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Allen Bradley - Motors

Y Series

Allen Bradley Y Series Servo Motors Selection Guide

Overview

The Allen-Bradley Y-Series features electronically commutated (EC) brushless servo motors, available with either 115V or 230V AC motor windings. These servo motors employ a closed-loop feedback system that allows for precise control of velocity, position (linear or angular), and acceleration. They are typically designed and built to drive machinery in light industrial applications, including the following:

  • Light packaging machinery
  • Robotics
  • Office machinery
  • Semiconductor manufacturing
  • X-Y tables
  • Material handling
  • Laboratory/medical equipment
  • Specialty machinery

The Allen-Bradley Y-Series product line comprises the following servo motor models:

  • Y-1002-1 Model: 1002 Frame Size, 115V AC motor winding
  • Y-1002-2 Model: 1002 Frame Size, 230V AC motor winding
  • Y-1003-1 Model: 1003 Frame Size, 115V AC motor winding
  • Y-1003-2 Model: 1003 Frame Size, 230V AC motor winding
  • Y-2006-1 Model: 2006 Frame Size, 115V AC motor winding
  • Y-2006-2 Model: 2006 Frame Size, 230V AC motor winding
  • Y-2012-1 Model: 2012 Frame Size, 115V AC motor winding
  • Y-2012-2 Model: 2012 Frame Size, 230V AC motor winding
  • Y-3023-2 Model: 3023 Frame Size, 230V AC motor winding

Selecting the Right Allen Bradley Y Series Servo Motor

The process of selecting the correct servo motor for a given servo system or application is commonly referred to as motor sizing. This process is very important because the selected servo motor must produce the required load torque and speed, fit in the available installation space, and perform as intended under the subjected environmental conditions of a particular application. As such, the process of properly sizing a Y-Series servo motor begins with specifying the application and then selecting a motor that can best meet the requirements of that application.

Discussed below are the most important factors you should take into consideration when selecting an Allen-Bradley Y-Series brushless servo motor for a particular application or servo system.

1. Inertia

In servo systems, inertia can be defined as the tendency of the connected load to resist change in acceleration. It is important to calculate this parameter when sizing a Y-Series servo motor to ensure that your servo system will be able to control the connected load efficiently. As the selected Y-Series servo motor must be able to apply adequate torque (in a rotational servo system) to change the acceleration of the connected load, and it should do so in a controlled manner.

Essentially, to correctly size a Y-Series servo motor, you will need to calculate its Inertia Ratio – defined as the ratio of the system’s load inertia to the rotor inertia (inertia of the servo motor), mathematically expressed as: Inertia Ratio=JL/JM where,

  • JL = Moment of inertia of the overall system load
  • JM = Moment of inertia of the Y-Series servo motor

The Inertia Ratio provides a measure of how effectively a Y-Series servo motor can control the connected load. A high Inertia Ratio is an indication that the Y-Series servo motor will have problems controlling the load effectively. At the same time, a low Inertia Ratio (e.g., 2:1, 1:1, or 4:1) indicates that the servo motor can effectively control the load.

A lower Inertia Ratio is preferable for increased system performance as control loop tuning is easier at lower inertia ratios. However, selecting an extremely low Inertia Ratio may bring about a downside of more motor weight, size, and costs relative to the performance gains, as you might end up with an oversized servo motor for your application.

Note: You can find the values of the rotor moment of inertia (JM) for Y-Series servo motors from the data sheets provided by the manufacturer – Rockwell Automation. And when calculating the moment of inertia of the system’s load (JL), be sure to include any additional mechanical components that the selected Y-Series servo motor will be moving, such as belts, pulleys, couplings, power rails, lead screws, etc. – as they all contribute to the overall load inertia. In essence, the load inertia (JL) is more properly termed as the reflected inertia (JR) – the inertia reflected back to the shaft of the servo motor from the connected load and all the mechanical components in between.

2. Operating Speed

You will need to select a Y-Series servo motor rated for use at the speeds required by your application or servo system. Determining the inertia ratio and motion profile of the servo system will assist you in figuring out the speed, acceleration, and torque requirements that the selected servo motor will need to meet.  It also helps to know the distance the connected load will need to be moved by the Y-Series servo motor and at what speed.

In addition, you can refer to the Y-Series speed-torque curves provided by Rockwell Automation. These data plots describe the performance of Y-Series servo motors across different operating speeds. They thus provide an easy reference for determining whether the servo motor you intend to select will meet the speed requirements of your servo system. Generally, Allen-Bradley Y-Series servo motors are available with maximum operating speeds of 4500 RPM and 5000 RPM.

Note: The rated speed (in RPM) is the top speed at which the servo motor produces its rated torque. Maximum speed (given in RPM) is the highest speed the servo motor can attain without damaging the rotor bearings and other components.

3. Torque Requirements

Once the load inertia and speed requirements (desired acceleration and deceleration) are known, you can determine the torque (rotational force) required to move or position the connected load as needed. You can determine the amount of torque a Y-Series servo motor can generate from the Y-Series torque-speed curves provided by Rockwell Automation.

When sizing Y-Series servo motors, torque specifications generally refer to the following:

Continuous Torque: This refers to the maximum torque generated by a servo motor at normal running conditions, including acceleration, deceleration, constant velocity, and dwell. The continuous torque required by an application should ideally fall in the continuous operating zone of the torque-speed curve of the selected Y-Series servo motor to maintain the rated operating speed.

Continuous rated torque refers to the continuous torque a servo motor can output at rated RPM speed. The continuous torque rating measures a motor’s ability to generate the rated torque and rated RPM speed without its windings overheating; it defines the motor’s working range.

Note: The physical size of a Y-Series servo motor may be determined by its continuous torque-generating capacity with a trade-off between its length and diameter. For instance, a shorter servo motor with a large diameter can have the same continuous torque rating as a longer, smaller-diameter servo motor. You can also use a gear train or other torque-multiplying technologies with a smaller Y-Series servo motor to achieve the power requirements of your application.

Peak Torque: This is the highest amount of torque a servo motor can output at a given speed for a short period (usually a minute or two) throughout the motor’s operating cycle. Ideally, the peak torque that an application requires should fall in the intermittent zone of the torque-speed curve of the selected Y-Series servo motor because it is not sustainable. If it falls within the continuous operating zone of the motor’s torque-speed curve, the Y-Series servo motor may be oversized.

Servo motors are normally designed to operate in the peak torque range only when overcoming friction or decelerating/accelerating the connected load; thus, the amount of peak torque required by an application can be more than the rated torque of the selected Y-Series servo motor.

Stall Torque: This is the torque a servo motor generates when its output rotational speed (shaft speed) is zero. Continuous stall torque refers to the servo motor’s continuous torque at zero shaft speed (or stall).

4. Type of Feedback Device

Servo motors function as part of a closed-loop motion control system, producing torque and velocity as commanded by a servo controller and utilizing a feedback element to close the control loop. In most cases, the feedback device, which can be an encoder, resolver, Hall Effect sensor, linear transducer, or potentiometer, is integrated into the servo motor. In other cases, an external feedback device may be installed at a distance from the servo motor.

The integrated feedback device monitors the actual speed and/or position of the servo motor, and using the collected data, it generates an appropriate speed or position feedback signal and sends it to the servo drive or servo controller, which in turn adjusts the servo motor’s operating parameters to achieve the required motion. Therefore, be sure to select a Y-Series servo motor equipped with a feedback device that can best meet your servo system's resolution and control (torque/speed or position control) requirements.

Essentially, the Allen-Bradley Y-Series servo motors are available with an integral 2000 Standard Optical Encoder featuring a 2000 Line Count. As such, the Y-Series servo motors operate reliably with 2000 lines of encoder feedback.

5. Compatible Servo Drives

The Allen-Bradley Y-Series servo motors are designed to drive light industrial machinery. For this reason, they have to be used as part of a controlled servo system that incorporates a transistorized electronic servo drive or amplifier. They are not designed to connect directly to the system’s power supply or to be used with thyristor servo drives.

The function of the transistorized electronic servo drive is to amplify the control signal from the system’s servo controller to supply sufficient current and voltage to the connected Y-Series servo motor. This enables the servo motor to generate the required torque and speed to achieve the desired motion. That being the case, ensure that you select an Allen-Bradley Y-Series servo motor that is compatible with your system’s servo drive for effective performance of the servo system.

Generally, the Y-Series servo motors can be used with the following Allen-Bradley servo drives:

  • Ultra3000 (Bulletin 2098) Servo Drives: These are high-performance, digital servo drives that can be integrated with the ControlLogix control platform via the SERCOS (Serial Real-Time Communication System) digital interface for Kinetix Integrated Motion. They operate a wide array of Allen-Bradley rotary servo motors in various applications, from simple standalone indexing systems to multi-axis integrated motion platforms.
  • Kinetix 2000 (Bulletin 2093) Servo Drives: These multi-axis, low-power servo drives deliver a Kinetix Integrated Motion solution to motion control applications featuring output power requirements of 3 to 45 kW (4 …49 A).
  • Kinetix 6000 (Bulletin 2094) Servo Drives: These multi-axis servo drives provide Kinetix Integrated Motion capability through the SERCOS digital interface for demanding motion control applications. Typical applications for Kinetix 6000 servo drives include material handling, packaging, assembling, and converting.

Note: If you plan to use an Allen-Bradley Y-Series servo motor with either a Kinetix 6000 (Bulletin 2094) or Kinetix 2000 (Bulletin 2093) multi-axis servo drive, you will need to select an appropriate Integrated Axis Module (IAM) and an Axis Module (AM). The two are power modules that provide power and control to the Allen-Bradley servo motors operated by the servo above drives.

The Kinetix 2000 servo drive series is available with the following IAM and AM power modules:

  • 2093-AC05-MPx: This Integrated Axis Module mounts on a Bulletin 2093 power rail. It features a 230V AC power converter and inverter.
  • 2093-AMxx: This is an Axis Module that also mounts on a Bulletin 2093 power rail. It features a shared 230V DC bus power inverter. This power module must be used with a compatible Integrated Axis Module.
  • 2093-AMPx: This is an Axis Module installed on a Kinetix 2000 power rail. It features a shared 230V DC bus power inverter.  Also, it must be used with a compatible Integrated Axis Module.

The Kinetix 6000 servo drive series is available with the following IAM and AM power modules:

  • 2094-xCxx-Mxx-S: This product line includes Integrated Axis Modules with a 400V-class or 200 V-class AC supply and a safe torque-off feature. In addition, these IAM modules feature a power inverter and converter component. The 400V-Class (Series B or later) IAM power modules in this product line also include a peak enhancement feature.
  • 2094-xCxx-Mxx: This product line comprises Integrated Axis Modules with a 400V-class or 200 V-class AC input. These IAM power modules do not include a peak enhancement or a safe torque-off feature.
  • 2094-xMxx-S: These are Axis Modules with a safe torque-off feature. They feature shared DC-bus inverters and are rated for 400V or 200V-class AC operation. Each AM module in this series must be used with an Integrated Axis Module power module. The 400V-class (series B or later) Axis Modules are available with a peak enhancement feature.
  • 2094-xMxx: These are Axis Modules (AM) that include shared DC-bus inverters. They are rated for 400V-class or 200V-class AC input power. They do not have the peak-enhancement or safe torque-off feature. Each AM module in this series should be used with a compatible Integrated Axis Module.

6. Motor Brake Specifications

If your application or servo system requires holding brakes, be sure to select a Y-Series servo motor that’s available with a 24V DC optional brake. Also, check that the specifications of the included motor brake can meet the requirements of your servo system/application.

Note: The motor brakes provided as options on some of the Y-Series servo motors, such as Y-1002-2-H04AA, Y-1002-1-H04AA, Y-1003-2-H04AA, Y-1003-1-H04AA, Y-2006-2-H04AA, Y-2006-1-H04AA, Y-2012-2-H04AA, and Y-3023-2-H04AA function only as holding brakes. They are designed to clutch the shaft of the Y-Series servo motor at zero RPM until the rated holding torque is attained. Also, they are spring-type and release the motor shaft when an appropriate voltage is provided to the brake coil.

Application Guidelines for the Y Series Motor Brakes

The holding brakes on Y-Series servo motors are not designed to stop the rotational motion of the motor shaft; hence, they should not be used as mechanical restraining devices for safety purposes. Instead, it would be best if you stopped the rotation of the servo motor shaft using the inputs of the connected servo drive. The recommended technique for stopping the rotation of a Y-Series motor shaft is to command the connected servo drive to decelerate the Y-Series servo motor to zero RPM and engage the holding brakes once the servo drive has decelerated the servo motor to zero RPM. You will need a separate power supply to disengage the brakes.

Additionally, if the main power supply to the servo system fails, the holding brakes can withstand use as occasional stopping brakes. Using them as stopping brakes may create a mechanical-rotational- backlash, which can be potentially detrimental to the servo system. This also reduces the service life of the brakes due to increased wear.

7. Standard Motor Load-Force Ratings

Y-Series brushless servo motors can operate reliably with maximum axial or radial shaft loads.

  • Y Series Servo Motor: Y-3023
    • Maximum Axial Shaft Load (kg (lb)): 20 (44.1)
    • Maximum Radial Shaft Load (kg (lb)): 35 (77.175)
  • Y Series Servo Motor: Y-2012
    • Maximum Axial Shaft Load (kg (lb)): 10 (22.05)
    • Maximum Radial Shaft Load (kg (lb)): 25 (55.125)
  • Y Series Servo Motor: Y-2006
    • Maximum Axial Shaft Load (kg (lb)): 8 (17.64)
    • Maximum Radial Shaft Load (kg (lb)): 20 (44.1)
  • Y Series Servo Motor: Y-1003
    • Maximum Axial Shaft Load (kg (lb)): 3 (6.615)
    • Maximum Radial Shaft Load (kg (lb)): 10 (22.05)
  • Y Series Servo Motor: Y-1002
    • Maximum Axial Shaft Load (kg (lb)): 2 (6.615)
    • Maximum Radial Shaft Load (kg (lb)): 10 (22.05)

Note: The table above lists the axial and radial load factors that provide an L-10 bearing lifespan of 20,000 hours for the Y-Series rotor bearings. The 20,000-hour bearing-fatigue lifespan does not consider any application-specific lifespan reduction that may occur if external sources contaminate the bearing grease.  Also, the listed maximum radial loads are applied at the center of the servo motor’s shaft extension.

8. Compatible Motor Feedback and Power Cables

Select the appropriate cables, connectors, and other accessories required for wiring the power, feedback, and brake connections of the Y-Series servo motor you intend to use in your application.

Here are the various cable types you can use with the Allen-Bradley Y-Series servo motors:

  • Motor Feedback Cables
    • 2090-XXNFY-Sxx incremental feedback cables, with flying leads at the servo drive end.
    • 2090-UXNFBY-Sxx incremental feedback cables, with a pre-molded connector at the servo drive end.
  • Motor Power and Brake Cables
    • 2090-XXNPY-16Sxx power cables with brake wires
    • 2090-UXNPAY-16Sxx power cables with brake wires

9. Environmental Factors

Environmental factors such as operating and storage temperature, relative humidity, mechanical shock and vibration tolerance, contamination resistance, etc., should also be considered when selecting a Y-Series brushless servo motor. These factors affect the overall selection of a servo motor because if the intended working environment differs from the specified operating conditions, the servo motor will not perform as required.

For example, suppose a servo motor that is rated to produce 13.56 Nm of continuous torque in 40°C ambient conditions with a maximum coil temperature of 170°C and a windings’ temperature rise of 130°C is operated in a 50°C ambient environment. In that case, the specified maximum coil temperature and temperature rise of the motor windings will be exceeded when the servo motor is operated at the 13.56 Nm continuous torque rating. In such a case, the continuous torque produced by that servo motor will be much less than the rated amount unless a larger servo motor is selected. 

Thus, operating a servo motor at a higher ambient temperature than specified means a lower amount of continuous torque is produced. Similarly, extremely low ambient temperatures affect the lubricants of a servo motor, causing it to stall.  Also, if there are contaminants, dust, or moisture in the environment that the servo motor is to be operated in, you will require a more robust Y-Series servo motor that’s IP-rated or customized for such an environment; customized solutions may include special sealing arrangements, ruggedized enclosures, alternate motor construction materials, or other modifications.

Allen-Bradley Y-Series brushless servo motors feature the following environmental specifications:

  • Ambient Operating Temperature:  32 …104°F (0 to 40°C), ideal for industrial and factory environments.
  • Ambient Storage Temperature:  -4 … 149°F (-20 to 65°C)
  • Relative Humidity: 20% to 90% (non-condensing)

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