Haydon Kerk Motion Solutions recently announced the latest addition to its IDEA drive line of motor controllers: the PBL4850E programmable 3-phase brushless motor drive. With the PBL 4850E, Haydon Kerk replicates the functionality of stepper-based drives for its brushless counterparts as the two drive types now share a common graphical user interface. 

Among the features of the graphical user interface is automatic population of motion profile parameters based on entry of just a few motor characteristics. Complex parameter calculations or in-depth motor knowledge are completely unnecessary. Users are be able to prototype their applications with ease. Furthermore, Haydon Kerk’s IDEA software makes programming motors even easier through the use of intuitive, on-screen buttons, instead of complicated command sets or proprietary programming languages. 

The PBL4850E is a 4-quadrant brushless controller that utilizes sinusoidal commutation to produce smooth motion. The smooth torque produced by sinusoidal commutation minimizes torque ripple. The drive further refines motion by incorporating two motion profiles: trapezoidal and s-curve. The latter may be used to eliminate jerk due to rapid changes in velocity rates during motion. 

The drive offers programmable current control of up to 5.6A peak with an optional current boost during ramping of up to 6.5A peak. With an input voltage of 12-48 VDC, the drive can accommodate a wide range of brushless motors. Hall cell signals are used for phase initialization, and an encoder provides positional feedback. 

 

Other features include 8 opto-isolated general purpose inputs and outputs. Each input is rated for 5 to 24 VDC, 8 mA maximum per input. The outputs are open collector, 5 to 24 VDC, 200 mA maximum per output. The PBL4850E IDEA drive communicates via a USB to mini USB. 

The Idea software is configurable with numerous programming units to provide versatility in creating programs with the PBL4850E drive. Selecting units of revolutions creates a platform for users to generate complex velocity motion profiles geared towards rotary-based applications.

 Selecting units of inches or millimeters simplifies programming within a linear-based setup by allowing users to program with native units within the system to generate motion profiles. 

With the addition of the ECO series of brushless motors offered by Pittman Motors, another brand of AMETEK Precision Motion Control, users can more easily integrate brushless motors into linear-based systems. The Pittman motors are optimized for integration with Haydon Kerk lead screw assemblies and linear rail and guide systems.  

The combination of these capabilities sets the stage for a powerful platform in linear systems between stepper and brushless motor technology. With a common graphical user interface between the two drives and a common footprint between assemblies’, users now can seamlessly transition between the two technologies to find the best solution for new designs.

Real-time and programmable methods of operation make the drives ideal for prototyping and integration into systems. Users can instantly witness motion when sending commands directly to the drive via the USB interface. This allows users to easily send motion profiles with varying parameters to determine torque and speed limitations under load during design. 

The drive also is well suited for integrating into systems because it can store a wide range of programs into memory and is capable for executing them outside of the software, without a connection to a computer. The Idea software allows system designers to easily troubleshoot programs using line-by-line or multiple line program execution and an interactive debug feature. Inputs and outputs can be simulated using the software before connecting actual I/O hardware. Driving brushless motors has never been easier.