The Hyperdrive10 High Power Stepper Motor ControllerThe Hyperdrive10 controller shown in Figure 1 contains a dedicated, high performance, high power, bipolar stepper motor controller interfaced to a 32-bit Arm microprocessor configured with both 4-wire RS485 and USB Modbus interfaces. It provides four isolated high speed 24V inputs and two high current isolated 60V switching outputs. The USB Modbus interface provides easy IOT access via standard ethernet to USB adapters. The controller has been designed to provide high-power stepper motor control for applications requiring up to 72 volts and up to 10 amps.The screw connectors provide the 48V power and bipolar stepper motor connections, the 4 input connections, the 2 output connections, and the in and out 4-wire RS485 connections. The USB connector is mounted inside on the PCB. All inputs and outputs are electrically isolated.An internal 8-position switch allows for several possible software configurations. Three of these switches are dedicated to defining the controller’s address on a serial Modbus line with the remaining switches available for special configurations.In a multi-motor machine one controller can be specified as the master, and up to six other controllers slaved to that motor for speed, with an option to exactly match the master motor accel and decel rates regardless of individual speed settings. Controllers in such a system can include speed ratios and fine speed offsets to provide for gearing and fine master speed synchronisation.There are many control parameters configurable via Modbus registers. They are therefore accessible for either monitoring or modification by a Human Machine Interface (HMI) using RS485 or a control computer system using USB or ethernet. The various configurable parameters include defining I/O low- or high-going inputs, input debounce times, and several timer functions to set responses associated with input events. Nearly all the motor parameters are available for configuration. These include speed, accel and decel rates along with stopped, accel, decel and running power settings. Various limits can be set including what level of micro-stepping is used and at what speed the motor switches from micro-stepping to full-step to maintain high-speed torque.All the Modbus settings that must survive a power loss such as modes and accelerations are backed up within the controller and are automatically restored when power is restored.Ancillary controls monitor the input power and control voltages and the controller case temperature, and these are available via read-only Modbus registers.Control for a fan is provided for applications requiring particularly high powers or where the controller must function in a high temperature environment. The fan is temperature controlled, so in most situations will not run continuously.The control software is written to emulate the typical functions available on most PLC controllers, and so can be quickly configured to a particular motor control regime due to the number of inputs, outputs, internal timers, motor configurations and Modbus responses available.Of particular interest is the fact Kremford can provide controller software modifications to suit customer requirements. We can also provide HMI design both for an individual controller and for a set of controllers in a particular machine.
Stepper Motors, Motor Controllers, Hyperdrive,
Total Solutions Specialist
Kremford Pty Ltd are specialists in the design and manufacture of applications based motor
controllers for Australian industry
An excellent example is the successful Hyperdrive product; an Integrated PLC based Programmable Stepper Motor Controller. Designed for medium power applications, the Hyperdrive is fully programmable using a simple programming language with over forty commands to set speed, acceleration, delays and movement profiles, with versatile input/output options available that can modify motor profile behaviour and provide external device control. A powerful and easy to apply stepper motor controller.To complement our reputation as a solutions company, Kremford Pty Ltd is the Australian distributor for one of the top US electric motor manufacturers, Schneider Electric Motion.Kremford Pty Ltd has the knowledge and resources to assist you with unusual motor applications and help bring your vision to life and your inventions to market.Our background and experience in the design and manufacture of specialist electronics and associated software to customer specifications and requirements means we can help you with the design, specification and implementation for your specific machine. Not only all that, but we can also offer marketing and distribution advice, even becoming your distributor in some cases.
The Schneider Electric Motion range of products available from Kremford include: The new Lexium motors in a range of standard Nema sizes with control inputs ranging from step/direction, Ethernet, CANopen, Modbus and Profinet, all with the option to include Programmable Motion Control. These motors provide servo motor capabilities with stepper motor versatility.The established MDrive Plus Integrated Motion motors include compact and powerful Linear Actuators with an extensive range of screw lengths, and a range of Rotary motors with integrated electronics and optional Encoders. The MDrive Hybrid Rotary motors come with integrated electronics offering the benefit of both stepper motor and servo motor technologies, and higher torque output than conventional stepper motors. In addition to motors, the Schneider range includes Microstepping Panel Mounted Drivers providing high performance in a compact package, and Discrete PCB mounted Drivers offering high performance in an ultra-miniature package.