This article explores the key innovations of the powerful AZX Series, a servo motor and driver system designed to be user-friendly and cost-effective compared to traditional servo motor systems.
What’s Covered?
- Meeting Unmet Requirements
- Higher Torque and Higher Speed Characteristics
- Proven Battery-Free Mechanical Absolute Encoder Technology
- Challenge: Thermal Design Improvements
- Same Operability as the AZ Series
- Summary
Meeting Unmet Requirements
As someone who has spent years working with stepper motors across industries, I understand the demand for speed. Higher throughput boosts production efficiency, so faster is always better. Hybrid stepper motors often struggle with large inertial loads, long strokes, or quick acceleration/deceleration ramps. Even our high-performance AlphaSTEP closed-loop AZ Series Step-Servo motors face limitations.
By integrating proven mechanical absolute encoder (ABZO sensor) technology from the AZ Series with SPM (Surface Permanent Magnet) technology, the AZX Series servo motors deliver more torque and speed while maintaining ease of use. Whether upgrading existing equipment or designing new systems, understanding this technology could be crucial for meeting your needs.
Higher Torque and Higher Speed Characteristics
For the AZX Series, we aimed to generate more high-speed torque than the AZ Series, shifting from a hybrid stepper motor design to an SPM (Surface Permanent Magnet) design. In an SPM design, permanent magnets are attached to the surface of the rotor. This change allows us to output up to 3 times the maximum instantaneous torque compared to rated torque and maintain consistent torque output from low to high speeds (up to 5,500 RPM). This facilitates rapid acceleration and deceleration, significantly reducing positioning time even for long-distance moves.
Compared to the existing AlphaSTEP AZ Series Step-Servo motors, the speed-torque performance of the AZX Series offers higher max RPM and much more maximum instantaneous torque in the limited duty region. This maximum instantaneous torque can be used to accelerate or decelerate the load faster.
Proven Battery-Free Mechanical Absolute Encoder Technology
Unlike optical absolute encoders, which require an LED to produce light pulses through a wheel with slits, mechanical absolute encoders are simpler in design, more robust, and less expensive to manufacture. They operate by sensing the positions of permanent magnets on multiple disks, eliminating the need for a battery. This eliminates typical costs associated with optical absolute encoders, such as batteries, cables, external sensors, and maintenance, making the AZX Series more competitively priced than traditional servo motor and driver systems.
The integration of the mechanical absolute encoder into a servo motor brings several functional advantages from the AZ Series, such as multi-turn absolute position control, the ability to operate in harsher environments, instant resumption of operation after power failure without homing, wrap/proximity positioning, and fast sensorless homing cycles. However, the mechanical absolute encoder has limitations, such as a maximum of 1,800 rotations and lower resolution than optical encoders. Unless you're continuously moving for a long time or need to be ultra-precise, these limitations should not affect most applications.
Challenge: Thermal Design Improvements
One of the most impressive aspects of the AZX Series is its sophisticated thermal management system. As someone who has dealt with countless motor failure cases due to thermal issues, I can appreciate the engineering that went into this design.
The existing AZ Series could not reach higher RPM due to excessive heat generated by the iron loss of the motor. This heat could exceed the upper limit for the mechanical absolute sensor. For the AZX Series, we switched to an SPM (Surface Permanent Magnet) motor design to reduce heat generated during high-speed operation.
The AZX Series also integrates a heat dissipation sheet with higher thermal conductivity than air between the mechanical absolute encoder and the aluminum sensor cover, which efficiently conducts the heat the mechanical absolute encoder receives from the motor to the sensor cover. The installation of the heat insulation plate between the sensor cover and the motor (heat source) suppresses the temperature rise of the sensor cover and efficiently releases the heat.
The result is a 10° C reduction in the operating temperature of the mechanical absolute encoder, which maintains performance even at higher ambient temperatures and extends service life through better thermal management.
Same Operability as the AZ Series
While the performance characteristics are different, the control architecture of the AZX Series driver offers the same operability as the AZ Series, such as signal wiring, parameter functions, parameter IDs, and positioning functions. If you have used an AZ Series driver, there's no learning curve.
The AZX Series is compatible with three major industrial communication protocols: EtherNet/IP™, EtherCAT®, and PROFINET. Minimize wiring and enable more control by controlling or monitoring your motor via network commands.
In addition, the AZX Series includes several sophisticated features that simplify implementation:
- Gain Tuning Capabilities
- Automatic inertia estimation
- Real-time response adjustment
- Advanced resonance suppression
- Programming Functions
- Simple sequence function implementation
- Hierarchical I/O structure
- Wrap positioning functions specific for rotary index tables/actuator operation
The MEXE02 software used by the AZX Series is intuitive and easy to use. Up to 256 unique stored motion profiles can be programmed easily and linked in many different ways (more is possible through direct-data operation via network command).
Summary
The AZX Series represents a significant advancement in motor technology, especially in addressing the long-standing challenges of high-speed, high-torque applications. This series offers substantial improvements in performance while maintaining the same functionalities as the AZ Series. The combination of improved thermal management, advanced control capabilities, and simplified integration makes the AZX Series a compelling choice for various industrial applications, such as packaging, assembly, material handling, as well as precise applications like semiconductors, medical devices, and laboratory automation.
For the AZX Series, we currently offer two wattage models: 400 W (1/2 HP) and 600 W (4/5 HP) in either round-shaft (ungeared) or planetary geared types. An optional pre-assembled electromagnetic brake is available for vertical operations where loads need to be held when powered off. For round-shaft motors, rated torque ranges from 180 oz-in to 270 oz-in, and maximum instantaneous torque ranges from 540 oz-in to 1,020 oz-in. For geared motors, the rated torque ranges from 50 lb-in to 370 lb-in, and maximum instantaneous torque can be as much as 1,400 lb-in. Both position and speed control modes are available on the AZX Series. For advanced modes, such as tension control, please refer to our NX Series.
As manufacturing continues to evolve toward higher speeds and greater precision, technologies like the AZX Series will become increasingly important. The integration of advanced features while maintaining compatibility with existing systems positions this technology well for future adoption and expansion.
For engineers and system integrators looking to increase production throughput, improve precision in automated processes, or optimize their automation systems, the AZX Series provides a robust solution that addresses many common challenges while offering room for future growth and adaptation.
For help with motor sizing or selection, please contact our helpful technical support engineers.
die cavity
- A hollow or recessed section of a die into which the punch forces the metal to form it.
- Mold cavity is a mold term for production and manufacturing, that is, the part that constitutes the product space is called a molded part (that is, the entire mold), and the part that molds the outer surface of the product (mold) is called a cavity
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The concave part is the cavity, also known as the front mold or master mold,
The corresponding raised part is called the core. Also known as back mold or male mold.
The cavity of the mold is closed with the core, and the gap in the middle is the product.
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