Time (s)
Fe - Fext - Ff - Fx = m · a [N]

1 1 v2
Displacement: s = ___ · v · t = ___ · a · t 2 = ____ [m]
2 4 a

s a·t
Speed: v= 2· ___
= ________ = a·s [m/s]
t 2

s v v2
Acceleration: a=4· = 2 · ____ = ____
____
[m/s2]
t2 t s

36
Trapezoidal speed profile Speed (m/s)
The trapezoidal speed profile, acceleration, speed and
deceleration, allow simple calculation and represent
typical real application cases.
2
1 3 Time (s)
Speed (m/s)
t1 = td /3 t2 = td /3 t3 = td /3
4
t The shaded area equals td = 100 ms t4 = 100 ms
the movement length
during time t.

Unit 1 2 3 4

s (displacement) m 0,005 0,01 0,005 0

v (speed) m/s 0 ... 0,3 0,3 0,3 ... 0 0
t/3 t/3 t/3 Time (s) a (acceleration) m/s2 9,0 0 –9,0 0
t (time) s 0,033 0,033 0,033 0,100

2 1 v2 Calculation example
Displacement: s = · v · t = ______ · a · t 2 = 2 · ____
___ [m] Speed and acceleration of part 1
3 4,5 a
s 20 · 10-3
vmax. = 1,5 · ___ = 1,5 · _________________
= 0,3 m/s
s a·t a·s t 100 · 10-3
Speed: v = 1,5 · ___ = ________ = _________
[m/s]
t 3 2 s 20 · 10-3
a = 4,5 · ___ = 4,5 · ____________________
= 9 m/s2
s v v 2 t2 (100 · 10-3) 2
Acceleration: a = 4,5 · ___ = 3 · ___ = 2 · ____ [m/s2]
t2 t s Force definition
Assuming a load of 500 g and a friction coefficient of 0,2,
the following forces result:
How to select a linear DC-Servomotor Forward Backward
Force Unit Symbol 1 2 3 4 1 2 3 4
This section describes a step-by-step procedure to select a Friction N Ff 0,94 0,94 0,94 -0,94 0,94 0,94 0,94 0,94
linear DC-Servomotor. Parallel N Fx 1,71 1,71 1,71 1,71 -1,71 -1,71 -1,71 -1,71
Speed profile definition Acceleration N Fa 4,5 0 -4,5 0 4,5 0 -4,5 0
To start, it is necessary to define the speed profile of the Total N Ft 7,15 2,65 -1,85 0,77 3,73 -0,77 -5,27 -0,77
load movements.
Movement characteristics are the first issues to be con- Calculation example
sidered. Which is the maximum speed? How fast should Friction and acceleration forces of part 1

the mass be accelerated? Which is the length of movement Ff = m · g ·  · cos ()

= 0,5 · 10 · 0,2 · cos (20º) = 0,94 N

the mass needs to achieve? How long is the rest time?
Fa = m · a = 0,5 · 9 = 4,5 N = 4,5 N
Should the movement parameters not be clearly defin-
ed, it is recommended to use a triangular or trapezoidal
Motor selection
profile.
Now that the forces of the three parts of the profile
Lets assume a load of 500 g that needs to be moved are known, requested peak and continuous forces can
20 mm in 100 ms on a slope having a rising angle of 20° be calculated in function of the time of each part.
considering a trapezoidal speed profile.
The peak force is the highest one achieved during the
motion cycle.
Fp = max. ( | 7,15 | , | 2,65 | , | -1,85 | , | 0,77 | , | 3,73 | , | -0,77 | , | -5,27 | , | -0,77 | ) = 7,15 N

37
Linear DC-Servomotors
Technical Information

The continuous force is represented by the expression: Motor characteristic curves

Motion profile:

(t · Ft2 ) Trapezoidal (t1 = t2 = t3), back and forth
Fe = _______________
= ...
2 · 

t Motor characteristic curves of the linear DC-Servomotor
with the following parameters:
2 2
0,033 · 7,15 + 0,033 · 2,65 + 0,033 · (–1,85) + 0,1 · 0,77
2 2 Displacement distance: 20 mm
2 2 2 2
+ 0,033 · 3,73 + 0,033 · ( –0,77) + 0,033 · (–5,27) + 0,1 · (–0,77) Friction coefficient: 0,2
Fe = ________________________________________________________________________________________
= 2,98 N
2 · (0,033 + 0,033 + 0,033 + 0,1) Slope angle: 20°

Rest time: 0,1 s

With these two values it is now possible to select the
suitable motor for the application.
Load [kg] External force [N]
Linearer DC-Servomotor LM 1247–020–01
smax. = 20 mm ; Fe max = 3,09 N ; Fp max. = 9,26 N 2,5 2,5

2,0 2,0
Coil winding temperature calculation
To obtain the coil winding temperature, the continuous
motor current needs to be calculated. 1,5 1,5

For this example, considering a force constant kF equal

to 6,43 N/A, gives the result: 1,0 1,0

F e 2,98
Ie = = _________ = 0,46 A
_____ 0,5 0,5
kf 6,43

0
0 0,05 0,10 0,15 0,20 0,25 0,30 Speed
With an electrical resistance of 13,17 , a total thermal [m/s]
resistance of 26,2 °C / W (Rth1 + Rth2) and a reduced ther- LM 1247–020–01

mal resistance Rth2 by 55% (0,45 · Rth2), the resulting coil

Load curve
temperature is:
Allows knowing the maximum applicable load for a given
speed with 0 N external force.
3 ) 2· ( 1 –
22 · T22) + T22
R · (Rth1 + 0,45 · Rth2) · (Ie · _____
2 The graph shows that a maximum load ( ) of 0,87 kg can
Tc (I) = = ...
______________________________________________________________________________
be applied at a speed of 0,11 m/s.
1 –
22 · R · ( Rth1 + 0,45 · Rth2) · (Ie · ) 3
_____ 2

2
External force curve
Allows knowing the maximum applicable external force
3 ) · ( 1 - 0,0038 · 22) + 22
2 for a given speed with a load of 0,5 kg.
13,17 · (8,1 + 0,45 · 18,1) · (0,46 · _____
Tc (I) = 2 = 113,5 °C
_____________________________________________________________________________________________ The graph shows that the max. achievable speed ( )
3 2 without external forces, but with a load of 0,5 kg is 0,31 m/s.
1 – 0,0038 · 13,17 ( 8,1 + 0,45 · 18,1) · (0,46 · ) _____
2 Therefore, the maximum applicable external force ( )
at a speed of 0,3 m/s is 0,5 N.
The external peak force ( ) is achieved at a speed
of 0,17 m/s, corresponding to a maximum applicable
external force of 2,27 N.

38
Linear DC-Servomotors
QUICKSHAFT© Technology

1 7

2
8

Linear DC-Servomotor

1 Sleeve bearings
4
2 Bearing support 5
3 Coil 6
4 Housing
9
5 PCB
6 Hall sensors
7 Lead wires and connector
8 Cover
9 Forcer rod

Features Benefits
QUICKSHAFT® combines the speed and robustness of N High dynamics
a pneumatic system with the flexibility and reliability N Excellent force to volume ratio
features of an electro-mechanical linear motor. N No residual force present
The innovative design with a 3-phase self-supporting N Non-magnetic steel housing
coil and non-magnetic steel housing offers outstand- N Compact and robust construction
ing performance. N No lubrication required
N Simple installation and configuration
The absence of residual static force and the excellent
relationship between the linear force and current
make these motors ideal for use in micro-positioning
applications. Position control of the QUICKSHAFT®
Linear DC-Servomotor is made possible by the built-in
Product Code
Hall sensors.
Performance lifetime of the QUICKSHAFT® Linear DC-
Servomotors is mainly influenced by the wear of the
sleeve bearings, which depends on operating speed
and applied load of the cylinder rod.

LM Linear Motor
L M 1 2 4 7– 0 2 0 – 0 1
12 Motor width [mm]
47 Motor length [mm]
020 Stroke length [mm]
01 Sensors type: linear

39
Precision Gearheads

WE CREATE MOTION

40
Precision Gearheads
Technical Information

General information Input speed

The recommended maximum input speed for continuous
Life performance
operation serves as a guideline. It is possible to operate
The operational lifetime of a reduction gearhead and
the gearhead at higher speeds. However, to obtain
motor combination is determined by:
optimum life performance in applications that require con-
N Input speed tinuous operation and long life, the recommended speed
N Output torque should be considered.
N Operating conditions Ball bearings
N Environment and Integration into other systems Ratings on load and lifetime, if not stated, are according
Since a multitude of parameters prevail in any application, to the information from the ball bearing manufacturers.
it is nearly impossible to state the actual lifetime that can Operating temperature range
be expected from a specific type of gearhead or motor- Standard range as listed on the data sheets.
gearhead combination. A number of options to the Special executions for extended temperature range
standard reduction gearheads are available to increase available on request.
life performance: ball bearings, all metal gears, reinforced
lubrication etc. Reduction ratio
The listed ratios are nominal values only, the exact ratio
Bearings – Lubrication for each reduction gearhead can be calculated by means of
Gearheads are available with a range of bearings to meet the stage ratio applicable for each type.
various shaft loading requirements: sintered sleeve bear-
Output torque
ings, ball bearings and ceramic bearings. Where indicated,
Continuous operation.
ball bearings are preloaded with spring washers of limited
The continuous torque provides the maximum load pos-
force to avoid excessive current consumption.
sible applied to the output shaft; exceeding this value will
A higher axial shaft load or shaft pressfit force than speci- reduce the service life.
fied in the data sheets will neutralise the preload on the
Intermittent operation.
ball bearings.
The intermittent torque value may be applied for a short
The satellite gears in the 38/1-2 Series Planetary Gearheads period. It should be for short intervals only and not exceed
are individually supported on sintered sleeve bearings. 5% of the continuous duty cycle.
In the 44/1 Series, the satellite gears are individually sup-
ported on needle or ball bearings. Direction of rotation, reversible
All gearheads are designed for clockwise and counter-
All bearings are lubricated for life. Relubrication is not
clockwise rotation. The indication refers to the direction
necessary and not recommended. The use of non-approved
of rotation as seen from the shaft end, with the motor
lubricants on or around the gearheads or motors can
running in a clockwise direction.
negatively influence the function and life expectancy.
The standard lubrication of the reduction gears is such as Backlash
to provide optimum life performance at minimum cur- Backlash is defined by the amount by which the width
rent consumption at no-load conditions. For extended life of a tooth space exceeds the width of the engaging tooth
performance, all metal gears and heavy duty lubrication on the pitch circle. Backlash is not to be confused with
are available. Specially lubricated gearheads are available elasticity or torsional stiffness of the system.
for operation at extended temperature environments and The general purpose of backlash is to prevent gears from
under vacuum. jamming when making contact on both sides of their teeth
simultaneously. A small amount of backlash is desirable
Notes on technical data to provide for lubricant space and differential expansion
between gear components. The backlash is measured on
Unspecified tolerances
the output shaft, at the last geartrain stage.
Tolerances in accordance with ISO 2768 medium.

≤ 6 = ± 0,1 mm
≤ 30 = ± 0,2 mm
≤ 120 = ± 0,3 mm

41
Zero Backlash Gearheads How to select a reduction gearhead
The spur gearheads, series 08/3, 12/5, 15/8, 16/8 and 22/5,
with dual pass geartrains feature zero backlash when pre- This section gives an example of a step-by-step procedure
loaded with a FAULHABER DC-Micromotor. on how to select a reduction gearhead.
Preloaded gearheads result in a slight reduction in overall
Application data
efficiency and load capability.
The basic data required for any given application are:
Due to manufacturing tolerances, the preloaded gear-
Required torque M [mNm]
heads could present higher and irregular internal friction Required speed n [rpm]
torque resulting in higher and variable current consump- Duty cycle δ [%]
Available space, max. diameter/length [mm]
tion in the motor. Shaft load radial/axial [N]
However, the unusual design of the FAULHABER zero
backlash gearheads offers, with some compromise, an The assumed application data for the selected example are:
excellent and unique product for many low torque, Output torque M = 120 mNm
high precision postioning applications. Speed n = 30 rpm
Duty cycle δ = 100%
The preloading, especially with a small reduction ratios, Space dimensions, max. diameter = 18 mm
is very sensitive. This operation is achieved after a defined length = 60 mm
Shaft load radial = 20 N
burn-in in both directions of rotation. For this reason, axial = 4N
gearheads with pre-loaded zero backlash are only available
To simplify the calculation in this example, the duty cycle is
when factory assembled to the motor.
assumed to be continuous operation.
The true zero backlash properties are maintained with
new gearheads only. Depending on the application, a slight Preselection
backlash could appear with usage when the gears start A reduction gearhead which has a continuous output
wearing. If the wearing is not excessive, a new preload torque larger than the one required in the application
could be considered to return to the original zero backlash is selected from the catalogue.
properties. If the required torque load is for intermittent use, the
selection is based on the output torque for intermittent
Assembly instructions operation.
It is strongly recommended to have the motors and The shaft load, frame size and overall length with the
gearheads factory assembled and tested. This will assure motor must also meet the minimum requirements.
perfect matching and lowest current consumption. The product selected for this application is the planetary
The assembly of spur and hybrid gearheads with motors gearhead, type 16/7.
requires running the motor at very low speed to ensure
Output torque, continuous operation Mmax. = 300 mNm
the correct engagement of the gears without damage. Recommended max. input speed for
– Continuous operation n ≤ 5 000 rpm
The planetary gearheads must not be assembled with – Shaft load, max. radial ≤ 30 N
the motor running. The motor pinion must be matched axial ≤5N
with the planetary input-stage gears to avoid misalign-
Calculation of the reduction ratio
ment before the motor is secured to the gearhead.
To calculate the theoretical reduction ratio, the recom-
When face mounting any gearhead, care must be taken mended input speed for continuous operation is divided
not to exceed the specified screw depth. Driving screws by the required output speed.
beyond this point will damage the gearhead. Gearheads
with metal housing can be mounted using a radial set Recommended max. input speed
iN =
required output speed
screw.
From the gearhead data sheet, a reduction ratio is selected
which is equal to or less than the calculated one.

For this example, the reduction ratio selected is 159 : 1.

42
Precision Gearheads
Technical Information

Calculation of the input speed ninput

ninput = n · i [rpm]

ninput = 30 · 159 = 4 770 rpm

Calculation of the input torque Minput

M · 100
Minput = ––––––– [mNm]
i·

The efficiency of this gearhead is 60%, consequently:

Minput = 120 · 100

–––––––– = 1,26 mNm
159 · 60

The values of
Input speed ninput = 4 770 rpm
and
Input torque Minput = 1,26 mNm
are related to the motor calculation.

The motor suitable for the gearhead selected must be

capable of producing at least two times the input torque
needed.
For this example, the DC-Micromotor type 1624 E 024 S
supplied with 14 V DC will produce the required speed and
torque.
For practical applications, the calculation of the ideal
motor-gearhead drive is not always possible.
Detailed values on torque and speed are usually not
clearly defined.
It is recommended to select suitable components based
on a first estimation, and then test the units in the applica-
tion by varying the supply voltage until the required speed
and torque are obtained.
Recording the applied voltage and current at the point of
operation, along with the type numbers of the test assem-
bly, we can help you to select the ideal motor-gearhead.
The success of your product will depend on the best
possible selection being made!
For confirmation of your selection and peace of mind,
please contact our sales engineers.

43
Precision Gearheads
Planetary Gearheads 1

Planetary Gearhead
7

1 Motor flange
2 Screws 8
3 Washer
4 Satellite gears 9
5 Planet carrier 10
6 Sun gear
7 Satellite gear shafts
8 Output shaft 11
9 Washer
10 Sintered bearing
11 Housing / ring gear 10
12 Retaining ring 9
12

Features Benefits
Their robust construction make the planetary gearheads, N Available in all plastic or metal versions
in combination with FAULHABER DC-Micromotors, ideal N Use of high performance materials
for high torque, high performance applications. N Available with a variety of shaft bearings including
sintered, ceramic, and ball bearings
In most cases, the geartrain of the input stage is made of
plastic to keep noise levels as low as possible at higher N Modified versions for extended temperature and special
environmental conditions are available
RPM‘s. All steel input gears as well as a modified lubri-
N Custom modifications available
cation are available for applications requiring very high
torque, vacuum, or higher temperature compatability.

For applications requiring medium to high torque

FAULHABER offers planetary gearheads constructed of
high performance plastics. They are ideal solutions for
applications where low weight and high torque density Product Code
play a decisive role. The gearhead is mounted to the
motor with a threaded flange to ensure a solid fit.

All metal planetary

gearhead series 12/4 26 Outer diameter [mm]
2 6 A 6 4 :1
A Version
64:1 Reduction ratio

44
Precision Gearheads
Spur Gearheads

3
4

5
6

Spur Gearhead

8
1 Housing
2 Screws
2
3 End plate
4 Intermediate plate
9
5 Gear wheel
6 Sleeve
7 Dowel pin 7

8 Output shaft
10
9 Front cover
11
10 Spacer ring
12
11 Ball bearing
13
12 Spring washer 14
13 Washer
14 Retaining ring

Features gear passes to each other and locking them in place on

A wide range of high quality spur gearheads are avail- the motor pinion gear. They are ideal for positioning
able to compliment FAULHABER DC-Micromotors. applications with a very high resolution and moderate
The all metal or plastic input-stage geartrain assures torque. Zero backlash gearheads can only be delivered
extremely quiet running. The precise construction of the preloaded from the factory.
gearhead causes very low current consumption in the
motor, giving greater efficiency. The gearhead is sleeve Benefits
mounted on the motor, providing a seamless in-line fit. N Available in a wide variety of reduction ratios
The FAULHABER Spur Gearheads are ideal for high including very high ratios
precision, low torque and low noise applications. N Zero backlash versions are available
N Available with a variety of shaft bearings including
Zero Backlash Spur Gearhead sintered, ceramic, and ball bearings
1

1 Motor pinion
2 Dual-pass geartrain
Product Code
input stage
3 Zero backlash preloaded
engagement

2 3 3 2

FAULHABER offers a special version of a spur gearhead

with zero backlash. These gearheads consist of a dual pass
spur geartrain with all metal gears. The backlash is reduc- 22 Outer diameter [mm]
/5 Version 2 2/5 3 7 7 :1
ed to a minimum by counter-rotating the two individual 377:1 Reduction ratio

45
Precision Gearheads
Hybrid Gearheads
2

6
1

7
Hybrid Gearhead

1 Screw
2 End plate 10

3 Intermediate plate
Blind
4 Gear wheel

5
1 Sun
Blindgear 11
6
2 Satellite
Blind carrier
7
3 Satellite
Blind gear
8
8
4 Dowel
Blind pin
9
5 Pin
Blind 9
12
10
6 Support
Blind
13
11
7 Ball
Blindbearing 14
12 Ring gear 11
13 Housing
14 Spring washer 15
15 Output shaft

Features Benefits
Hybrid gearhead combine the smooth running input N Unique construction
stages of a spur gearhead with the power of a planetary N Combines the advantages of spur and planetary
output stage. For added power, the output shaft and gearhead technology in one unit

planet carrier are one single piece. The geartrain is metal

but the casing is plastic thereby reducing the overall
weight of the gearhead without compromising its perfor-
mance.

The motor is assembled with a slip fit in the gearhead

housing for a seamless concentric fit.

Product Code

22 Outer diameter [mm]

2 2 /6 3 4 :1
/6 Version
34:1 Reduction ratio

46
Encoders

WE CREATE MOTION

47
Encoders
Technical Information

Output current, max. (l OUT)

Indicates the maximum allowable load current at the
signal outputs.
Encoders
Puls width (P)
Optical Encoders with Line Driver
Width of the output signal in electrical degrees (°e) of
the channels A and B. The value corresponds to one full
period, or 360°e at channel A or B.
Series 40B Index pulse width (P0)
40B
Lines per revolution N 1 000 Indicates the width of the index pulse signal in electrical
Signal output, square wave 2 + 1 index an
Supply voltage V CC 4,5 ... 5,5 degrees.
Current consumption, max. (VCC = 5 V DC) I CC 100
Pulse width P 180 ± 18 Tolerance ΔP0:


Notes on technical data 




 

 


Lines per revolution (N)
The number of incremental encoder pulses per revolution Phase shift, channel A to B (&)
per channel. The phase shift in electrical degrees between the fol-
The output signal is a quadrature signal which means that lowing edge of output channel A and the leading edge
both the leading and following edge, or flank, can be of output channel B.
evaluated. For example, an encoder with two channels Phase shift tolerance (Δ&)
and 256 lines per revolution has 1024 edges, or flanks per Indicates the allowable position error, in electrical degrees,
revolution. between the following edge of channel A to the leading
Output signal edge of channel B.
The number of output channels. For example, the IE3
encoders offer 2 channels, A and B, plus an 1 additional 





 


index channel.  

Signal period (C)

 The total period, measured in electrical degrees of one


pulse on channel A or B.
Typically one period is 360 °e.


C
 P

Amplitude

A






S S S S
tr tf
Supply Voltage (UDD)
Defines the range of supply voltage necessary for the B
encoder to function properly.

Current consumption, typical (IDD) Direction of Rotation

Indicates the typical current consumption of the encoder
at the given supply voltage.

48
Logic state width (S)
The distance measured in electrical degrees (°e) between
two neighbouring signal edges, for example the leading
edge of signal A to the leading edge of signal B.
Typically this has a value of 90 °e.

Signal rise/fall time, typical (tr/tf)

Corresponds to the slope of the rising and falling signal
edges.

Frequency range (f)

Indicates the maximum encoder frequency. The maximum
achievable motor speed can be derived using the follow-
ing formula.

60 . f
n=
N

Inertia of the code disc (J)

Indicates the additional inertial load due on the motor
due to the code wheel.
Operating temperature range
Indicates the minimum and maximum allowable
temperature range for encoder operation.
Test speed
The speed at which the encoder specifications were
measured.

Line Driver
This is an integrated signal amplifier in the encoder that
makes it possible to send the encoder signals through
much longer connection cables. It is a differential
signal with complementary signals to all channels which
eliminates sensitivity to ambient electrical noise.

49
Optical Encoders
Technical Information

6
Optical Encoder

1 Output shaft
2 Motor
3 Code wheel
4 Adapter flange
5 Encoder PCB
6 End cap 7
7 Flex cable

Features Benefits
Optical encoders use a continuous infrared light source N Very low current
transmitting through a low-inertia multi-section rotor disk consumption

which is fitted directly on the motor rear end shaft. N Precise signal resolution

The unit thus generates two output signals with a 90° N Ideal for low voltage
battery operation
phase shift.
N Insensitive to magnetic
In optoreflective encoders, the light source is sent interference

and reflected back or alternately absorbed to create the N Extremely light and compact

necessary phase shifted pulse.

Product Code

PA Encoder series
2 Number of Channels
PA 2 - 5 0
50 Resolution

50
Integrated Encoders
Technical Information
1

4 7

DC-Micromotor
with integrated Encoder 5
8

1 Shaft
2 Coil
3 Commutator
4 DC-Micromotor
5 Magnet wheel
6 Brush cover
7 Brushes
8 Flat cable
9
9 Encoder PCB
10 End cap

Features Benefits
10
Series IE2 encoders consist of a rotormounted magnetic N Highly compact design
toothed ring and a special hybrid circuit. N High resolution up to 2 048 steps per revolution
The magnetic field differences between the tip and base (corresponding to an angular resolution of 0,18°)
of each tooth are converted into electrical signals by a N No pull-up resistors across outputs because no
open-collector outputs
sensor integrated into the circuit.
N Symmetrical pulse edges, CMOS- and TTL -compatible
This signal is then processed by a proprietary circuit.
N Low power consumption
The output consists of two 90°-offset square-wave signals
N Available in many combinations
with up to 512 pulses.

The encoder is integrated into the SR-Series motors, in-

creasing its length by a mere 1,4 mm and as built-on option
for DC-Micromotors and brushless DC-Servomotors.
Product Code

IE Incremental Encoder
IE 2 – 5 1 2
2 Number of Channels
512 Resolution

51
Magnetic Encoders
Single Chip
1

Magnetic Encoder
Single Chip 7

1 Screws
2 Rear cover
3 Encoder PCB
8
4 Encoder flange
5 Screws
6 Motor flange
7 Sensor magnet
8 Motor Serie CR/CXR

Features Benefits
FAULHABER IE3 encoders are designed with a diametri- N Compact modular system
cally magnetized code wheel which is pressed onto the N A wide range of resolutions are available
motor shaft and provides the axial magnetic field to the N Index channel
encoder electronics. The electronics contain all the N Line Drivers are available
necessary functions of an encoder including Hall sensors, N Standardized encoder outuputs
interpolation, and driver. The Hall sensors sensed the N Ideal for combination with FAULHABER
rotational position of the sensor magnet and the signal is Motion Controllers and Speed Controllers

interpolated to provide a high resolution position signal. N Custom modifications including custom resolution,
index position and index pulse width are possible
The encoder signal is a two channel quadrature output
with a 90 °e phase shift between channels.
A third channel provides a single index pulse per revolu-
tion. These encoders are available as attachable kits Product Code
or preassembled to FAULHABER DC-Motors with graphite
commutation, or as integrated assemblies for many
FAULHABER Brushless DC-Servomotors.

IE Incremental Encoder
IE3 – 256 L
3 Number of Channels
256 Resolution
L with integrated Line Driver

52
DR. FRITZ FAULHABER
GMBH & CO. KG
Daimlerstraße 23/25
71101 Schönaich · Germany
Tel.: +49 (0) 7031 638 0
Fax: +49 (0) 7031 638 100
info@faulhaber.de

DFF_TI_03-2010_EN

www.faulhaber.com

53