En Technical Information PDF

Technical Information
WE CREATE MOTION EN
Imprint
As at:
16th edition, 2020
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
Contents
DC-Motors DC-Micromotors 4 – 25
Flat DC-Micromotors & DC-Gearmotors
Brushless DC-Motors Brushless DC-Servomotors 26 – 51

Brushless Flat DC-Micromotors & DC-Gearmotors
Motors with integrated Brushless DC-Motors with integrated Speed Controller 52 – 87

Electronics Brushless DC-Servomotors with integrated
Motion Controller
Stepper Motors Stepper Motors 90 – 99
Linear DC-Servomotors Linear DC-Servomotors 100 – 107
Precision Gearheads Precision Gearheads 108 – 121
Linear Components Lead Screws and Options 122 – 125
Encoders Encoders – 2 Channel 126 – 139

Encoders – 3 Channel
Encoder – Absolute
Drive Electronics Speed Controller 140 – 159

Motion Controller
DC-Motors
WE CREATE MOTION
DC-Micromotors
Magnets:
General information
FAULHABER S/G Page
FAULHABER DC Motors are designed with a variety of
DC-Micromotors Portfolio description 32 – 33
The FAULHABER Winding: different types of magnets to suit the particular perfor-
0615 … S Precious Metal Commutation 0,17 mNm 34 – 35
Originally invented by Dr. Fritz Faulhaber mance of the given motor type. These materials include
1219 …Sr. G and patented Precious Metal Commutation 0,72 mNm 36 – 37
in 1958, the System FAULHABER coreless1516 …(orS ironless) pro- AlNiCo magnets and high performance
Precious Metal Commutation
rare earth types
0,59 mNm 38 – 39
gressive, self-supporting, skew-wound rotor
1624 … S winding is at such asMetal
Precious SmCo and NdFeB.
Commutation 2 mNm 40 – 41
the heart of every System FAULHABER DC…Motor.
2230 S This revo- Precious Metal Commutation 4,7 mNm 42 – 43
Operational Lifetime:
2233 … Sand created
lutionary technology changed the industry Precious Metal Commutation 5,9 mNm 44 – 45
The lifetime of a FAULHABER DC Motor depends mainly
new possibilities for customer application of DC Motors
FAULHABER SR on the operational duty point and the ambient conditions Page
where the highest power, best dynamic performance, in
DC-Micromotors Portfolio description during operation. The total hours of operation can46 there-
– 47
the smallest possible size and weight are required. The
0816 … SR fore vary
Precious Metalgreatly from some hundreds
Commutation 0,7of hours under
mNm 48 – 49
main benefits of this technology include:
1016 … SR extreme
Precious conditions
Metal Commutationto over 25 000 hours under optimal
0,92 mNm 50 – 51
1024 …positioning
■ No cogging torque resulting in smooth SR Precious Metal Commutation
conditions. 1,6 mNm
Under typical load conditions 52 – 53
a FAULHABER
1224 effi
and speed control and higher overall … SR ciency than Precious
DC motor Metalwill
Commutation 1,7 mNm anywhere
have an operational lifetime 54 – 55
other DC motor types 1319 … SR Precious Metal Commutation
between 1 000 to 5 000 hours. 1,4 mNm 56 – 57
1331 … SR Precious Metal Commutation 3,8 mNm 58 – 59
■ Extremely high torque and power1516
in relation
… SR to motor In general the operational lifetime of0,97
a FAULHABER
mNm
DC
60 – 61
size and weight 1524 … SR MotorMetal
Precious is limited by the effects of electrical
Commutation 2,9 mNmand mechanical
62 – 63
1717 load
■ Absolute linear relationship between … SR to speed, wear on
Precious the
Metal commutator and brushes.
Commutation 2,2The
mNmelectrical64
wear
– 65
1724
current to torque, and voltage to speed… SR (sparking)
Precious Metaldepends heavily on the electrical
Commutation 4,5 mNmload and66the– 67
2224 … SR motorMetal
Precious speed. As the electrical load and
Commutation 6,8 speed
mNm increase,68 – the
69
■ Very low rotor inertia which results in superior dynamic
2232 … SR typicalMetal
Precious motor operational lifetime will10normally
Commutation mNm decrease.
70 – 71
characteristics for starting and stopping
FAULHABER CXR The effects of electrical wear are more significant for Page
■ Extremely low torque ripple and EMI motors with precious metal commutation and vary depend-
DC-Micromotors Portfolio description 72 – 73
ing on the nominal voltage of the winding. Where neces-
DC Motor Types: 1336 … CXR Graphite Commutation 3,6 mNm 74 – 75
sary FAULHABER
Commutation DC Motors are therefore fitted with
FAULHABER DC Motors are built with1727
two…different
CXR types Graphite 4,9 mNm 76 – 77
1741 commutation
… CXR integrated
Graphite spark suppression to minimize
Commutation the negative
8,8 mNm 78 – 79
of commutation systems: precious metal and
2237 … CXR effectsCommutation
Graphite of sparking on the operational12lifetime.
mNm 80 – 81
graphite commutation.
2642 … CXR Graphite Commutationwear of the commutation
The mechanical 26 mNm 82 – 83
system is depend-
The term precious metal commutation refers to the ma-
2657 … CXR Graphite
ent onCommutation 40 mNm
the motor speed and will increase with higher84 – 85
terials used in the brushes and commutator which consist
speeds. In general, for applications with higher than speci Page -
ofFAULHABER CR precious metal alloys. This type of
high performance
fied speeds and loads, a longer operational lifetime can be
commutation system is used mainly because
DC-Micromotors of its very
Portfolio description 86 – 87
achieved by graphite commutated motors.19 mNm It is also 88
impor-
small size, very low contact resistance2342
and …theCR very pre- Graphite Commutation – 89
2642 … CR tant not to exceed
Graphite Commutation the load characteristics
32 mNmfor the motor
90 – 91
cise commutation signal. This commutation system is
2657 … CR bearings
Graphite given in the data sheet for continuous
Commutation 51 mNm duty92opera-
– 93
particularly well suited for low current applications such
2668 … CR tion. Doing
Graphite so will also limit the achievable
Commutation 70 mNmmotor lifetime.
94 – 95
as battery operated devices.
3242 … CR Graphite Commutation
Other effects 41 mNm ambient
limiting motor lifetime include 96 con-
– 97
In general, precious metal commutated motors
3257 … CR exhibit the Graphite Commutation 73 mNm 98 – 99
ditions like excessive humidity and temperature, excessive
best overall performance at continuous
3272 … CRwith a load at
duty Graphite Commutation 120 mNm 100 – 101
vibration and shock, and an incorrect or suboptimal mount-
or around the point of maximum nominal
3863 …effi
CR ciency. Graphite Commutation 131 mNm 102 – 103
ing configuration of the motor in the application.
The term graphite commutation refers 3890
to… theCRbrush ma- Graphite Commutation 224 mNm 104 – 105
It is also important to note that the method of driving
terial used in combination
FAULHABER SR-Flat with a copper alloy commutator. Page
and controlling the motor will have a large effect on the
This type of commutation
Flat DC-Micromotors and
system is very robust and is better
operational lifetime of the motor. For example, for control
suited to dynamic
DC-Gearmotors high power applications
1506 …withSR rapid start / Precious Metal Commutation 0,45 mNm 108 – 109
using a PWM signal, FAULHABER recommends a minimum
stops or periodic overload conditions.1506 … SR IE2-8 with integrated Encoder 0,4 mNm 110 – 111
frequency of 20 kHz.
1512 … SR with integrated Gearhead 30 mNm 112
1512 … SR IE2-8 with integrated Gearhead und Encoder 30 mNm 114 – 115
2607 … SR Precious Metal Commutation 3,4 mNm 116 – 117
2607 … SR IE2-16 with integrated Encoder 2,9 mNm 118 – 119
2619 … SR with integrated Gearhead 100 mNm 120
2619 … SR IE2-16 with integrated Gearhead und Encoder 100 mNm 122 – 123
5
DC-Micromotors
Modifications:
FAULHABER specializes in the configuration of its standard DC-Micromotors
products to fit the customer application. Available modifi-
cations for FAULHABER DC Motors include:
■ Many other nominal voltage types
■ Motor leads (PTFE and PVC) and connectors
Series 0615 ... S
■ Configurable shaft lengths and second shaft ends Values at 22°C and nominal voltage 0615 N
1 Nominal voltage UN
■ Modified shaft dimensions and pinion configurations 2 Terminal resistance R
3 Efficiency, max. Kmax.
such as flats, gears, pulley and eccenters 4 No-load speed n0
5 No-load current, typ. (with shaft ø 0,8 mm) I0
■ Modifications for extreme high and low temperature 6 Stall torque MH
7 F i ti t M
operation
■ Modifications for operation in a vacuum (ex. 10-5 Pa)
■ Modifications for high speed and / or high load Notes on technical datasheet
applications The following values are measured or calculated at
■ Modifications for motors with tighter than standard nominal voltage with an ambient temperature of 22 °C.
electrical or mechanical tolerances Nominal voltage UN [V]
The nominal voltage at which all other characteristics
Product Combinations
indicated are measured and rated.
FAULHABER offers the industry’s largest selection of com-
plementary products tailor made for all of its DC Motors Terminal resistance R [Ω] ±12%
including: The resistance measured across the motor terminals.
The value will vary according to the winding temperature.
■ Precision Gearheads (planetary, spur, and low
(temperature coefficient: α22 = 0,004 K-1).
backlash spur)
This type of measurement is not possible for the graphite
■ High resolution Encoders (Incremental and Absolute) commutated motors due to the transition resistance of the
■ High Performance Drive Electronics (Speed Controllers, brushes.
Motion Controllers) Efficiency ηmax. [%]
The maximum ratio between the absorbed electrical
power and the obtained mechanical power of the motor.
2
Io· R
= 1– ––––
max.
UN
No-load speed no [min-1] ±12%

Describes the motor speed under no-load conditions
at steady state and 22 °C ambient temperature. If not
otherwise defined the tolerance for the no-load speed is
assumed to be ±12%.
UN - (Io · R)
no = –––––––––
2π · kM
No-load current (typical) Io [A]

Describes the typical current consumption of the motor
without load at an ambient temperature of 22 °C after
reaching a steady state condition.
The no-load current is speed and temperature dependent.
Changes in ambient temperature or cooling conditions
will influence the value. In addition, modifications to the
2020-2021_EPIM-Vorlage_Motoren_Getriebe_dff.indd 1
6
DC-Micromotors
shaft, bearing, lubrication, and commutation system or Mechanical time constant τm [ms]
combinations with other components such as gearheads or The time required for the motor to reach a speed of 63%
encoders will all result in a change to the no-load current of its final no-load speed, from standstill.
of the motor.
R·J
= ––––
m
Stall torque MH [mNm] kM 2
The torque developed by the motor at zero speed (locked
Rotor inertia J [gcm2]
rotor) and nominal voltage. This value may vary due to the
The dynamic moment of inertia of the rotor.
magnet Vtype and temperature and the temperature of the
4,5
winding. Angular acceleration α max. [rad/s2]
-¹
The acceleration obtained from standstill under no-load-
UN – M
MH = kM · ––– conditions and at nominal voltage.
R
R
-¹/V
-¹
max.
MH
= –––––
Friction torque MR [mNm] J
Torque losses caused by the friction of brushes, commuta-
-¹/mNm
tor and bearings. This value varies due to temperature. Thermal resistance Rth1; Rth2 [K/W]
10 10 ms
Rth1 corresponds to the thermal resistance between the
3rad/s²
winding and housing. Rth2 corresponds to the thermal
MR = kM · Io
K/W
s
resistance between the housing and the ambient air.
Rth2 can be reduced by enabling exchange of heat between
Speed constant
°C kn [min-1/V] the motor and the ambient air (for example, a thermally
°C
The speed variation per Volt applied to the motor coupled mounting configuration, using a heat sink, and /
terminals
mmat constant load. or forced air cooling).
N
N
N no
kn = –––––––– =1
–– Thermal time constant τw1; τw2 [s]
UN – I o · R k E The thermal time constant specifies the time needed for
mm
mm the winding (τw1) and housing (τw2) to reach a temperature
Back-EMF constant kE [mV/min-1]
g equal to 63% of final steady state value.
The constant corresponding to the relationship between
min-¹
the induced voltage in the rotor and the speed of rotation. em
Final
temperature
kE = 2 π · kM
63 % of
final
temperature (t ) Thermal
time constant
Torque constant kM [mNm/A]
The constant
-¹ corresponding to the relationship between
the torque developed by the motor and the current drawn.
Rth2 value has been reduced by 0%. o th
t
Current constant k I [A/mNm]
Describes the relation of the current in the motor winding
0615N1.5S
Operating temperature range [°C]
0615N1.5S (R -50%)
th2
andoperation
Intermittent the torque developed at the output shaft. Indicates the minimum and maximum standard motor
0,5 Operating point
at nominal value
1 operating temperature, as well as the maximum allowable
kl = –––
kM temperature of the standard motor winding.
Shaft bearings
Slope of n-M curve ∆n/∆M [min-1/mNm]
The bearings used for the DC-Micromotors.
The ratio of the speed variation to the torque variation.
The smaller the value, the more powerful the motor. Shaft load max. [N]
The output shaft load at a specified shaft diameter for the
R –––
Δn = –––
––– 1
·
ΔM kM 2 2π
primary output shaft. For motors with ball bearings the
M [mNm]
load and lifetime are in accordance with the values given
0,2 0,24
Rotor inductance L [µH] by the bearing manufacturers. This value does not apply to
The inductance measured on the motor terminals at 1 kHz. second, or rear shaft ends.
© DR. FRITZ FAULHABER GMBH & CO. KG
Specifications subject to change without notice. Shaft play [mm]
www.faulhaber.com
The play between the shaft and bearings, including the
additional bearing play in the case of ball bearings.
22.01.20 13:48
7
DC-Micromotors
Housing material
shaft, bearing, lubrication, and commutation system or Mechanical
Please note, time choosingτma[ms]
whenconstant precious metal commutated
combinations
The with other
housing material andcomponents such as gearheads or
the surface protection. The time
motor required
that for the
they exhibit themotor to reach
best overall a speed of
continuous 63%
duty
encoders will all result in a change to the no-load current of its final no-load
performance speed, from
at or around standstill.
the point of highest efficiency.
Mass [g]
of the motor. For continuous duty operating conditions that require the
The typical mass of the motor in its standard configuration. R·J
= its
––––
motor to operate closemto kM 2thermal limits, a DC Motor
Stall torque MH [mNm]
Direction of rotation with graphite commutation is recommended.
The direction of rotation as viewed from the front face. Rotor inertia J [gcm2]
rotor) and nominal voltage. This value may vary due to the For DC Motors with graphite commutation:
Positive voltage applied to the (+) terminal gives clockwise The dynamic moment of inertia of the rotor.
magnet type and temperature and the temperature of the The maximum continuous duty torque (S1 operation) at
rotation of the motor shaft. All motors are designed for
winding. Angular voltage
nominal acceleration α max.in
resulting [rad/s 2
]
a steady state temperature
clockwise (CW) and counter-clockwise (CCW) operation; The acceleration obtained from standstill under no-load-
not exceeding the maximum winding temperature and / or
the direction of rotation is Ureversible. conditions and at nominal voltage.
MH = kM · ––– – MR
N
operating temperature range of the motor. The motor
R
Speed up to n max. [min-1] is rated with a reduction of the Rth2 value of 25% which
MH
max. = –––––
The maximum
Friction torquerecommended
MR [mNm] motor speed for continuous approximates the amount of cooling
J available from a typi-
operation.
Torque lossesThiscaused
value is
bybased on the of
the friction recommended operat-
brushes, commuta- cal mounting configuration of the motor. This value can
ing range
tor and for the standard
bearings. This valuemotorvariesbearings, winding, and
due to temperature. Thermal
be safelyresistance
exceeded R ifth1; Rth2
the motor[K/W] is operated intermittently,
commutation system. All values in excess of this value will R
for corresponds
th1 example, to operation
in S2 the thermal resistance
and/or if morebetween
coolingthe
is
negatively affect theMmaximum achievable operational winding and housing. Rth2 corresponds to the thermal
applied.
R = kM · Io
lifetime of the motor. Rated Current (thermal limit) I N [A]
Speed constant The typical maximum continuous current at steady state
of pole kpairs
n [min /V]
-1
Number the motor and the ambient air (for example, a thermally
The speedthe
variation resulting from the rated continuous duty torque. This
Indicates numberper of Volt
pole applied
pairs of to
thethe motor motor.
standard coupled mounting configuration, using a heat sink, and /
terminals at constant load. value includes the effects of a loss of Km (torque constant)
or forced air cooling).
Magnet material as it relates to the temperature coefficient of the winding
Describes the basic ktype ofnthe 1
magnet
n = –––––––– = ––
o used in the Thermal
as well astime
the thermal τw1; τw2 [s]
constantcharacteristics of the given magnet
UN – I o · R k E The thermal
standard motor. material. Thistime
valueconstant
can be specifi
safely es the timeif needed
exceeded for
the motor
the
is operated (τw1) and housing (τw2) to reach a temperature
windingintermittently, during start / stop, in the ramp
Unspecifi
Back-EMFed mechanical
constant tolerances:
kE [mV/min -1
]
equal
up phasesto 63% of fi
of the nal steadycycle
operating stateand/or
value.if more cooling
The constant
Tolerances in corresponding
accordance withtoISO
the2768.
relationship between
the induced voltage in the rotor and the speed of rotation. is applied. For certain series and lower voltage types this
≤ 6 = ± 0,1 mm em
current
Final is limited by the capacity of the brush and commu-
≤ 30 = ± 0,2 mm temperature
tation system.
kE = 2 π · kM
≤ 120 = ± 0,3 mm 63 % of
Rated
final
Speed nN [min-1]
The tolerances
Torque ofkvalues
constant not specified are given on request.
M [mNm/A]
The typical speedt at steady stateThermal
temperature ( ) timefrom
resulting
constantthe appli-
The constant corresponding
All mechanical to the to
dimensions related relationship
the motorbetween
shaft are cation of the given rated torque. This value includes the
the effects of motor heating on the slope of the n/M curve.
meatorque developed
sured with an axialbypreload
the motor andshaft
of the the current
toward drawn.
the
Higher speeds can be achieved o th by increasing the input
motor.
Current constant k I [A/mNm]
t
voltage to the motor, however the rated current (thermal
Describes the relation of the current in the motor winding limit) remains
Operating the same.range [°C]
temperature
Rated
and values
the torque for continuous
developed duty
at the output operation
shaft. Indicates the minimum and maximum standard motor
The following values are1 measured or calculated at operating
n [min-1] temperature, as well as the maximum allowable
Continuous operation (R 0%)
kl = –––
th2
nominal voltage with ankMambient temperature of 22 °C. temperature

9 000
of the standard
Watt motor winding.
Continuous operation (R -50%)
Intermittent operation
th2
8 16 24 32 Operating point at nominal value

Rated Torque MN [mNm] Shaft
7 500bearings
n
Slope of n-M curve ∆n/∆M [min-1/mNm] max.

P D
The DC
For ratio of thewith
motors speed variation
precious to the
metal torque variation.
commutation: 6 000 U N
n0
The maximum
The smaller thecontinuous
value, the duty
moretorque
powerful the motor.
at nominal voltage Shaft
4 500
load max. [N]
M M N= D
resulting in steady state The output shaft load at a specified shaft diameter for the
Δn = current
––– R –––
––– 1 and speed not exceeding 3 000
the capacity of the brush
ΔM kand 2 ·
commutation
2π system. The primary output shaft. For motors with ball bearings the
M
1 500
motor is rated without a reduction to the Rth2 value (with-
out external cooling). This value can be safely exceeded 0 M [mNm]
The inductance measuredintermittently,
on the motorfor
terminals at 1 second,0 or rear
10 shaft20ends. 30
inkHz.
40 50
if the motor is operated example, Recommended operation areas
S2 operation and/or if more cooling is applied. For the Shaft play [mm]
purposes of the rating, certain motors are limited by the The play between
Example: the shaft
Performance and for
diagram bearings, including
rated values the
with
resulting rated speed (< 2 500 min-1) at nominal voltage. additional bearing play in the case of ball
continuous operation (graphite commutation) bearings.
8
DC-Micromotors
Explanations on the performance diagram How to select a DC-Micromotor

The performance diagram shows the range of possible This section provides a very basic step-by-step procedure
operating points of a drive at an ambient temperature of of how to select a DC-Micromotor for an application that
22 °C and includes both the operation in the thermally requires continuous duty operation under constant load
insulated and in the cooled state. The possible speed ranges and ambient conditions. The example describes the calcula-
are shown in dependence on the shaft torque. tions necessary to create a basic motor characteristic curve
The sector shown dashed describes possible operating to describe the behaviour of the motor in the application.
points in which the drive can be engaged in intermittent To simplify the calculation, in this example continuous opera-
operation or with increased cooling. tion and optimum life performance are assumed and the
influence of temperature and tolerances has been omitted.
Continuous torque MD [mNm]
Describes the max. recommended continuous torque in Application data:
the steady-state condition at nominal voltage and with The basic data required for any given application are:
thermal reduction of the Rth 2 value by 25 % for graphite Required torque M
Required speed n
commutation and by 0 % for precious metal commutation. Duty cycle δ
With brush motors, the continuous torque corresponds Available supply voltage, max. U
to the respective rated torque MN. The value is independ- Available current, max. I
Available space, max. diameter/length
ent of the continuous output and can be exceeded if the Shaft load radial/axial
motor is intermittently operated and/or more cooling is Ambient temperature
put to use.
This example is based on the following application data:
Continuous output PD [W]
Output torque M = 3 mNm
Describes the max. possible output in continuous operation Speed n = 5 500 min-1
in the steady-state condition with thermal reduction of the Duty cycle δ = 100 %
Rth 2 value by 50 %. The value is independent of the continu- Supply voltage U = 20 V
Current source, max. I = 0,5 A
ous torque and can be exceeded if the motor is intermit- Space max diameter = 25 mm
tently operated and/or more cooling is put to use. length = 50 mm
Shaft load radial = 1,0 N
axial = 0,2 N
Nominal voltage characteristic curve UN [V] Ambient temperature = 22 °C constant
The nominal voltage curve describes the operating points
at UN in the uncooled and cooled state. In steady-state, the
Preselection
starting point corresponds to the no-load speed n0 of the
The first step is to calculate the power the motor is
drive. Operating points above this curve can be attained by
an increase, operating points below by a reduction of the expected to deliver:
nominal voltage .
P2 = M · 2 π n
P2 = 3 mNm · 5 500 min-1 · 2π = 1,73 W
Second, compare the physical dimensions (diameter and

length) to the motor sizes given in the data sheets. Then,
from the available motor sizes, compare the required
output torque to the diagram for the recommended
areas of operation for the motor types in question. Please
choose a motor type where the required output torque
and speed are well within the limits given in the diagram.
For the best results it is recommended to operate the
motor close to the "operating point at nominal value"
indicated in the diagram. Please note that the diagram in
the data sheet is a representative example regarding one
nominal voltage type and should be used for orientation
purposes only.
9
DC-Micromotors
The motor
shaft, selected
bearing, from the
lubrication, catalogue
and for this
commutation particular
system or Mechanical time
Performance constant τmat
characteristics nominal voltage (24 V)
[ms]
application,
combinationsis with
seriesother
2224components
U 024 SR with theasfollowing
such gearheads or The
A time required
graphic for the
presentation of motor to reach
the motor‘s a speed of 63%
characteristics
characteristics:
encoders will all result in a change to the no-load current of itsbefinal
can no-load
obtained byspeed, from the
calculating standstill.
stall current IH and
of the motor.
Nominal voltage UN = 24 V the torque Mopt. at its point of max. efficiency. All other
R·J
m = ––––
parameters are taken directly
Frame size:
Stall torque MH [mNm]
Ø = 22 mm kM 2 from the data sheet of the
L = 24 mm
selected motor.
The
Shafttorque developed by the motorradial
load, max.: at zero =speed
1,5 (locked
N
axial = 0,2 N Rotorcurrent
Stall inertia J [gcm2]
rotor) and nominal voltage. This value
No-load current Io
may vary due to the
= 0,007 A The dynamic moment of inertia of the rotor.
magnet type and temperature and the
No-load speed no temperature of -1the
= 7 800 min UN
Stall torque
winding. M H = 19 mNm IH = –––
Angular acceleration α max. [rad/s2]
R
The acceleration obtained from standstill under no-load-
Optimizing the preselection UN – M
MH = kM · ––– R conditions and 24at V
nominal voltage.
R
To optimize the motor‘s operation and life performance, IH = ––––––– = 0,661 A
36,3 Ω
the required speed n has to be higher than half the no- MH
max. = –––––
Friction torque MR [mNm] J
load speed no at nominal voltage, and the load torque M Torque at max. efficiency
Torque losses caused by the friction of brushes, commuta-
has to be less than half the stall torque MH. Thermal resistance Rth1; Rth2 [K/W]
tor and bearings. This value varies due to temperature.
Mopt. = toMthe
Rth1 corresponds H · Mthermal
R resistance between the
no
n ≥ ––– MH
M ≤ ––– winding and housing. Rth2 corresponds to the thermal
MR 2= kM · Io 2
opt. = 19 by
mNm · 0,2 mNm
From the data sheet for the DC-Micromotor, 2224 U 024 SR Rth2 can beMreduced enabling exchange=of1,95
heat mNm
between
Speed
the constantmeet
parameters kn [min -1
/V]
the above requirements. the motor and the ambient air (for example, a thermally
The speed variation per Volt applied to the motor It is now mounting
coupled possible toconfi
make a graphic
guration, presentation
using and
a heat sink, and /
terminals is higher
at -1constant load. ––––––––––
7 800 min-1 no draw the motor diagram (see diagram 1).
n = 5 500 min = 3 900 min-1 = ––– or forced air cooling).
than 2 2
n
kn = –––––––– = ––
o 1 Thermal time constant τw1; τw2 [s] Diagram 1
is lowerUN – Io · R19 mNm
kE MH The thermal time constant specifies the time needed for
M = 3 mNm –––––––– = 9,5 mNm = –––– P I n
than 2 2
η
the% winding
W
2
and housing (τw2) to reach a temperature
A (τw1)min -1

equal to 63% of final steady state value.
This constant
The DC-Micromotor will be ato
corresponding good
the firelationship
rst choice tobetween
test in this 90 4 0,7 8 000
n o = 7 800 min-1
application.
the induced Should
voltagethe required
in the rotor speed
and then be less than
speed half
of rotation. η max = 80,6 % em
IH = 0,661 A
the no-load speed no, and the load torque M be less than Final
80
3,5
0,6
7 000
temperature tI
half the stall torquekME =H,2the
π · kMmotor with the next higher
70
3 6 000
Ef
fic
ie
nc Cu
rr
en
63 % of
0,5
y
nominal voltage UN should be selected. 60
η
final
2,5 5 000
(t ) Thermal
time constant
Should
Torque the required
constant torque M be compliant but the
kM [mNm/A] temperature
50
0,4
Ou
2 4 000
required
The speed
constant n be less thanto
corresponding half
thethe no-load speed
relationship no, try
between
tpu
t po
40
0,3
a lower
the supply
torque voltage by
developed or the
another
motorsmaller frame
and the size motor.
current drawn.
we
1,5 3 000
Sp
r P2
30 ee
o th d
n
Should the required speed be well below half the no-load
0,2
t
Current constant k I [A/mNm] 20
1 2 000
Describes the relation torque

speed and or the load M be more
of the current than
in the half winding
motor the stall
10
0,5
0,1
1 000
torque M H, a gearhead or a larger frame size motor has to

and the torque developed at the output shaft. MH = 19 mNm
Indicates the minimum and maximum standard motor
Io M Opt. = 1,95 mNm
be selected. 0 0 0 0
0 2 4 6 8 10 12 14 16 18 20
M
mNm
1 operating temperature, as well as the maximum allowable

MR = 0,2 mNm
kl = –––
kM temperature of the standard motor winding.
Shaft bearings
Slope of n-M curve ∆n/∆M [min-1/mNm]
The ratio of the speed variation to the torque variation.
R –––
Δn = –––
––– 1
·
ΔM kM 2 2π
Shaft play [mm]
10
DC-Micromotors
Calculation of the main parameters Calculation of the operating point at 20 V

In this application the available supply voltage is lower When the torque (M = 3 mNm) at the working point is
than the nominal voltage of the selected motor. taken into consideration I, n, P2 and η can be calculated:
The calculation under load therefore is made at 20 V.
Current at the operating point
No-load speed no at 20 V
U – (Io · R ) ILast = –M + MR
–––––––
no = ––––––––– kM
2 π · kM
inserting the values 3 mNm + 0,2 mNm

ILast = –––––––––––––––––– = 0,11 A
Supply voltage U = 20 V 29,1 mNm / A
Terminal resistance R = 36,3 Ω
No-load current IO = 0,007 A
Torque constant kM = 29,1 mNm / A
Speed at the operating point
U – R · ILast
n = ––––––––––
2π · kM
20 V – (0,007 A · 36,3 Ω)
no = ––––––––––––––––––––––– = 6 481 min-1
2 π · 29,1 mNm / A
20 V – 36,3 Ω · 0,11 A
n = ––––––––––––––––––––– = 5 253 min-1
Stall current IH 2 π · 29,1 mNm / A
IH = –U
–– Output power at the operating point
R
P2 = M · 2 π · n
20 V
–––––
IH = ––– = 0,551 A
36,3 Ω
P2 = 3 mNm · 2π · 5 253 min-1 = 1,65 W
Stall torque MH
MH = kM ––
R (
U –I
o ) Efficiency at the operating point
P2
= ––––
20 V U·I
MH = 29,1 mNm / A · –––––– – 0,007 A = 15,83 mNm
36,3 Ω
1,65 W
= ––––––––––––
Efficiency, max. ηmax. = 75,0 %
20 V · 0,11 A
R 2
max. = 1 – I0 · ––– In this example the calculated speed at the working point
U
is different to the required speed, therefore the supply
2 voltage has to be changed and the calculation repeated.
36,3 Ω
max. = 1 – 0,007 A · –––––– = 78,9 %
20 V Supply voltage at the operating point
The exact supply voltage at the operating point can now
At the point of max. efficiency, the torque delivered is: be obtained with the following equation:
U = R · ILoad + 2π · n · kM
Mopt. = MH · MR
U = 36,3 Ω · 0,11 A + 2π · 5 500 min-1 · 29,1 mNm / A = 20,75 V
inserting the values In this calculated example, the parameters at the operating
Friction torque MR = 0,2 mNm point are summarized as follows:
and
Stall torque with 20 V MH = 15,83 mNm Supply voltage U = 20,75 V
Speed n = 5 500 min-1
Output torque MN = 3 mNm
Mopt. = 15,83 mNm · 0,2 mNm = 1,78 mNm Current I = 0,11 A
Output power P2 = 1,73 W
Efficiency η = 75,7 %
11
DC-Micromotors
Estimating the lubrication,

shaft, bearing, temperatureand of the motor winding
commutation systemin or Motor characteristic
Mechanical curvesτm [ms]
time constant
operation:
combinations with other components such as gearheads or The
For atime required
specifi forthe
c torque, thevarious
motor to reach a speed
parameters of read
can be 63%
To ensurewill
encoders thatall
the motor
result in aoperates
change within a permissible
to the no-load current of
on its final no-load
diagram 2. speed, from standstill.
temperature
of the motor.range, it is necessary to calculate the tem- To simplify the calculation,R the
· J influence of temperature
perature of the winding and housing under load. m = ––––
Stall torque MH [mNm] and tolerances has deliberately
kM 2 been omitted.
First calculate the approximate motor losses using the
following formula: Rotor inertia J [gcm2] Diagram 2
rotor) and nominal voltage. This value may vary due to the P I n
= ltemperature
Load · R The
% dynamic
η 2
moment of inertia of the rotor.
magnet typePLoss
2 W A min
and and the temperature of the
-1
winding.
inserting the values Angular acceleration α max. [rad/s2]
80 3 0,7 7 000
Current lLoad = 0,11 A The acceleration obtained from standstill under no-load- 76 %
Resistance UN – M
MH = kM · ––– R = 36,3 Ω conditions and at nominal voltage.
70
0,6 6 000
R
R 2,5
60 5 500 min-1
0,5 5 000 20,75 V
max.
MH
= –––––
Friction torque
PLoss M R [mNm]
= (0,11 A)2 · 36,3 Ω = 0,44 W 50
2
J
1,73 W
Torque losses caused by the friction of brushes, commuta- 0,4 4 000
Then
tor andmultiply theThis
bearings. value for the
value power
varies due losses by the com-
to temperature. Thermal resistance Rth1; Rth2 [K/W]
40 1,5
bined thermal resistances of the motor to estimate the Rth1 corresponds to the thermal resistance between the
0,3 3 000
30
change in the temperature of the motor due to the load. winding and housing. Rth2 corresponds to the thermal
1
M =k I
R M · o 20
0,2 2 000

∆ T = PLoss · ( Rth1 + Rth2) 0,5 0,11 A
10
0,1 1 000
Speed constant kn [min /V] -1

the motor and the ambient air (for example, a thermally
M
mNm
inserting
The speedthe values per Volt applied to the motor
variation
0 0 0 0
Thermal resistance 1 Rth1 = 5 K/W coupled mounting configuration, using a heat sink, and /
0 2 3 4 6 8 10 12 14 16 18
terminals at constant
Thermal resistance 2 load. Rth2 = 20 K/W or forced air cooling).
no
kn = –––––––– =1
–– Thermal time constant τw1; τw2 [s]
∆ T = 0,44 W U N –K/W
· (5 Io · R + 20
kE K/W) = 11 K The thermal time constant specifies the time needed for
Add the resulting change in temperature ∆T to the ambi- the winding (τw1) and housing (τw2) to reach a temperature
ent temperature to estimate the motor winding tempera- equal to 63% of final steady state value.
ture under load.
the induced voltage in the rotor and the speed of rotation. em
TWinding = ∆T + TAmb Final
temperature
2π+ ·22
E =K
TWinding = k11 kM °C = 33 °C
63 % of
This calculation confirms that the temperature is well final
(t ) Thermal
time constant
Torque the
constant temperature
within specifiked
M [mNm/A]
standard operating temperature range
The constant
as well as thecorresponding
maximum winding to the relationship between
temperature.
the torque developed by the motor and the current drawn.
The calculation given above is for the purposes of a quick o th
t
Current constant
estimation k I [A/mNm]
only. The non-linear effects of temperature
Describes the relation
on the resistance of the ofwinding
the current
andin the
the motor winding
resulting torque Operating temperature range [°C]
and the torque developed at the output shaft.
constant (kM) of the motor due to the temperature coef- Indicates the minimum and maximum standard motor
ficient of the magnet material1 used have not been taken operating temperature, as well as the maximum allowable
kl = –––
into account and can have kM a large effect on motor perfor- temperature of the standard motor winding.
mance at higher temperatures. A more detailed calcula-
Shaft bearings
Slope of n-Mbecurve
tion should ∆n/∆Mbefore
performed [min-1/mNm]
operating the motor The bearings used for the DC-Micromotors.
The ratio
close to itsofthermal
the speed variation to the torque variation.
limits.
R –––
Δn = –––
––– 1
·
ΔM kM 2 2π
Shaft play [mm]
12
DC-Micromotors
Basic design
1
6
2
FAULHABER SR
1 End cap
2 Terminals
3 Brushes with brush cover
4 Commutator 8
5 Winding
6 Shaft
7 Housing
8 Magnet with sintered bearing
and retaining ring
9 3
FAULHABER CR
6
1 Graphite brushes
with brush cover and
ball bearing 7
2 Insulating ring
3 Commutator
4 Winding
5 Shaft 8
6 Magnet
7 Magnet cover
8 Housing with ball bearing
9 Terminals
13
Flat DC-Micromotors
Basic design
1
6
FAULHABER SR-Flat
1 End cap with encoder PCB

7
2 Brush cover with sintered bearing
3 Windings and collector
4 Housing with integrated gears
and sintered bearing
5 Intermediate plate with
sintered bearing
6 Output shaft
7 Front cover with bearing
14
Notes
15
DC-Micromotors with
precious metal commutation
Originally invented by Dr. Fritz Faulhaber Sr. and patented in Series
1958, the System FAULHABER coreless (or ironless) progres-
sive, self-supporting, skew wound rotor winding is at the 0615 … S 1219 … G
heart of every System FAULHABER DC Motor. This revolu- 1516 … S 1624 … S
tionary technology changed the industry and created new
2230 … S 2233 … S
possibilities for customer application of DC Motors where
the highest power, best dynamic performance, in the smallest
possible size and weight are required.
Key Features
The main benefits of this technology include no cogging
Motor diameter 6 ... 22 mm
torque resulting in smooth positioning and speed con-
trol, higher overall efficiency than other DC Motor types, Motor length 15 ... 33 mm
extremely high torque and power in relation to motor size Nominal voltage 1,5 ... 40 V
and weight, and a linear relationship between load to speed, Speed up to 24.000 min-1
current to torque, and voltage to speed. The very low rotor Torque up to 5,9 mNm
inertia results in superior dynamic characteristics for starting
Continuous output up to 8 W
and stopping and the motors exhibit extremely low torque
ripple and EMI.
Product Code
22 Motor diameter [mm]

30 Motor length [mm]
T Shaft type
22 30 T 0 1 2 S
012 Nominal voltage [V]
S Product family
WE CREATE MOTION
FAULHABER S/G
Advantages of this series at a glance
Low torque ripple and high efficiency Low current and starting voltage
Wide operating temperature range Compact and lightweight
No cogging torque
DC-Micromotors with
precious metal commutation
These ironless DC motors are the most compact in the indus- Series
try today and most types feature integrated high resolution
encoders for use in highly precise positioning and speed 0816 … SR 1016 … SR
control applications. 1024 … SR 1224 … SR
The commutation system is characterized by its small size, low 1319 … SR 1331 … SR
contact resistance and clean low noise commutation signal. It 1516 … SR 1524 … SR
is ideal for use in battery operated applications where current
1717 … SR 1724 … SR
is at a premium.
2224 … SR 2232 … SR
Combinations with a wide variety of gearheads and control-
lers make it possible to create the best system solution for
even the most challenging applications. Key Features

Motor length 16 ... 32 mm
Nominal voltage 3 ... 36 V
Speed up to 17.000 min-1
Torque up to 10 mNm
Continuous output up to 8,5 W
Product Code

T Shaft type
15 24 T 0 1 2 SR
SR Product family
WE CREATE MOTION
FAULHABER SR
Powerful rare-earth magnets Low torque ripple and high efficiency

Wide operating temperature range: No cogging torque
-30 °C to +85 °C (optional -55 °C to +125 °C) Low current and starting voltage
All-steel housing with Extremely compact and lightweight design
corrosion-resistant coating with integrated encoder
DC-Micromotors with
graphite commutation
The CXR series combines power, robustness and control in a Series
compact form. This is ensured by graphite commutation, high-
quality neodymium magnets and the tried-and-tested winding 1336 … CXR 1727 … CXR
of the FAULHABER rotor. 1741 … CXR 2237 … CXR
The powerful neodymium magnet gives the motors a high 2642 … CXR 2657 … CXR
power density with a continuous torque ranging from 3.6 to
40 mNm. The impressive performance data and the compact
size open up a wide spectrum of possible applications at an Key Features
optimised price/performance ratio. The standard drive can be
combined with high-resolution optical or magnetic encoders
for applications with precise speed control or positioning Motor length 27 ... 57 mm
tasks. A broad and optimally matched selection of gearheads is Nominal voltage 6 ... 48 V
available to extend the range of requirements that this series Speed up to 10.000 min-1
is able to fulfil. Torque up to 40 mNm
Product Code

W Shaft type
26 57 W 024 CXR
CXR Product family
WE CREATE MOTION
FAULHABER CXR
Highly dynamic performance Wide operating temperature range:

due to a low rotor inertia -30°C to +100°C (optional -55°C)
Shockproof all-steel housing with Durable graphite commutation
corrosion-resistant coating No cogging
Powerful rare-earth magnet Very high power density
DC-Micromotors with
graphite commutation
Highly stable and low-wear graphite commutation, extremely Series
powerful neodymium magnets and a particularly high copper
content in the winding of the FAULHABER rotor give the CR 2342 … CR 2642 … CR
series its enormous power. The impressive power range of 19 2657 … CR 2668 … CR
to 224 mNm is ideal for high-performance applications with
3242 … CR 3257 … CR
fast start/stop operation or periodic overload conditions.
3272 … CR 3863 … CR
Thanks to the extremely high power density as well as the
outstanding dynamics with minimal rotor inertia, the CR family 3890 … CR
is the most powerful product family of the entire FAULHABER
DC range. The standard drive can be combined with high-
resolution optical or magnetic encoders for applications with Key Features
precise speed control or positioning tasks. A broad and
optimally matched selection of gearheads is available to
extend the range of requirements that this series is able
to fulfil. Nominal voltage 6 ... 48 V
Torque up to 224 mNm
Product Code

G Shaft type
32 72 G 024 CR
CR Product family
WE CREATE MOTION
FAULHABER CR
Best dynamic performance due Extremely wide operating temperature range

to a low rotor inertia -30 °C to 125 °C (optionally -55 °C, winding
Shockproof all-steel housing with up to 155 °C)
corrosion-resistant coating Durable graphite commutation
Powerful rare-earth magnet No cogging
Highest power density
Flat DC-Micromotors
and DC-Gearmotors
Precious-metal commutated DC-Micromotors with uniquely Series
flat coil technology with three flat, self-supporting copper
windings used in the SR-Flat series form the basis for drive 1506 … SR 1506 … SR IE2-8
systems in applications where space is extremely limited. 1512 … SR 1512 … SR IE2-8
With their powerful rare-earth magnets, the motors deliver a
2607 … SR 2607 … SR IE2-16
continuous output of 0.8 W to 4 W and at the same time have
2619 … SR 2619 … SR IE2-16
only minimal inertia. The motors are available with integrated
gearheads and optical encoders – both with an extremely flat
design matched to the motors. When combined with inte-
grated gearheads and encoders, they provide a very compact Key Features
drive system with increased output torque. Motor diameter 15 ... 26 mm
Product Code

U Shaft type
15 12 U 0 0 6 SR 3 2 4 : 1
SR Product family
324:1 Gearhead reduction
WE CREATE MOTION
FAULHABER SR-Flat
Extremely flat design. Integrated spur gearheads of minimal length

Lengths ranging from 6 mm to 19 mm with high gear ratio are available
4-pole design Available with integrated optical encoders
Minimal moment of inertia
Brushless DC-Motors
WE CREATE MOTION
Brushless DC-Servomotors
For highly dynamic servo applications requiring very high

General information
FAULHABER B-Micro Page
torque in the most compact dimensions, the FAULHABER
Brushless DC-Servomotors Portfolio description 138 – 139
The FAULHABER winding: BX4 and BP4 Series 4-pole, DC-Servomotors are ideal. Their
0308 … B sensorless 18 µNm 140 – 141
Originally invented by Dr. Fritz Faulhaber robust design with very few parts and no glued compo-
0515 …Sr. B and patented sensorless 0,13 mNm 142 – 143
in 1958, the System FAULHABER coreless (or ironless) nents means that they are extremely durable and well
FAULHABER
progressive, B
self-supporting, skew-wound rotor winding is suited for challenging ambient conditions such as extreme
Page
Brushless DC-Servomotors Portfolio description
at the heart of every FAULHABER DC-Motor. This revolu- temperatures and high shock and vibration loads.144 – 145
0620 …
tionary technology changed the industry andB created new with
Theintegrated
FAULHABERHall sensors
BP4 family of 4-pole0,36 mNm brushless
slotless 146 – 147
possibilities for customer application0824 …B
of DC-Motors where with integrated Hall sensors 1,1 mNm
motors are ideal for applications requiring the highest 148 – 149
1028 … B with integrated Hall sensors 2,2
peak torque and extremely dynamic motion control. mNm 150 – 151
the highest power, best dynamic performance, in the
1218 … B with integrated Hall sensors 1,2 mNm 152 – 153
smallest possible size and weight are required. Applied in FAULHABER Brushless
1226 … B with integrated Hall sensors DC-Flat Motors2,6are mNm3 phase,154
slotless,
– 155
a three phase brushless motor, the winding no longer axial fl ux gap motors with a rotating back iron. They
1628 … B with integrated Hall sensors 3,3 mNm 156 – have
157
rotates but rather becomes the basis2036of …a slotless
B stator. a much
with higher
integrated efficiency than other fl
Hall sensors 7,2atmNm
brushless158
motors
– 159
The main benefits of this technology2057
include:
…B andintegrated
with their rotating back iron provides20amNm
Hall sensors high rotor160
inertia
– 161
■ No cogging torque resulting NEW 2057 …positioning
in smooth BA and thatintegrated
with is idealHall
forsensors
applications requiring18,7 mNm 162 – 163
2444ciency
speed control and higher overall effi … B than other with
lowintegrated
torque Hall sensors
ripple 18 mNm
and very precise continuous 164 – 165
speed
brushless motor types 3056 … B with integrated Hall sensors
control. 33 mNm 166 – 167
3564 … B with integrated Hall sensors 66 mNm 168 – 169
■ Extremely high torque and high performance in relation The FAULHABER BXT family of flat slotted brushless
4490 … B with integrated Hall sensors 190 mNm 170 – 171
to the size and weight of the motor
4490 … BS
motors offer the highest possible torque
with integrated Hall sensors 217 mNm
in a very172 – 173
■ Absolute linear relationship between load to speed, compact design.
FAULHABER BHx
current to torque, and voltage to speed, with a highly FAULHABER also offers a range of 2-pole Brushless
Page
Brushless
sensitiveDC-Servomotors – behaviourPortfolio description
current/torque Motors with a cylindrical rotating back iron sometimes 174 – 175
2 Pole Technology NEW 1645 … BHS with integrated Hall sensors 8 mNm 176 – 177
■ Extremely low torque ripple referred to as ironless external rotor motors. What sets
1660 … BHS with integrated Hall sensors 15,9 mNm 178 – 179
the FAULHABER Motor apart is the slotless design which
Brushless DC-Motor Types: 1660 … BHT with integrated Hall sensors 18,7 mNm 180 – 181
eliminates the cogging effect. The high inertia rotor
Whether
FAULHABER it’s highBX4
torque 4-pole DC-Servomotors, highly
makes these motors ideal for continuous duty applica- Page
efficient flat DC-Micromotors, or compact slotless motors,
Brushless DC-Servomotors – Portfolio description tions requiring very precise speed control. These motors182 – 183
FAULHABER specializes in getting the most performance
4 Pole Technology 2232 … BX4 alsointegrated
with have on-board
Hall sensorsspeed control electronics
18 mNm that184
can be
– 185
out of the smallest package. 2250 … BX4 S with integrated
confi gured Hall
forsensors 18 mNm
different speed profiles. 186 – 187
Due to their design FAULHABER Brushless
2250 …DC-Motors
BX4 are with integrated Hall sensors 32 mNm 188 – 189
ideal for heavy duty servo applications with
3242 frequent over-
… BX4 Sensors:
with integrated Hall sensors 53 mNm 190 – 191
3268 duty
load conditions as well as for continuous … BX4applications FAULHABER
with 2-pole
integrated Hall sensorsor 4-pole DC-Servomotors
96 mNm and192
Brush-
– 193
where maximum BP4
operational lifetime is required. less DC-Flat Motors come standard with 3 discrete digital
FAULHABER Page
Hall sensors with a 120° phase shift.
FAULHABER high precision
Brushless DC-Servomotors – 2-pole Brushless DC-Motors are
three
4 Polephase slotless motors that have2264
Technology a wide
… BP4speed and with integrated
0° Hall sensors
120° 240° 59 mNm360° 196 – 197
torque range and are ideal for mid- to high
3274 … BP4speed applica- with integrated
1
Hall sensors 162 mNm 198 – 199
tions requiring smooth speed control, high efficiency, and HA
FAULHABER B-Flat 0 Page
long operational lifetimes.
Brushless DC-Flat Motors Portfolio description 200 – 201
FAULHABER BHx motors are three phase slotless brushless
and DC-Gearmotors
1
1509 … B with
H integrated Hall sensors
B 0,5 mNm 202 – 203
motors designed for the very highest1515
power
… B to volume 0
with integrated Gearhead 30 mNm 204 – 205
ratio and peak efficiency for cool operation
2610 … B even at very with integrated Hall sensors 3,1 mNm 206 – 207
high speed. They feature a six phase 2622
coil …
connected
B for with
1
H integrated Gearhead 100 mNm 208 – 209
C
Digital Hall
three phase operation which give the motors a signifi- 0
sensor
FAULHABER
cant BXT
boost in motor performance with no reduction in Page
output signal
Brushless
effi ciency.DC-Flat
They are designed for highPortfolio
Motors to very description
high speed S1 S2 S3 S4 S5 S6 S1 2-pole motor
210 – 211
operation. They are available inNEWhigh2214
speed… BXT R and high
(BHS) External rotor technology, without housing 10,2 mNm 212 – 213
NEW 2214 … BXT H External rotor technology, with housing 9,7 mNm 214 – 215
torque (BHT) versions to maximize the speed or torque
NEW 3216 … BXT R External rotor technology, without housing 41 mNm 216 – 217
available in a given application.
NEW 3216 … BXT H External rotor technology, with housing 38 mNm 218 – 219
NEW 4221 … BXT R External rotor technology, without housing 134 mNm 220 – 221
NEW 4221 … BXT H External rotor technology, with housing 112 mNm 222 – 223
27
As an option, most FAULHABER Brushless DC-Servomotors Modifi

For cations:
highly dynamic servo applications requiring very high
General information
are available with analog (linear) Hall sensors. torque in thespecialises
FAULHABER most compact
in thedimensions,
adaptationthe FAULHABER
of its standard
The FAULHABER winding: BX4 and BP4
products Series 4-pole, DC-Servomotors
for customer-specifi c applications. are ideal. Their
Available
Hall signals Hall – Hall
robust design with
modifications very few parts
for FAULHABER and noDC-Servomotors
Brushless glued compo-
A C
Originally
5
invented by Dr. Fritz Faulhaber Sr. and patented Hall
nents means that they are extremely durable and well
A
in 1958,
4.5 the System FAULHABER coreless (or ironless) Hall
B
include:
progressive, self-supporting, skew-wound rotor winding Hall is suited for challenging ambient conditions such as extreme
4
■ Additional voltage types
C
at the
3.5 heart of every FAULHABER DC-Motor. This revolu-
temperatures and high shock and vibration loads.
■ Connecting cables (PTFE and PVC) and plugs
tionary
3 technology changed the industry and created new The FAULHABER BP4 family of 4-pole slotless brushless
U A … UC
possibilities for customer application of DC-Motors where

2.5 ■ Confiare
motors gurable
ideal shaft lengths andrequiring
for applications second shaft ends
the highest
the highest
2
power, best dynamic performance, in the peak torque
■ Modifi and extremely
ed shaft dimensions dynamic motion
and pinion control.
confi gurations
smallest possible size and weight are required. Applied in
1.5
such as flats,
FAULHABER gears, DC-Flat
Brushless pulleys and eccenters
Motors are 3 phase, slotless,
1
a three phase brushless motor, the winding no longer
Analog Hall axial flux gaptemperature
■ Extended motors withrange
a rotating back iron. They have
0.5
rotates but rather becomes the basis of a slotless sensorstator. a much higher efficiency than other
0 output signal ■ Vacuum compatibility (e.g. 10 -5
Pa)flat brushless motors
The main0°
benefi
60°
ts120°
of this technology
180° 240°
include:
300° 360° 2-pole motor and their rotating back iron provides a high rotor inertia
■ Modifications for high speed and/or high load
■ No cogging torque resulting in smooth positioning and
Absolute mechanical angle
that is ideal for applications requiring
applications
speed control and higher overall efficiency than other low torque ripple and very precise continuous speed
These sensors can replace the need for a high resolu- ■ Modifications for high shock & vibration loads
brushless motor types control.
tion encoder in many applications and provide the basic
■ Extremely high torque and high performance in relation ■ Autoclavable
The FAULHABERMotors
BXT family of flat slotted brushless
commutation signal for the Brushless DC-Servomotors in
to the size and weight of the motor
combination with FAULHABER Motion Controllers. motors offer
■ Modifi the for
cations highest possible
motors torque than
with tighter in a very
standard
Absolute linear relationship compact design.
electrical or mechanical tolerances
■ some
In cases, for example, thebetween
FAUHABER load to family,
BHx speed,
current to torque, and voltage to speed, with
discrete sensors are replaced by a commutation PCB a highly
which FAULHABER also offers a range of 2-pole Brushless
Product Combinations:
sensitive current/torque behaviour
provide the hall signals but can, in some cases, also provide Motors with a cylindrical rotating back iron sometimes
FAULHABER offers the industry’s largest selection of
■ Extremely
sinusoidal low torque signals.
commutation ripple referred to as ironless external rotor motors. What sets
complementary products tailor made for all of its Brushless
Brushless DC-Servomotors including:
Magnets: DC-Motor Types: eliminates the cogging effect. The high inertia rotor
Whether
FAULHABER it’s Brushless
high torque 4-pole DC-Servomotors,
DC-Servomotors are designedhighly
with a ■ Precision
makes thesegearheads (planetary
motors ideal gearheads,
for continuous dutyspur gear-
applica-
effi cient fl at DC-Micromotors, or compact slotless motors,
variety of different types of magnets to suit the particular heads and zero-backlash spur gearheads)
tions requiring very precise speed control. These motors
FAULHABER
performancespecializes in getting
of the given the or
motor type most performance
application condi- also have
■ High on-boardEncoders
resolution speed control electronics
(Incremental andthat can be
Absolute)
out of the smallest package.
tions. These materials include high performance rare earth confi gured for different speed profiles.
■ High Performance Drive Electronics (Speed Controllers,
Due
magnetto their
typesdesign
such asFAULHABER Brushless DC-Motors are
SmCo and NdFeB.
Motion Controllers)
Sensors:
ideal for heavy duty servo applications with frequent over-
Service
load life:
conditions as well as for continuous duty applications ■ Integrated2-pole
FAULHABER drive electronics (Motion and Speed
or 4-pole DC-Servomotors Control)
and Brush-
Due to the
where maximum fact that motor commutation
operational is achieved elec-
lifetime is required. less DC-Flat Motors come standard with 3 discrete digital
tronically and not mechanically, the operational lifetime of Hall sensors with a 120° phase shift.
FAULHABER high precision 2-pole Brushless DC-Motors are
a FAULHABER Brushless DC-Servomotor depends mainly on
three phase slotless motors that have a wide speed and 0° 120° 240° 360°
the lifetime performance of the motor bearings. FAULHABER
torque range and are ideal for mid- to high speed applica-
uses high precision preloaded ball bearings in all of its 1
tions requiring smooth speed control, high efficiency, and HA
Brushless DC-Servomotors 6 mm in diameter and larger. 0
long operational lifetimes.
Factors affecting the life of the motor bearings include
FAULHABER
the static and BHx motorsaxial
dynamic are and
threeradial
phase slotlessloads,
bearing brushless
the 1
HB
motors designed for the very highest power
ambient thermal conditions, the motor speed, shock andto volume 0
ratio and peak

vibrational effiand
loads, ciency
thefor cool operation
precision evencoupling
of the shaft at very
high speed. They feature a six phase coil connected
to the given application. If operated according to the fordata HC
1
Digital Hall
three phase operation which give the motors a
sheet Brushless DC-Servomotors have an operational life- signifi- 0
sensor
cant boost in motor performance with no reduction
time many times that of mechanically commutated (brush) in output signal
effi ciency. They are designed for high to very high speed S1 S2 S3 S4 S5 S6 S1 2-pole motor
DC-Motors.
operation. They are available in high speed (BHS) and high
28
Changes in ambient temperature or cooling conditions
will influence the value. In addition, modifications to the
Brushless DC-Servomotors shaft, bearing, lubrication, and commutation system or
2 Pole Technology combinations with other components such as gearheads or
encoders will all result in a change to the no-load current
of the motor.
Series 1628 ... B Stall torque MH [mNm]

Values at 22°C and nominal voltage 1628 T The torque developed by the motor at zero speed (locked
1 Nominal voltage UN
2 Terminal resistance, phase-phase R rotor) and nominal voltage. This value may vary due to the
3 Efficiency, max. Kmax.
4 No-load speed n0 magnet type and temperature and the temperature of the
5 No-load current, typ. (with shaft ø 1,5 mm) I0 winding.
6 Stall torque MH
7 Friction torque, static C0
Starting torque MA [mNm]
Maximum torque that the motor can produce at room
Notes on technical datasheet temperature and nominal voltage for a short time during
startup. This value can change due to possible current
The following values are measured or calculated at limits in the control electronics.
nominal voltage, without integrated drive electronics, Both the stall torque MH and the starting torque MA can be
at an ambient temperature of 22 °C. Not all specifications approximated using the following formula:
are given for all motor types and will vary due to the
motor technology and type. UN – C
MH = MA = kM · —— o
R
Nominal voltage UN [V]
This is the voltage applied between two winding phases Friction torque CO [mNm]
using block commutation. This is the voltage at which the The torque caused by static mechanical friction of the ball
other data sheet parameters are measured or calculated. bearings and magnetic hysteresis of the stator.
Depending on the required speed, higher or lower voltage
Viscous damping factor CV [mNm/min-1]
can be applied to the motor within the given limits.
This factor is made up of the torque due to the viscous
Terminal resistance, phase to phase R [ ] ±12 % friction of the ball bearings as well as the Foucault
Is the resistance between two motor phases without an currents, caused by the cyclical changes in the magnetic
additional cable. This value will vary with the winding field of the stator. These losses are proportional to the
temperature (temperature coefficient: α22 = 0,004 K-1). speed of the motor.
Efficiency η max. [%] Speed constant kn [min-1/V]
The maximum ratio between the absorbed electrical The speed variation per Volt applied to the motor
power and the obtained mechanical power of the motor. terminals at constant load.
2
Io· R
= 1– ––––
max.
UN
no
kn = –––––––– =1
––
U N – Io · R k E
No-load speed no [min-1] ±12 %
Describes the motor speed under no-load conditions Back-EMF constant kE [mV/min-1]
at steady state and 22 °C ambient temperature. If not The constant corresponding to the relationship between
otherwise defined the tolerance for the no-load speed is the induced voltage in the rotor and the speed of rotation.
assumed to be ±12 %.
k E = 2π · kM
UN - (Io · R)
no = –––––––––
2π · kM
Torque constant kM [mNm/A]
No-load current, typ. Io [A] The constant corresponding to the relationship between
Describes the typical current consumption of the motor the torque developed by the motor and the current
without load at an ambient temperature of 22 °C after drawn.
reaching a steady state condition.
The no-load current is speed and temperature dependent.
20190716_EPIM-Vorlage_Motoren_Getriebe_dff.indd 15 11.02.20 09:33
29
Current constant kI [A/mNm] For highly dynamic

Operating servo
temperature applications
range [°C] requiring very high
General information
Describes the relation of the current in the motor winding torque
Indicatesin the
the minimum
most compact dimensions,
and maximum the FAULHABER
standard motor
and the torque developed
The FAULHABER winding: at the output shaft. BX4 and BP4
operating Series 4-pole,
temperature, DC-Servomotors
as well as the maximum are ideal. Their
allowable
Originally invented by Dr. Fritz Faulhaber Sr. and patented robust designof
temperature with
thevery few parts
standard motor and no glued compo-
winding.
kI = —— 1 nents means that they are extremely durable and well
in 1958, the System FAULHABER kM coreless (or ironless) Shaft bearings
progressive, self-supporting, skew-wound rotor winding is suited for challenging ambient conditions such as extreme
The bearings used for the Brushless DC-Servomotor.
at the of
heart temperatures and high shock and vibration loads.
Slope n-Mof every∆n/∆M
curve FAULHABER DC-Motor. This revolu-
[min-1/mNm] Shaft load max. [N]
tionary
The ratio technology changed
of the speed variationthe to
industry and created
the torque new
variation. The FAULHABER BP4 family of 4-pole slotless brushless
possibilities
The smaller for
the customer
value, theapplication
more powerful of DC-Motors
the motor.where motors are ideal for applications requiring the highest
the highest power, best dynamic performance, in the peak torque and extremely dynamic motion control.
Δnand Rweight1 load and lifetime are in accordance with the values given
smallest possible size––– = ––– · ––– are required. Applied in FAULHABER Brushless DC-Flat Motors aredoes
3 phase, slotless,
ΔM kM 2 2π by the bearing manufacturers. This value not apply to
a three phase brushless motor, the winding no longer axial fl ux gap motors with a rotating back iron. They have
second, or rear shaft ends.
rotates but rather becomes the basis of a slotless stator. a much higher efficiency than other flat brushless motors
Terminal inductance, phase to phase L [µH]
The main benefits of this technology include: Shafttheir
and playrotating
[mm] back iron provides a high rotor inertia
The inductance measured between two phases at 1 kHz.
■ No cogging torque resulting in smooth positioning and
The play between the shaft and
that is ideal for applications bearings, including the
requiring
Mechanical time constant τ m [ms] low torque ripple and very preciseof
additional bearing play in the case ball bearings.
continuous speed
speed control and higher overall efficiency than other
The time required by the motor to reach a speed of 63 % control.
Housing material
brushless motor types
of its final no-load speed, from standstill. The FAULHABER
housing material and the
■ Extremely high torque and high performance in relation BXT family ofsurface protection.
flat slotted brushless
to the size and weight of R · the
J motor motors
Mass [g]offer the highest possible torque in a very
m = ––––
kM 2 between load to speed,
■ Absolute linear relationship compact design.
The average mass of the basic motor type.
current to torque, and voltage to speed, with a highly FAULHABER also offers a range of 2-pole Brushless
Direction of rotation
Rotor inertia J [gcm2]
sensitive current/torque behaviour Motors
Most motors aare
with cylindrical
designedrotating back iron
for clockwise (CW)sometimes
and
The dynamic moment of inertia of the rotor.
■ Extremely low torque ripple referred to as ironless external rotor motors.
counter-clockwise (CCW) operation; the direction Whatofsets
Angular acceleration αmax. [rad/s2] the FAULHABER
rotation Motor apart is the slotless design which
is reversible.
Brushless DC-Motor
The acceleration Types:from standstill under no-load
obtained eliminates the cogging effect. The high inertia rotor
Whether it’s high torque 4-pole DC-Servomotors, highly Please note that for motors with integrated electronics,
conditions and at nominal voltage. makes these motors ideal for continuous duty applica-
efficient flat DC-Micromotors, or compact slotless motors, the direction of rotation may not be reversible.
tions requiring very precise speed control. These motors
FAULHABER specializes max.
in getting
M H the most performance Speed up on-board
to nmax. [min -1
] control electronics that can be
= ––––– also have speed
out of the smallest package. J The
confimaximum
gured for recommended
different speedmotor speed for continuous
profiles.
Due
Thermalto their design RFAULHABER
resistance th1; Rth2 [K/W]
Brushless DC-Motors are operation at a given cooling level. This value is based on
ideal for heavy duty servo applications with frequent over- Sensors:
the recommended operating range for the standard motor
Rth1 corresponds to the thermal resistance between the FAULHABER
load conditions as well as for continuous duty applications
winding and housing. Rth2 corresponds to the thermal bearings and2-pole or 4-pole
the winding. AllDC-Servomotors and nega-
higher values have Brush-
where maximum operational lifetime is required. less DC-Flat Motors come standard with 3 discrete
tive effects on the maximum achievable service life of the digital
resistance between the housing and the ambient air. Hall sensors with a 120° phase shift.
FAULHABER
R high precision 2-pole Brushless DC-Motors are
th2 can be reduced by enabling exchange of heat between
motor.
three
the motorphase slotless
and motors that
the ambient have
air (for a wide speed
example, and
a thermally Number 0° 120°
of pole pairs 240° 360°
torque
coupledrange and are
mounting ideal
confi for mid-
guration, to high
using speed
a heat sink,applica-
and/or Indicates
1 the number of pole pairs of the standard motor.
tions requiring
forced air cooling). smooth speed control, high efficiency, and HA
long operational lifetimes. Hall sensors

0
Thermal time constant τ w1; τ w2 [s] Describes the type of motor commutation feedback
FAULHABER BHx motors are three phase slotless brushless 1
The thermal time constant specifies the time needed for components
HB in the standard motor.
motors designed for the very highest power to volume 0
the winding (τw1) and housing (τw2) to reach a temperature Magnet material
ratio and peak efficiency for cool operation even at very
equal to 63 % of final steady state value. Describes the basic type of the magnet used in the
high speed. They feature a six phase coil connected for H
1
standard
C
motor. Digital Hall
sensor
em
cant Final
boost in motor performance with no reduction in output signal
temperature 2-pole motor
efficiency. They are designed for high to very high speed S1 S2 S3 S4 S5 S6 S1

63 % of
torque (BHT) versions
final ( )t to maximize the speed
Thermal
or torque
time constant
temperature
o th
t
30
Unspecified mechanical tolerances: Autoclavable

Tolerances in accordance with ISO 2768.
FAULHABER Brushless DC Motors specified “for Autoclave
≤ 6 = ± 0,1 mm
Sterilisation” have been specifically designed to withstand
≤ 30 = ± 0,2 mm
steam sterilization processes. The sterilization cycle used as
≤ 120 = ± 0,3 mm
reference is the following:
The tolerances of non-specified values are available on
Reference Autoclave Sterilization Cycle:
request.
Sterilizer, Pulse Vacuum Steam Sterlizer
All mechanical dimensions related to the motor shaft are
Air removal Fractioned pre-vacuum air removal
measured with an axial preload of the shaft toward the Holding Temperature 134 °C
motor. Holding Pressure ca. 3 100 mbar abs.
Relative Humidity 100 %
Holding Time 18 minutes
Drying Post-vacuum drying
Air removal Heating Holding time Exhaust Drying
T [°C] Abs. P
[mbar]
120 3 000
80 2 000
40 Atmospheric
Pressure
0 0
0 10 20 30 40 50 t [min]
The above mentioned sterilization cycle does not include

any preparation activities such as cleaning or disinfection.
The typical number of cycles that the brushless DC motor
will withstand is indicated in the datasheet. This value
could be exceeded if the motor is encapsulated in the
final assembly.
31

Rated values
General for continuous duty operation
information n [min-1in
] the most compact dimensions,
torque Watt
the FAULHABER
Continuous operation (R 0%)
th2
Continuous operation (R -50%)

th2
The following
FAULHABER values are measured at nominal voltage,
winding: BX4 and
35 000 BP4
6
Series
12 18
4-pole,
24
DC-Servomotors are
Intermittent ideal. Their
operation
Operating point
without
Originally invented by Dr.electronics,
integrated drive at anSr.
Fritz Faulhaber ambient tem-
and patented robust
30 000 design with very few parts andatno glued
nominal value compo-
perature of 22 °C.
in 1958, the System FAULHABER coreless (or ironless) nents means
25 000
n that they are extremely durable and well
max.
progressive, self-supporting, skew-wound rotor winding is suited

20 000
for challenging ambient
P conditions such as extreme
D
Rated Torque MN [mNm] temperatures and high shock and vibration loads.
at the heart of every FAULHABER DC-Motor. This revolu- 15 000
The maximum continuous duty torque (S1 Operation) at
tionary technology changed the industry and created new The
10 FAULHABER
000 BP4 family of 4-pole slotless brushless
nominal voltage resulting in a steady state temperature U N
possibilities for customer application of DC-Motors where motors are ideal for applications requiring
M the highest
not exceeding either the maximum winding tempera- M
N
5 000 n 0
D
the highest power, best dynamic performance, in the peak torque and extremely dynamic motion control.
ture and/or operating temperature range of the motor. 0 M [mNm]
smallest possible size and weight are required. Applied in FAULHABER0 2 Brushless
4 6 8DC-Flat
10 12 Motors
14 16 are
18 320phase,
22 slotless,
Additionally the motors are specified either with a 25 % Recommended operation areas
a three phase brushless motor, the winding no longer axial flux gap motors with a rotating back iron. They have
reduction of the Rth2 value or with an additional mount-
rotates but rather becomes the basis of a slotless stator. a much higher efficiency than other flat brushless motors
ing condition on a metal flange. Both types of diagram Example: Power diagram for rated values at continuous
The main benefits of this technology include: and their rotating back iron provides a high rotor inertia
approximate the cooling of the motor given by a typical operation.
■ No cogging
method torque resulting
of installation. This valuein can
smooth positioning
be exceeded and
if the that is ideal for applications requiring
speed control and higher overall efficiency
motor is operated intermittently, for example, in S2 mode than other low torque ripple and very precise continuous speed
brushless
and/or if more motor types
cooling is applied. control.
■ Extremely high torque and high performance in relation Explanations
The FAULHABER BXT on family
the performance diagram
of flat slotted brushless
Rated
to theCurrent
size and (thermal
weight limit) IN [A]
of the motor motors offer the highest possible torque in a very
The typical maximum continuous currentload
at steady state The performance
compact design. diagram shows the range of possible
■ Absolute linear relationship between to speed,
resulting operating points of a drive at an ambient temperature
currentfrom the rated
to torque, andcontinuous
voltage to duty
speed,torque.
with aThis
highly FAULHABER also offers a range of 2-pole Brushless
value includes the effects ofbehaviour
a loss of kM (torque constant) of 22 °C and includes both the operation in the thermally
sensitive current/torque Motors with a cylindrical rotating back iron sometimes
as it relates to the temperature coefficient of the wind- insulated and in the cooled state. The possible speed
■ Extremely low torque ripple referred to as ironless external rotor motors. What sets
ing, losses due to the effects of the dynamic coefficient of ranges are shown in dependence on the shaft torque.
Brushless
friction DC-Motor
which include Types:
the Foucault (eddy current) losses, The sector shown
eliminates dashed
the cogging describes
effect. potential
The high operating
inertia rotor
Whether it’s high torque 4-pole DC-Servomotors,
as well as the thermal characteristics of the given highly
magnet points in which the drive
makes these motors idealcan
for be engaged duty
continuous in intermittent
applica-
material. This value can be exceeded if theslotless
effi cient flat DC-Micromotors, or compact motor motors,
is oper- operation
tions or with
requiring increased
very cooling.
precise speed control. These motors
FAULHABER
ated specializes
intermittently, in gettingmode,
in start/stop the most performance
in the starting also have on-board speed
Continuous torque MD [mNm] control electronics that can be
out of and/or
phase the smallest
if morepackage.
cooling is used. confi gured for different speed profiles.
Describes the max. continuous torque in the steady state
Due toSpeed
Rated their design
nN [minFAULHABER
-1
] Brushless DC-Motors are
at nominal voltage and with a thermal reduction of the
Sensors:
ideal for heavy duty servo applications
The typical speed at steady state resulting with frequent
from over-
the appli- Rth2 value by 50
FAULHABER %. The
2-pole continuous
or 4-pole speed decreases
DC-Servomotors linearly
and Brush-
load conditions as well as for continuous duty applications
cation of the given rated torque. This value includes the vis-à-vis the continuous torque. In the case of slotted
less DC-Flat Motors come standard with 3 discrete digital flat
where
effects maximum operational
of motor losses on thelifetime
slope ofisthe
required.
n/M curve. brushless motors, this point is indicated
Hall sensors with a 120° phase shift. with the motor
FAULHABER high precision 2-pole Brushless DC-Motors are mounted on a metal flange and is the same as MN. The
Rated Slope of the n-M curve
three phase slotless motors that have a wide speed and continuous
0°
torque120°
is independent240°
of the continuous
360°
output
An approximation
torque range and areof the slope
ideal of the
for mid- tocurve
high at a given
speed applica- power 1 and can be exceeded if the motor is operated
rated operating point. This value is derived from
tions requiring smooth speed control, high efficiency, the no
and H
intermittently,
A
for example, in S2 operation and/or if more
load speed
long and the
operational speed under load.
lifetimes.
0
cooling is applied.
FAULHABER BHx motors are no –three
nN phase slotless brushless 1
––––––––
MNhighest power to volume
Continuous
H
B output power PD [W]
motors designed for the very 0
Describes the max. possible output power in continuous
ratio and peak efficiency for cool operation even at very
operation in steady state with a thermal reduction of the
high speed. They feature a six phase coil connected for 1
H value by 50 %. The value is independent of the con-
Rth2
C
Digital Hall
sensor
tinuous torque, responds linearly to the cooling factor and
cant boost in motor performance with no reduction in output signal
can be exceeded ifS3the motor isS5operated intermittently,
2-pole motor for
efficiency. They are designed for high to very high speed S1 S2 S4 S6 S1
example, in S2 operation and/or if more cooling is applied.

32
Nominal voltage curve UN [V]

The nominal voltage curve describes the operating points
at UN in the uncooled and cooled state. In steady state, the
starting point corresponds to the no-load speed n0 of the
drive. Operating points above this curve can be attained by
an increase, operating points below by a reduction of the
nominal voltage.
Additional Information for Slotted Brushless Motors
The performance curves for slotted motors with a hous-
ing will be significantly different than the diagrams of the
motors without housing. Typically motors without a hous-
ing will have a higher performance due to the effects of
ambient air flow cooling.
n [min-1] Plastic flange

Metal flange
Watt
12 000 30 60 90 120 Operating point
at nominal value
10 000
8 000
UN
6 000
4 000
2 000
0 M [mNm]
0 15 30 45 60 75 90 105 120 135 150 175
Recommended operation areas (example: nominal voltage 24V)
Example: Performance diagram for rated values with

continuous operation. (BXT R)

Metal flange
Watt
12 000 30 60 90 120 Operating point
at nominal value
10 000
8 000
UN
6 000
4 000
2 000
0 M [mNm]
0 15 30 45 60 75 90 105 120 135 150 175
Recommended operation areas (example: nominal voltage 24V)

continuous operation. (BXT H)
33
Basic design
5
FAULHABER B
1 Rear cover with bearing

2 PCB 6
3 Winding
4 Magnet
7
5 Shaft
6 Stator laminations
FAULHABER BHx
6
1 Rear cover
2 PCB
3 Intermediate bearing flange
4 Winding with PCB
5 Stator laminations with housing 7
6 Rotor
7 Bearing flange
34
Basic design
FAULHABER BX4 5
1 Rear cover
2 PCB 6
3 Winding with Hall sensors
4 Stator laminations with housing 7
5 Magnet
6 Shaft
7 Bearing flange
2
3
7
FAULHABER BP4
1 Bearing flange
2 Winding PCB
3 Hall connection PCB
4 Stainless steel housing
5 Winding with stator laminations 8
6 Shaft
7 4 Pole magnet
8 Front bearing flange
35
Brushless DC-Flat Motors
Basic design
1
FAULHABER B-Flat
1 End cap with ball bearing

2 Hall Sensor PCB
3 Rotor and output shaft
4 Stator Winding
5 Rotor, Back-Iron and Magnet
FAULHABER BXT
1 Housing (for BXT H)

2 Rotor with shaft and ball bearing
3 Stator with PCB
4
4 Cover
5 Front flange with ball bearing
36
Notes
37
2 Pole Technology, sensorless
The brushless, sensorless DC-Servomotors can be used even Series
in the most challenging applications where space is extremely
limited. After many years of development and experience 0308 … B 0515 … B
in microsystem technology, FAULHABER has succeeded in
reducing the size of all components and modules to a mini-
mum in order to provide reliable drive functions even with Key Features
the smallest of dimensions. The brushless DC-Servomotors
are sensorless and available with matching, highly compact
gearheads for increasing the output torque, and speed Motor length 8 ... 15 mm
controllers. The brushless DC-Servomotors provide a techno- Nominal voltage 3 ... 6 V
logy basis that can be modified for projects according to the Speed up to 96.000 min-1
requirements of the individual customer. Torque up to 0,13 mNm
Product Code

G Shaft type
05 15 G 0 0 6 B
B Product family
WE CREATE MOTION
FAULHABER B-Micro
Extremely compact design. 2-pole design with medium to high speeds

Diameters ranging from 3 mm to 5 mm Matching, highly compact gearheads available
For applications where space is very limited Matching speed controllers available
2 Pole Technology
The original FAULHABER brushless DC servomotors. Series
These ironless slotless motors are built for use in highly
challenging areas of application and environmental conditions 0620 … B 0824 … B
from the vacuum of space to medical device technology. 1028 … B 1218 … B
They are precise, have extremely long operational lifetimes,
1226 … B 1628 … B
and are highly reliable. They are available with a wide variety
2036 … B 2057 … B
of complementary products such as high resolution encoders
and precision gearheads. For maximum integration and 2057 … BA 2444 … B
reduction of size the standard digital hall sensors in the 3056 … B 3564 … B
motors can be replaced with optional analog (linear) hall 4490 … B 4490 … BS
sensors which can eliminate the need for an encoder in
most applications.
Key Features

Product Code

K Shaft type
35 64 K 0 2 4 B
B Product family
WE CREATE MOTION
FAULHABER B
High density ironless system FAULHABER winding Extremely smooth speed control
Digital or analog hall sensors available Sensitive positioning control
2 Pole Technology
The BHx series uses 2-pole brushless technology based on Series
an innovative and robust design to deliver high power in a
compact size. These motors come in 2 distinct versions to 1645 … BHS 1660 … BHS
support a wide variety of different application needs: the 1660 … BHT
BHT variant is dedicated to high torque for large impulsive
cycles, and the BHS model is focused on very high speed
for continuous use. Key Features
BHx series is capable of driving variable load with minimum
Motor diameter 16 mm
speed fluctuation to guarantee smooth behavior at constant
speed. Furthermore their low inertia and short response time
provide also high dynamics. Those characteristics make BHx Nominal voltage 24 ... 48 V
series ideal for both-high speed operation and fast accurate Speed up to 100.000 min-1
positioning, especially in intermittent operation when Torque up to 18,7 mNm
combined with integrated high resolution encoder. BHx series Continuous output up to 96 W
exhibits low vibration level and low noise to reduce human
fatigue and stress inside application environment. Their high
efficiency minimizes heat generation and helps to increase
comfort when used as handtools.
Product Code

S Shaft type
16 60 S 024 BHT
BHT Product family
WE CREATE MOTION
FAULHABER BHx
Large power up to 96 W in small diameter Very dynamic and responsive with low inertia
High speed close to 100‘000 min-1 (BHS version) Low vibration and low noise, suitable for handtools
Huge impulsive torque > 30 mNm (BHT version) Optional integrated encoder
4 Pole Technology
From dynamic start/stop operation to speed control and high- Series
precision, integrated position control in confined installation
spaces – the flexible BX4 modular system can be combined 2232 … BX4 2250 … BX4 S
with a wide variety of gearhead attachments and offers 2250 … BX4 3242 … BX4
customised solutions for a broad range of different
3268 … BX4
applications.
The long service life, high torque and an innovative as well

as compact design are further outstanding features of this Key Features
4-pole product family.
Smooth running, low vibration and low noise mean that
these motors can be used in sensitive markets, e.g. medical
technology, in addition to market sectors such as automation
technology, robotics and machine construction. Speed up to 29.000 min-1
Torque up to 96 mNm
Product Code

S Shaft type
22 50 S 0 2 4 BX4
BX4 Product family
WE CREATE MOTION
FAULHABER BX4
High torque and speed rigidity Versions with integrated Speed or

thanks to 4-pole technology Motion Controllers available
Position control in extremely confined High reliability and long service life
installation spaces thanks to optional Dynamically balanced rotor, quiet running
analogue Hall sensors
Modular, diameter-compliant mounting
concept for high-resolution magnetic and
optical encoders
4 Pole Technology
The four-pole brushless DC-Servomotors of the BP4 Series
series are characterised by their extremely high torques,
despite the compact 22 mm and 32 mm diameter 2264 ... BP4 3274 ... BP4
design and low weight. At the heart of the motors lies
innovative winding technology that not only allows a
very high copper content in the stator, but also has a Key Features
high electrical and geometric winding symmetry.
This minimises losses and maximises efficiency. The BP4
series is overload-resistant and suitable for applica- Motor length 64 ... 74 mm
tions involving high power where the lowest possible Nominal voltage 12 ... 48 V
total weight and smallest possible installation space are Speed up to 34.500 min-1
required, and also for dynamic start/stop operation. Torque up to 162 mNm
Product Code

W Shaft type
2264 W 0 2 4 BP 4
BP4 Product family
WE CREATE MOTION
FAULHABER BP4
High-power motors with maximum torque Fully integrated analogue Hall sensors and
Continuous output from 133 W to 150 W matching encoders, gearheads and controllers
are available
Outstanding ratio of torque to weight and size
For dynamic start/stop operation
Very high efficiency of up to 91 %
and DC-Gearmotors
The four-pole brushless DC-Servomotors, which have uniquely Series
flat coil technology with three flat, self-supporting copper
windings and are used in the B-Flat series, form the basis for 1509 … B 1515 … B
drive systems in applications where space is extremely limited. 2610 … B 2622 … B
With their powerful rare-earth magnets, the motors deliver a
continuous output of 1.5 W to 9 W and at the same time have
only minimal inertia. In combination with the integrated gear- Key Features
heads in extremely flat design, the motors provide a very com-
pact drive system with increased output torque. Due to the Motor diameter 15 ... 26 mm
electronic commutation of the drives, the service life is many Motor length 9 ... 22 mm
times longer compared to mechanically commutated motors. Nominal voltage 6 ... 12 V
Product Code

T Shaft type
26 10 T 0 1 2 B
B Product family
WE CREATE MOTION
FAULHABER B-Flat
Extremely flat design. Integrated spur gearheads

Lengths ranging from 9 mm to 22 mm of minimal length with high
4-pole design gear ratio are available
Electronic commutation using Precise speed control

three digital Hall sensors
Brushless flat motors
with External rotor technology
The external rotor motors of the BXT series set new Series
standards: thanks to innovative winding technology and
optimum design, the BXT motors deliver a torque of 2214 … BXT R 2214 … BXT H
up to 134 mNm. The ratio of torque to weight and size is 3216 … BXT R 3216 … BXT H
unmatched. The iron-core motors with 14 high-performance
4221 … BXT R 4221 … BXT H
rare earth magnets on the rotor and 12 teeth on the stator
are just 14 mm, 16 mm and 21 mm long, making them suitable
for applications that require a short drive solution with high
Key Features
torque. Combined with optical and magnetic encoders,
gearheads and controls, the result is a compact drive system. Motor diameter 22 ... 42 mm
Product Code

G Shaft type
42 21 G 024 BXT R
BXT Product family
R Open construction
WE CREATE MOTION
FAULHABER BXT
External rotor motors Flat design for space-critical applications.

with very high torque Length range of 14 to 21 mm.
Continuous output up to 100 W Matching optical and magnetic encoders,
Outstanding ratio of torque gearheads and controls available
to weight and size 14-pole construction
Motors with integrated Electronics
WE CREATE MOTION
Speed Control Systems
Connection
FAULHABERvariants
BRC Page
Brushless DC-Motors with Portfolio description
Brushless DC-Servomotors 234 – 235
integrated Speed Controller 1525 … BRC with
with integrated
integrated Speed Controller
Speed Controller 1,9 mNm 236 – 237
1935 … BRC with integrated Speed Controller 4,4 mNm 238 – 239
3153 … BRC with integrated Speed Controller 36,5 mNm 240 – 241
FAULHABER BX4 SC Page

Series 22/32xx…BX4 SC
Brushless DC-Servomotors with Portfolio description 242 – 243
integrated Speed Controller – 2232 … BX4 SC with integrated Speed Controller 17,5 mNm 244 – 245
4 Pole Technology 2250 … BX4 S SC with integrated Speed Controller 13,3 mNm 246 – 247
2250 … BX4 SC with integrated Speed Controller 25 mNm 248 – 249
3242 … BX4 SC with integrated Speed Controller 60 mNm 250 – 251
3242 … BX4 SCDC with integrated Speed Controller, 2-wire Series 2214/3216/4221…BXTH
45 mNm 252 – 253
SC
3268USB
… BX4 SC with integrated Speed Controller 99 mNm 254 – 255
3268 … BX4 SCDC with integrated Speed Controller, 2-wire 60 mNm 256 – 257
FAULHABER B-Flat SC Page

Brushless Flat DC-Micromotors and Portfolio description 258 – 259
DC-Gearmotors with integrated 2610 … B SC with integrated Speed Controller 3,12 mNm 260 – 261
Series 26xx…B SC
Speed Controller 2622 … B SC with integrated Speed Controller 100 mNm 262 – 263
FAULHABER B Cx Page
integrated Motion Controller 3564 ... B Cx with integrated Motion Controller 71 mNm 282 – 283
Series 1525/1935/3153…BRC
FAULHABER BX4 CxD/Cx Page

Speed Control Systems can be adapted to the application
General Information
integrated Motion Controller – 2232 ... BX4 CxD with integrated Motion Controller 16 mNm 286 – 287
via the FAULHABER Motion Manager software. The type
4 Pole Technology 2250 ... BX4 CxD with integrated Motion Controller 25 mNm 288 – 289
FAULHABER Speed Control Systems are 3242highly dynamic
... BX4 Cx andintegrated
with scalingMotion
of the setpoint input, the67operating
Controller mNm mode and
290 – 291
drive systems with controlled speed. 3268
The ...drive electron-
BX4 Cx the control parameters
with integrated Motion Controllercan be adjusted. The
96 mNm USB program-
292 – 293
ics are already integrated and matched to the respective ming adapter for Speed Controllers is used for configu-
FAULHABER MCS
motor. ration, and a contacting board is used for connectingPage
the
Brushless DC-Servomotors with Portfolio description ribbon cables. 294 – 295
The compact integration of the Speed Controller as well
integrated Motion Controller – MCS 3242 ... BX4 RS/CO with integrated Motion Controller 76 mNm 296 – 297
as4the
PoleflTechnology
exible connection possibilities open
MCS 3242a...wide
BX4 ETrange with integrated Motion Controller 76 mNm 298 – 299
of applications in areas such as laboratory technology Interfaces – discrete I/O
MCS 3268 ... BX4 RS/CO with integrated Motion Controller 96 mNm 300 – 301
and equipment manufacturing, automation technology,
MCS 3268 ... BX4 ET ■ Analog
with integrated input
Motion as setpoint input for96setting
Controller mNm the speed via
302 – 303
pick-and-place machines and machine tools,
MCS orBP4
3274 ... pumps.
RS/CO with PWM or Motion
integrated analog voltage value
Controller 160 mNm 304 – 305
MCS 3274
The integration of the control electronics ... BP4 ET
in space- with integratedinput
■ Digital Motionas
Controller
switching input for160 mNm
defi 306direc-
ning the – 307
optimised add-on systems reduces space requirements tion of rotation of the motor
and simplifies installation and start-up. ■ Digital output, can be programmed either as frequency
The integrated electronics facilitate speed control by output or as error output
means of a PI controller with external setpoint input.
The direction of rotation can be changed via a separate Note
switching input; the speed signal can be read out via the
frequency output. Device manuals for installation and start-up, as well as the
The motors can optionally be operated as a voltage con- "FAULHABER Motion Manager" software, are available on
troller or in fixed speed mode. request or on the Internet under www.faulhaber.com.
53
8000
7000
Brushless DC-Servomotors 6000
with integrated Speed Controller UN
Speed [min-1]
5000
4 Pole Technology Operation point
4000
Peak torque
3000
3242 ... BX4 SC 2000
Values at 22°C and nominal voltage 3242 G 1000

Power supply electronic UP
Power supply motor Umot 0
Nominal voltage for motor UN 0 25 50 75 100 125 150 175 200
Torque [mNm]
No-load speed (at UN) n0
Peak torque (S2 operation for max. 3s/2s) Mmax.
Torque constant kM
PWM switching frequency fPWM Example: 3242...BX4 SC
Torque constant km [mNm/A]

Notes on technical data sheet Constant that describes the ratio between motor torque
and current input.
The following data sheet values of the Speed Control Sys-
Starting torque [MA]
tems are measured or calculated at nominal voltage and at
Load torque with which the motor starts at room tempera-
an ambient temperature of 22°C.
ture and nominal voltage. This value can change depend-
Power supply for electronics Up [V DC] ing on the magnet type and magnet temperature as well
Describes the range of the permissible supply voltage for as the winding temperature.
the control electronics.
PWM switching frequency ƒPWM [kHz]
Power supply for motor Umot [V DC] Pulse width modulation describes the change of the elec-
Describes the range of the permissible supply voltage for trical voltage between two values. The motors integrated
the base motor integrated in the complete system. in the SCS have a low electrical time constant. To keep the
losses associated with PWM low, a high switching fre-
Motor nominal voltage UN [V]
quency is necessary.
The voltage applied between two winding phases. This is
the voltage at which the data sheet parameters are mea- Electronics efficiency η [%]
sured or calculated. Depending on the required speed, a Ratio between consumed and delivered power of the
higher or lower voltage can be applied within the permis- control electronics.
sible range of the supply voltage.
Standby current for the electronics Iel [A]
No-load speed n0 [min-1] Describes the additional current consumption of the
Describes the motor speed when idling and in the steady- complete system that can be attributed to the integrated
state condition at nominal voltage. electronics.
Peak torque Mmax. [mNm] Speed range [min-1]
Specifies the torque that the drive can reach in S2 oper- Describes the maximum no-load speed for continuous
ation (cold start without additional cooling) at nominal operation in the steady-state condition at elevated nom-
voltage and nominal conditions under constant load for inal voltage. Depending on the required speed, higher
the time specified in the data sheet without exceeding or lower voltage can be applied within the given system
the thermal limit. Unless otherwise defined, the value limits.
that applies for the peak torque is equal to two times the Mounting of the system on a plastic flange according to
continuous torque. installation type IM B 5.
Shaft bearings
The bearings used for the brushless DC motors.
EN,DE,FR,CN.indd 13 11.02.20 15:37

54
Shaft load, max. permissible [N] Rated current IN [A]

Max. permissible shaft load of the output shaft with spec- Typical maximum continuous current in the steady-state
ified shaft diameter. The values for load and service life condition which results from the rated torque in contin-
of motors with ball bearings are based on manufacturer uous operation. This value can be exceeded if the drive is
specifications. This value is not applicable for a possibly operated intermittently, in start/stop mode, in the starting
available rear or second shaft end. phase and/or if more cooling is used.
Shaft play [mm] Rated speed nN [min-1]

Clearance between the shaft and bearing including the Typical rated speed in the steady-state condition which is
additional bearing clearance in the case of ball bearings. determined from the given rated torque.
Operating temperature range [°C] This value takes into account the effects that motor losses
Shows the minimum and maximum operating temperature have on the slope of the n/M characteristic curve.
of the complete system under nominal conditions.
Housing material n [min-1] Plastic flange

Watt Metal flange
Housing materials and, if necessary, surface treatment. 8 000
10 20 30
intermittent operation
Operating point at rated values
7 000
n0@ 30V
Mass [g] 6 000
The typical mass of the standard system may vary due to 5 000
n0 @ UN
the different component variants. 4 000 PD
3 000
Length dimensions without mechanical tolerance specifi-
2 000 MN =MD
cations:
1 000
Tolerances according to ISO 2768:
0 M [mNm]
≤ 6 = ± 0.1 mm 0 10 20 30 40 50 60 70 80 90
Recommended operation areas
≤ 30 = ± 0.2 mm
≤ 120 = ± 0.3 mm
The tolerances of non-specified values are available on continuous operation.
request.
All mechanical dimensions of the motor shaft are mea- Explanations on the Performance Diagram
sured with an axial shaft load in the direction of the
The performance diagram shows the possible operating
motor.
points of the servo-drives.
Rated Values for Continuous Operation Operating points in the dark blue area are reached con-
tinually in the case of pure flange mounting (IM B5) on a
The following values are measured at nominal voltage, plastic flange (approx. 100mm x 100mm x 10mm) and at
an ambient temperature of 22°C and with mounting type an ambient temperature of 22°C.
IM B 5.
Operating points in the light blue area up to PD are
Mounting type IM B 5 defines the flange mounting of the reached continually in the case of pure flange mounting
drive without mounting feet with two bearing plates, free (IM B5) on an aluminium flange (approx. 100mm x 100mm
front shaft end and mounting flange close to the bearing. x 10mm) and at an ambient temperature of 22°C.
Rated torque MN [mNm] The maximum achievable speed depends on the motor
Maximum continuous torque (S1 mode) at nominal volt- supply voltage. At nominal voltage, the maximum achiev-
age at which in the steady-state condition the tempera- able operating points are those on the nominal voltage
ture does not exceed the maximum permissible winding line through the no-load point and nominal point.
temperature and/or the operating temperature range of Speeds above the nominal voltage line are reached at an
the motor. The motor is fastened to a metal flange here, increased supply voltage.
which approximates the amount of cooling available from
In this case, the maximum voltage for the electronics or
a typical mounting configuration of the motor. This value
motor supply must never be exceeded.
can be exceeded if the motor is operated intermittently,
for example, in S2 mode and/or if more cooling is applied. The possible speed ranges are shown in dependence on
the shaft torque.
55
The
Shaftsector
load,shown dashed describes
max. permissible [N] possible operating Rated current IN [A]
points in which the
Max. permissible drive
shaft canofbe
load engaged
the output in intermittent
shaft with spec- Typical maximum continuous current in the steady-state
operation
ified shaft or with increased
diameter. cooling.
The values for load and service life condition which results from the rated torque in contin-
of motors with ball bearings are based on manufacturer uous operation. This value can be exceeded if the drive is
specifications. This value is not applicable for a possibly operated intermittently, in start/stop mode, in the starting
Describes the max. recommended continuous torque in
available rear or second shaft end. phase and/or if more cooling is used.
the steady-state condition at nominal voltage and mount-
Shaft
ing onplay [mm]
an aluminium flange. With Speed Control Systems, Rated speed nN [min-1]
Clearance
the between
continuous thesimultaneously
torque shaft and bearing includingto
corresponds thethe Typical rated speed in the steady-state condition which is
additional
rated bearing clearance in the case of ball bearings.
torque. determined from the given rated torque.
Here, the speed
Operating is linearrange
temperature to the[°C]
continuous torque. The This value takes into account the effects that motor losses
continuous
Shows the minimum and maximumofoperating
torque is independent the continuous
temperature have on the slope of the n/M characteristic curve.
output
of the complete system under nominalthe
power and can be exceeded if motor is oper-
conditions.
ated intermittently, for example, in S2 operation and/or if
Housing
more material
cooling is applied. n [min-1] Plastic flange
Watt Metal flange
Housing materials and, if necessary, surface treatment. 8 000
10 20 30
Continuous output power PD [W] 7 000
n0@ 30V
Mass [g] the max. possible output power in continuous
Describes 6 000
The typicalinmass
operation of the standard
steady-state system
condition withmay vary due
mounting on to 5 000
n0 @ UN
thealuminium
an different component
flange. Thevariants.
value is independent of the 4 000 PD
continuous torque, responds linearly to the cooling factor 3 000

Length dimensions without mechanical tolerance specifi-
and can be exceeded if the motor is operated intermit- 2 000 MN =MD
cations:
tently, for example, in S2 operation and/or if more cooling 1 000
is applied. 0 M [mNm]
≤ 6 = ± 0.1 mm 0 10 20 30 40 50 60 70 80 90
Nominal voltage curve UN [V]
≤ 30 = ± 0.2 mm
The nominal voltage curve describes the possible contin-

≤ 120 = ± 0.3 mm
uous operating points at UN. In steady state, the starting Example: Performance diagram for rated values with
The tolerances
point of non-specifi
corresponds ed values
to the no-load speedare
n0 available on
of the drive. continuous operation.
request.
Operating points above this curve can be attained by an
increase,
All operating
mechanical points below
dimensions of the by a reduction
motor shaft areofmea-
the Explanations on the Performance Diagram
nominal
sured withvoltage.
an axial shaft load in the direction of the
motor.
Note
Rated Values for Continuous Operation Operating points in the dark blue area are reached con-
Easy commissioning
The following with the new
values are measured at nominal voltage, plastic flange (approx. 100mm x 100mm x 10mm) and at
Motion
an ambient Manager 6.of 22°C and with mounting type
temperature an ambient temperature of 22°C.
IM B 5.
Depending on the cooling factor, operating point and Operating points in the light blue area up to PD are
Mountingtemperature,
ambient type IM B 5 defi nesbe
it may thenecessary
flange mounting
to adjust of
thethe reached continually in the case of pure flange mounting
drive without
current mounting
limitation feet with
parameters usingtwo
thebearing plates,
operating soft-free (IM B5) on an aluminium flange (approx. 100mm x 100mm
front shaft
ware. end and manual
See technical mountingforfldetails.
ange close to the bearing. x 10mm) and at an ambient temperature of 22°C.
Rated torque MN [mNm] The maximum achievable speed depends on the motor
Maximum continuous torque (S1 mode) at nominal volt- supply voltage. At nominal voltage, the maximum achiev-
age at which in the steady-state condition the tempera- able operating points are those on the nominal voltage
ture does not exceed the maximum permissible winding line through the no-load point and nominal point.
temperature and/or the operating temperature range of Speeds above the nominal voltage line are reached at an
the motor. The motor is fastened to a metal flange here, increased supply voltage.
which approximates the amount of cooling available from
In this case, the maximum voltage for the electronics or
a typical mounting configuration of the motor. This value
for example, in S2 mode and/or if more cooling is applied. The possible speed ranges are shown in dependence on
the shaft torque.
56
Basic design
FAULHABER BRC 5
1 Rear cover 6
2 Drive Electronics
3 Housing with ball bearing 7
4 Winding
5 Magnet
6 Shaft
8
7 Rotor back-iron
8 Washer with ball bearing
FAULHABER BX4 SC
1 Motor
2 Housing
3 Mounting flange
4 Electronics PCB
5 End cap
57
Basic design
FAULHABER BRC 5
1 Rear cover 6
2 Drive Electronics
3 Housing with ball bearing 7
FAULHABER
4 Winding B-Flat SC
5 Magnet
1
6 Shaftcap
End
8
2
7 Rotor back-iron
Electronics PCB
3
8 Washer(Front)
Motor with ball bearing
1
2
2 3
3
4
FAULHABER BX4 SC
FAULHABER
1 Motor BXTH SC
2 Housing
1
3 End cap flange
Mounting
2
4 Electronics PCB
Electronics PCB
3
5 Motor
End cap(Front)
58
Notes
59
Brushless DC-Motors with
The efficient motor series with continuously smooth running Series
impresses with an extraordinarily long service life. In optimised
continuous operation, the motors of the BRC family convince 1525 … BRC 1935 … BRC
with their high-performance bearings and cogging-free 3153 … BRC
running in the linear speed and torque range. The brushless
motors with integrated speed controller operate with precise
speed control. Key Features
This allows the operating point and the operating behaviour
to be precisely controlled by means of corresponding software.
Measuring 15 to 31 mm in diameter, these motors are suitable
for installation in extremely confined spaces and – thanks to Nominal voltage 6 ... 24 V
their robust design – also for applications with high loads. The Speed up to 25.000 min-1
motors can be operated reversibly in a clockwise or anti-clock- Torque up to 5,9 mNm
wise direction, depending on the required control mode. The Continuous output up to 17,5 W
frequency output of these motors enables precise reproduc-
tion and determination of the speed of the motor.
Product Code

K Shaft type
31 53 K 012 BRC
BRC Product family
WE CREATE MOTION
FAULHABER BRC
Programmable motor characteristics through No cogging

integrated speed controller Wide, more linear speed/torque range
Outstanding reliability, long service life Smooth running
Dynamically balanced rotor, quiet running
Brushless DC-Servomotors with
The drives with integrated speed controller combine the Series
advantages of brushless DC-Servomotors with diameter-
compliant control electronics installed in the mounted motor 2232 … BX4 SC 2250 … BX4S SC
unit measuring just 18mm in length. 2250 … BX4 SC 3242 … BX4 SC
Combinable with various precision gearheads, they can be 3242 … BX4 SCDC 3268 … BX4 SC
used in a wide variety of market sectors such as laboratory 3268 … BX4 SCDC
technology, equipment manufacturing, automation technol-
ogy or machine construction. The default factory preconfigu-
ration in combination with the Motion Manager allows quick Key Features
and easy commissioning of the system.
The selectable Hall sensor type (digital/analogue) ensures
Motor length 49,6 ... 85,4 mm
optimum coverage over a wide speed range. The integrated
current limitation matched to the respective type protects the Nominal voltage 12 ... 24 V
motor against overloading and therefore against potential Speed up to 14.000 min-1
destruction. The two-wire version SCDC allows brushed DC- Torque up to 99 mNm
Motors to be replaced easily in certain applications. Continuous output up to 53 W
Product Code

S Shaft type
22 32 S 0 2 4 BX4 SC
BX4 Product family
SC Integrated Speed Controller
WE CREATE MOTION
FAULHABER BX4 SC
High torque and speed rigidity thanks to Simple and convenient programming using the
4-pole technology Motion Manager and programming adapter
Speed control in tight installation spaces; thanks High reliability and long service life
to optional analogue Hall sensors, also available Dynamically balanced rotor, quiet running
in the low speed range from 50 min-1
Modular, diameter-compliant mounting concept
with integrated current limitation
and DC-Gearmotors with
The brushless DC-Servomotors with integrated electronics Series
are based on the motors of the B-Flat series. In the case of
the B-Flat series, the four-pole brushless DC-Servomotors 2610 … B SC 2622 … B SC
with their uniquely flat coil technology with three flat, self-
supporting copper windings form the basis for drive systems
in applications where installation space is extremely limited. Key Features
As an integrated electronic actuation unit, a speed controller
Motor diameter 26 mm
is already available for these motors. What makes this speed
controller so special is that it is fully integrated on the motor Motor length 10,4 ... 22 mm
circuit board and does not increase the length of the motor in Nominal voltage 6 ... 12 V
any way. In combination with the extremely flat, integrated Speed up to 13.000 min-1
gearheads, these motors provide an extremely compact drive Torque up to 100 mNm
system with increased output torque.
Product Code

S Shaft type
26 22 S 0 1 2 B SC 8:1
B Product family
8:1 Gearhead reduction
WE CREATE MOTION
FAULHABER B-Flat SC
Extremely flat design. Lengths ranging from Easy to use

10 mm to 22 mm with speed controller Integrated spur gearheads of minimal
already integrated length with high gear ratio are available
4-pole design Precise speed control
Brushless DC-Servomotors with
The drives with integrated speed controller combine the advantages Series
of brushless DC-servomotors with diameter-compliant control
electronics which, fully integrated, extend the motor by only 6.2 mm. 2214 … BXT H SC 3216 … BXT H SC
Combinable with various precision gearheads, they can be used 4221 … BXT H SC
in a wide variety of market sectors such as pumps, handheld devices,
equipment manufacturing or laboratory and industrial automation.
The default factory preconfiguration in combination with the Key Features
Motion Manager allows quick and easy commissioning of
Motor diameter 22 / 32 / 42 mm
the system.
Motor length 21 / 23 / 28 mm
The high number of poles of the motors ensures optimum coverage Nominal voltage 12 ... 24 V
of a wide speed range, also with digital Hall sensors. The integrated
current limitation matched to the respective type protects the motor
against overloading and therefore against potential destruction. Continuous torque up to 92 mNm
The combination of the BXT H motors with the integrated Speed Continuous output up to 60 W
Controller is the ideal solution if speeds need to be controlled
precisely in the smallest of spaces and high torques are also required.
Product Code

S Output type
22 14 S 0 2 4 BXTH SC
BXTH Product family
WE CREATE MOTION
FAULHABER BXT SC
High torque and speed rigidity thanks to Simple and convenient programming
14-pole technology using the Motion Manager and
Speed control in tight installation spaces; thanks programming adapter
to the high number of poles of the motors, also High reliability and long service life
available in the low speed range from 200 rpm Second shaft end available in sizes
Modular, diameter-compliant mounting concept 32 and 42 mm
with integrated current limitation
Motion Control Systems
Feature Comparison
Generation V3.0
General Information
A new generation of integrated Motion Controllers for
The space-optimized FAULHABER Motion Control systems applications that go beyond the features and performance
are available in various series. The different variants are offered by the V2.5 series.
suitable for a variety of market segments and the flexible
■ More power
connection possibilities open a wide range of applications
■ Faster control
in areas such as equipment manufacturing, pick-and-place
machines and machine tools, robotics or special machinery ■ New operating modes
construction. They can be put into operation easily and ■ Flexible use of the I/Os for setpoints and actual values
quickly via Motion Manager, which is available for down- ■ Additional I/Os and interfaces
load at no charge.
■ Sequential programs can be programmed in BASIC for
Generation V2.5 simple, local automation in all interface technologies
■ Proven technology for BL motors in various sizes and ■ Expanded diagnostic functions
performance classes
■ Simple start-up via Motion Manager beginning with ver-
■ Very simple configuration and start-up sion 6.0
■ Numerous configuration options
■ Successfully used in medical and laboratory technology,
equipment manufacturing, automation, medical tech-
nology and aerospace
Generation V2.5 Generation V3.0

Voltage ranges ■ Motor: max. 30V ■ Motor: max. 50V
■ Electronics: max. 30V, optionally separated ■ Electronics: max. 50V, separated standard
PWM switching frequency 78 kHz 100 kHz
Peak torque Up to 190 mNm Up to 320 mNm
Motor types 22xx BX4 CxD 32xx BX4 RS / CO / ET
32xx BX4 Cx 3274 BP4 RS / CO / ET
3564 B Cx
Inputs/outputs DigIn: max. 3 DigIn: 3
DigOut: max. 1 DigOut: 2
AnIn: 1 AnIn ±10V: 2
(not all I/Os available depending on wiring) (standard)
Communication ■ RS232 ■ RS232
■ CANopen ■ EtherCAT
■ CANopen
■ USB
Controller Position, speed, current limiting Position, speed, current / torque
Operating modes ■ Depending on the interface variant, ■ Profile Position mode (PP) and Profile Velocity mode
position, speed and current control (PV), taking into account profile settings
with setpoint input via the interface or analog (RS) ■ Cyclic Synchronous Position, speed or torque (CSP, CSV
or CST)
■ Analog input for position, speed, torque or voltage
(APC, AVC, ATC, volt)
Profile operation Linear trapezoidal profiles in all operating modes Linear or sin² speed
in PP and PV modes
Autonomous processes Available in the versions with RS232 interface. Up to eight sequential programs in all versions,
with optional password protection
Protection class n/a IP 54 (optionally with shaft seal)
68
Motion Control Systems V2.5
Connection variants
Brushless DC-Servomotors with integrated

Motion Controller and RS232 or CAN interface.
Series 32xx...BX4 CS/CO
CANopen
USB
RS232
Series 3564...B CS/CO
Series 22xx...BX4 CSD/COD
Features Benefits
FAULHABER Motion Control Systems of generation V2.5 are ■ Compact construction
highly dynamic positioning systems. The drive electronics ■ Modular design, various performance ratings
are already integrated and matched to the motor. The func- ■ Minimal wiring required
tion of the Motion Control Systems is completely identical ■ Parametrization via “FAULHABER Motion Manager“
to the external MCBL 300x FAULHABER Motion Controllers software
of generation V2.5. ■ Wide range of accessories
In addition to use as a servo drive with controlled position, ■ Adapter for connection to USB interface
the speed can also be controlled. Via an integrated cur- ■ Simple start-up
rent control, the torque is limited and the drive protected
against overload.
Motion Control Systems of generation V2.5 are available

Product code
with RS232 or with CAN interface and, as a result, can also
be integrated in networks. In addition to operation on a PC,
the systems can also be operated on all common industrial
controls.
The integration of the motor and control electronics

reduces space requirements and simplifies installation and
start-up. 3268 motor series 3268 G 024 BX4 CS
G shaft type
024 nominal voltage
BX4 electronic commutation brushless
CS Serial interface RS232
69
Configuration, networking, interfaces
Operating modes Options

Positioning operation Separate supply of power to the motor and electronic
The drive moves to the preset target position and, in doing actuator is optional (important for safety-critical appli-
so, maintains the specified limits for speed and position. cations). Third Input is not available with this option.
The dynamics of the control can be adapted to a wide Depending on the drive, additional programming adapters
range of loads. Limit switches can be evaluated directly. and connection aids are available. The modes and param-
The position can be initialised via limit switches or a refer- eters can be specially pre-configured on request.
ence switch.
Interfaces – discrete I/O
Speed control
The drive controls the the preset target speed via a PI Setpoint input
speed controller without lasting deviation. Depending on the operating mode, setpoints can be input
via the command interface, via an analog voltage value, a
Current control PWM signal or a quadrature signal.
Protects the drive by limiting the motor current to the set
Error output (Open Collector)
peak current. By means of integrated thermal models, the
Configured as error output (factory setting). Also usable
current is limited to the continuous current if necessary.
as digital input, free switch output, for speed control or
Motion profiles signaling an achieved position.
Acceleration and brake ramp as well as the maximum
Additional digital inputs
speed can be preset in speed and positioning operation.
For evaluating reference switches.
Autonomous operation
In version RS, freely programmable processes can be stored Networking
in the Motion Controller. Operation is then also possible
FAULHABER Motion Control Systems of generation V2.5
without RS232 interface.
are available in all two networking variants.
Protective features
RS – systems with RS232 interface
■ Protection against ESD Ideal for equipment manufacturing and for all applications
■ Overload protection for electronics and motor in which the controller is also to be used without a higher
■ Self-protection from overheating level controller. Using Net mode, it is also possible to oper-
ate multiple RS controllers on an RS232 interface.
■ Overvoltage protection in generator mode
Operating modes (CS) CO – CANopen acc. to CiA 402

The ideal variant for the operation of a FAULHABER
■ Position control
Motion Controller on a PLC – directly via the CANopen
– with setpoint input via the interface
interface or via a gateway on, e.g., Profibus/ProfiNET or
– with analog setpoint
on EtherCAT.
– gearing mode
– stepper motor operation
■ Speed control
■ Torque control
■ Operation as Servo Amplifier in voltage controller mode
Operating modes (CO)

■ Profile Position mode (PP)
■ Profile Velocity mode (PV)
■ Homing mode
70
The CO version is particularly suitable for users who
Interfaces – Bus Connection
already use various CANopen devices or operate the
Version with RS232 Motion Controllers on a PLC. With dynamic PDO mapping
For coupling to a PC with a transfer rate of up to it is possible to achieve highly efficient networking on the
115 kbaud. Multiple drives can be connected to a single CAN.
controller using the RS232 interface. As regards the control
computer, no special arrangements are necessary. The Features CO
interface also offers the possibility of retrieving online CO
operational data and values. NMT with node guarding •
A comprehensive ASCII command set is available for Baud rate 1 Mbit max., LSS
programming and operation. This can be preset from the
EMCY object •
PC using the “FAULHABER Motion Manager“ software or
from another control computer.
SYNCH object •
Server SDO 1x
Additionally, there is the possibility of creating complex
processes from these commands and storing them on the PDOs 4 x Rx
4 x Tx
drive. Once programmed as a speed or positioning each with dynamic
controller via the analog input, as step motor or electronic mapping
gear unit, the drive can operate independently PDO ID adjustable
of the RS232 interface. Configuration Motion Manager from V5
Version with CANopen CO Trace Any PDO
A controller variant with CANopen interface is available Standard operating •

modes
to allow optimal integration in a wide variety of different
- Profile Position Mode
applications. CANopen is ideal for networking microdrives - Profile Velocity Mode
because the interface can also be integrated in small - Homing
electronics modules. Its size and the efficient communica-
tion procedures mean that it is ideally suited for use in
industrial automation.
The CO version provides the CiA 402 standard operating The model supports the CANopen communication profile
modes. All the parameters are directly stored in the object acc. to CiA 301 V4.02. Transfer rate and node number are
directory. Configuration can therefore be performed with set via the network in accordance with the LSS protocol
the help of the FAULHABER Motion Manager or by apply- as defined in CiA 305 V1.11.
ing available standardized configuratons tools common to For this purpose, we recommend using the latest version
the automation market. of the FAULHABER Motion Manager.
Note
Device manuals for installation and commissioning,
communication and function manuals as well as the
“FAULHABER Motion Manager” software are available on
request or on the Internet under www.faulhaber.com.
71
General Information Modifications and accessories

System description FAULHABER specialises in the adaptation of its standard
The drive systems integrate a brushless DC servomotor, a products for customer-specific applications. The follow-
high-resolution encoder and a Motion Controller in a com- ing standard options and accessory parts are available for
pact, complete drive unit. FAULHABER Motion Control Systems:
Due to the fact that motor commutation is achieved ■ Configurable shaft lengths
electronically and not mechanically, the service life of a ■ Modified shaft dimensions and pinion configurations
FAULHABER Motion Control Systems depends mainly on such as flats, gears, pulleys and eccenters
the service life of the motor bearings.
■ Modifications for applications with higher speeds and/
FAULHABER uses high-precision, preloaded ball bearings or higher loads
in all of its systems with integrated Motion Controller.
■ Customized special configuration and firmware
Factors affecting the life of the motor bearings include
the static and dynamic axial and radial bearing loads, the ■ Separate voltage supply for motor and electronics
ambient thermal conditions, the speed, vibrational and ■ Configuration and connection adapter
shock loads, and the precision of the shaft coupling to the
given application.
torque in the most compact dimensions, the integrated
FAULHABER BX4 Series 4-pole, DC-Servomotors are ideal.
Their robust design with very few parts and no glued
components means that they are extremely durable and
well suited for harsh ambient conditions such as extreme
temperatures and high vibration and shock loads.
Thanks to their robust construction and their compact
design, the FAULHABER Motion Control Systems of the
V2.5 generation are perfectly suited for use in automation
applications.
72
8000
7000
Motion Control Systems 6000
Speed [min-1]
5000
V2.5, 4-Quadrant PWM UN
Operation point
4000
with RS232 or CANopen interface
3000
Peak torque
2000
3242 ... BX4 Cx 1000

Values at 22°C and nominal voltage 3242 G
0
Power supply electronic UB/UEL 0 25 50 75 100 125 150 175 200
Power supply motor1) --/UB Torque [mNm]
Nominal voltage for motor UN
Example: 3242...BX4 Cx
Explanatory Notes for Data Sheets Torque constant km [mNm/A]

Constant that describes the ratio between motor torque
The following data sheet values of the Motion Control Sys- and current input.
an ambient temperature of 22°C. PWM switching frequency ƒPWM [kHz]
In their standard version, MCSs of generation V2.5 do not Pulse width modulation describes the change of the elec-
have separate supply inputs for motor and electronics, trical voltage between two values. The motors integrated
but can optionally be equipped with these inputs (via 3rd in the MCS have a low electrical time constant. To keep the
input). losses associated with PWM low, a high switching fre-
Power supply for electronics UB /UEL [V DC]
Describes the range of the permissible supply voltage for Electronics efficiency η [%]
the integrated control electronics. Ratio between consumed and delivered power of the
control electronics.
Power supply for motor -- /UB [V DC]
Describes the range of the permissible supply voltage for Standby current for the electronics Iel [A]
the base motor integrated in the complete system. Describes the additional current consumption of the
complete system that can be attributed to the integrated
Motor nominal voltage UN [V] electronics.
The voltage applied between two winding phases. This is
the voltage at which the data sheet parameters are mea- Speed range [min-1]
sured or calculated. Depending on the required speed, a Describes the maximum no-load speed for continu-
higher or lower voltage can be applied within the permis- ous operation in the steady-state condition at elevated
sible range of the supply voltage. nominal voltage (30 V). Depending on the required speed,
higher or lower voltage can be applied within the given
No-load speed n0 [min-1] system limits.
Describes the motor speed when idling and in the steady- Mounting of the system on a plastic flange according to
state condition at nominal voltage and sinus commutation. installation type IM B 5.
Peak torque Mmax. [mNm] Shaft bearings
Specifies the torque that the drive can reach in S2 opera- The bearings used for the brushless DC motors.
tion (cold start without additional cooling) at nominal
voltage and nominal conditions under constant load for Shaft load, max. permissible [N]
the time specified in the data sheet without exceeding Max. permissible shaft load of the output shaft with speci-
the thermal limit. Unless otherwise defined, the value fied shaft diameter. The values for load and service life
that applies for the peak torque is equal to two times the of motors with ball bearings are based on manufacturer
continuous torque. specifications. This value is not applicable for a possibly
available rear or second shaft end.
EN,DE,FR,CN.indd 29 11.02.20 15:37

73
Shaft play [mm] Rated Values for Continuous Operation

Clearance between the shaft and bearing including the
additional bearing clearance in the case of ball bearings. The following values are measured at nominal voltage,
an ambient temperature of 22°C and with mounting type
IM B 5.
Shows the minimum and maximum operating temperature
of the complete system under nominal conditions. Mounting type IM B 5 defines the flange mounting of the
drive without mounting feet with two bearing plates, free
Housing material front shaft end and mounting flange close to the bearing.
Housing materials and, if necessary, surface treatment.
Rated torque MN [mNm]
Mass [g] Maximum continuous torque (S1 mode) at nominal volt-
The typical mass of the standard system may vary within age at which in the steady-state condition the tempera-
the individual interface variants due to the different com- ture does not exceed the maximum permissible winding
ponent variants. temperature and/or the operating temperature range of
Length dimensions without mechanical tolerance specifi- the motor. The motor is fastened to a metal flange here,
cations: which approximates the amount of cooling available
Tolerances according to ISO 2768: from a typical mounting configuration of the motor. This
value can be exceeded if the motor is operated intermit-
≤ 6 = ± 0.1 mm
tently, for example, in S2 mode and/or if more cooling is
≤ 30 = ± 0.2 mm applied.
≤ 120 = ± 0.3 mm
Rated current IN [A]
The tolerances of non-specified values are available on
Typical maximum continuous current in the steady-state
request.
condition which results from the rated torque in continu-
All mechanical dimensions of the motor shaft are mea- ous operation. This value can be exceeded if the drive is
sured with an axial shaft load in the direction of the operated intermittently, in start/stop mode, in the starting
motor. phase and/or if more cooling is used.
Rated speed nN [min-1]

Typical rated speed in the steady-state condition which is
determined from the given rated torque.
This value takes into account the effects that motor losses
have on the slope of the n/M characteristic curve.

Watt Metal flange
8 000 intermittent operation
10 20 30 Operating point at rated values
7 000
n0@ 30V
6 000
n0 @ UN
5 000
4 000 PD
3 000
2 000 MN =MD
1 000
0 M [mNm]
0 10 20 30 40 50 60 70 80 90

continuous operation.
74
Explanations on the Performance Diagram Continuous output power PD [W]
The possible speed ranges are shown in dependence on operation in steady-state condition with mounting on
the shaft torque. an aluminium flange. The value is independent of the
continuous torque, responds linearly to the cooling factor
and can be exceeded if the motor is operated intermit-
tently, for example, in S2 operation and/or if more cooling
Operating points in the dark blue area are reached con- is applied.
plastic flange (approx. 100mm x 100mm x 10mm) and at Nominal voltage curve UN [V]
an ambient temperature of 22°C. The nominal voltage curve describes the possible continu-
ous operating points at UN. In steady state, the starting
Operating points in the light blue area up to PD are point corresponds to the no-load speed n0 of the drive.
reached continually in the case of pure flange mount- Operating points above this curve can be attained by an
ing (IM B5) on an aluminium flange (approx. 100mm x increase, operating points below by a reduction of the
100mm x 10mm) and at an ambient temperature of 22°C. nominal voltage.
The maximum achievable speed depends on the motor
supply voltage. At nominal voltage, the maximum Easy commissioning with the new
achievable operating points are those on the nominal Motion Manager 6.
voltage line through the no-load point and nominal
point.
Depending on the cooling factor, operating point and
Speeds above the nominal voltage line are reached at an ambient temperature, it may be necessary to adjust the
increased supply voltage. current limitation parameters using the operating soft-
In this case, the maximum voltage for the electronics or ware. See technical manual for details.
The sector shown dashed describes possible operating
points in which the drive can be engaged in intermittent
operation or with increased cooling.

Describes the max. recommended continuous torque in the
steady-state condition at nominal voltage and mounting
on an aluminium flange. With Motion Control Systems,
the continuous torque simultaneously corresponds to the
rated torque.
Here, the speed is linear to the continuous torque. The
continuous torque is independent of the continuous
output power and can be exceeded if the motor is oper-
ated intermittently, for example, in S2 operation and/or if
more cooling is applied.
75
Basic design
FAULHABER B Cx
1 Heat sink/cover
2 Thermal conduction pad
3 Thermal protection
4 Motion Controller
with power stage
5 Housing
6 Analog Hall sensors
7 Brushless DC-Servomotors
FAULHABER BX4 CxD/Cx

7
1 End cover
2 Thermal coupling pad
3 PCB with flexboard
4 Flange, electronics side
5 Flange, motor side
6 Housing
7 Brushless DC-Servomotors
76
Supported as communication interfaces are – depending on

the device – RS232 or CANopen and optionally EtherCAT. All
functions of the drive are available here without limitation
via all interfaces.
FAULHABER Motion Control Systems of generation V3.0 are

available in three motor variants and are, thus, perfectly
scalable:
■ MCS 3242 ... BX4

■ MCS 3268 ... BX4
■ MCS 3274 ... BP4
The possible applications are diverse: from laboratory auto-

mation to industrial equipment manufacturing, automation
technology and robotics to aerospace.
The electrical connection of the systems is established via

M12 plugs and extension cables. The flange profile is identi-
cal for all sizes.
Features Benefits
■ Perfectly scalable thanks to various sizes
FAULHABER Motion Control systems of generation V3.0 are
highly dynamic positioning systems in three motor designs ■ Very dynamic control
for use in combination with matched gearheads and ball ■ Various setpoint interfaces
screws from the FAULHABER product portfolio. The motor ■ Stand-alone operation possible in all variants
parameters are preconfigured ex works. Adaptation to ■ Connection via standard M12 plugs
the path is performed during commissioning using the ■ Fast feedback with status LEDs
FAULHABER Motion Manager from version 6.0.
■ Commissioning with the free FAULHABER
Motion Manager from version 6.0
In addition to use as a servo drive with controlled position,
the speed or current can also be controlled. The actual ■ Configuration via programming adapter
values for speed and position are ascertained via the inte-
grated encoders. Limit switches and reference switches can
be directly connected. Product code
The control setpoints can be preset via the communication
interface, via the analogue input or a PWM input or can
come from internally stored sequential programs.
MCS Motion Control System MCS 3268 G 024 BX4 ET

3268 Motor series
G Type of drive
024 Nominal voltage - motor
BX4 Brushless electronic commutation
ET EtherCAT interface
77
Cyclic Synchronous Position (CSP) / Cyclic Synchronous

Error handling Diagnosis Velocity (CSV) / Cyclic Synchronous Torque (CST)
For applications in which a higher-level controller per-
Device control Motor control forms the path planning, even synchronised for multiple
axes. The setpoints for position, speed and current are
Object dictionary
constantly updated. Typical update rates are in the range

+ of a few milliseconds. Cyclic modes are, thus, primarily
suited for combination with EtherCAT. CANopen can also
–
be used.
Analogue Position Control (APC) / Analogue Velocity

Control (AVC) / Analogue Torque Control (ATC)
Hardware driver For applications in which the setpoints of the control
are specified as an analogue value or, e.g., via a directly
connected reference encoder. These operating modes are
Operating modes therefore particularly well suited for stand-alone opera-
tion without higher-level master.
Motor control
Current, speed and position of the drive can be controlled Voltage controller (voltage mode)
via the controller cascade. By means of the optional pilot In the voltage controller, only a current limiting control-
paths, even the fastest movements can be reliably con- ler is used. All control loops are closed by a higher-level
trolled in a reproducible manner. Adjustable filters enable system. The setpoint can be set via the communication
adaptation to a wide range of encoders and loads. system or via an analogue input.
Motion profiles Interfaces – discrete I/O

Acceleration and brake ramp as well as the maximum Three digital inputs for connecting limit and reference
speed can be preset in speed and positioning operation in switches or for connecting a reference encoder. The logic
the Profile Position Mode (PP) and Profile Velocity Mode levels are switchable.
(PV) operating modes. Two analogue inputs (±10V) are available that can be
freely used as setpoint or actual value.
Autonomous operation
Up to eight sequential programs written in BASIC can be Two digital outputs are available that can be freely used as
stored and executed directly on the controller. One of error output, for direct actuation of a holding brake or as
these can be configured from the autostart application. flexible diagnosis output.
Access protection can be activated.
Options
Protection and diagnostic functions
FAULHABER Motion Control systems of generation V3.0 All controllers can optionally be equipped with an Ether-
protect motors and electronics against overload by means CAT interface.
of thermal models. The supply voltage is monitored and For highly dynamic applications, the use of a braking chop-
can also be used in regenerative operation. External per can help to dissipate recovered energy.
devices are thereby protected against overvoltage during
dynamic operation.
Profile Position Mode (PP) / Profile Velocity Mode (PV)

For applications in which only the target of the movement
is specified for the controller. The acceleration and brake
ramp as well as a possible maximum speed are taken into
account via the integrated profile generator. Profile-based
movements are, thus, suited for a combination with stand-
ard networks, such as RS232 or CANopen.
78
Networking General Information
RS – systems with RS232 interface System description
Ideal for device construction and for all applications in The drive systems integrate a brushless DC servomotor,
which the Motion Controller is to be operated on an a high-resolution encoder and a Motion Controller in a
embedded controller. Using Net mode, it is also possible compact, complete drive unit.
to operate multiple RS controllers on an RS232 interface. Due to the fact that motor commutation is achieved
The transmission rate can lie between 9600 baud and 115 electronically and not mechanically, the lifetime of a
kbaud. FAULHABER Motion Control System depends mainly on
CO – CANopen acc. to CiA 402 the lifetime of the motor bearings.
The ideal variant for the operation of a FAULHABER FAULHABER uses high-precision, preloaded ball bearings
Motion Controller on a PLC – directly via the CANopen in all of its systems with integrated Motion Controller.
interface or via a gateway on, e.g., Profibus/ProfiNET or on Factors affecting the life of the motor bearings include
EtherCAT. Dynamic PDO mapping as well as node guarding the static and dynamic axial and radial bearing loads, the
or heartbeat are supported. Refresh rates for setpoint and ambient thermal conditions, the speed, vibrational and
actual values are typically from 10 ms here. shock loads, and the precision of the shaft coupling to
the given application.
ET – EtherCAT
Motion Controller with direct EtherCAT interface. The con-
torque in the most compact dimensions, the integrated
trollers are addressed via CoE via the CiA 402 servo drive
4-pole DC-Servomotors, FAULHABER BX4 / BP4 series are
profile. Ideal in combination with a high-performance
ideal. Their robust design with very few parts and no
industrial controller that also performs path planning and
glued components means that they are extremely dura-
interpolation of the movement for multiple axes. Refresh
ble and well suited for harsh ambient conditions such
rates for setpoint and actual values from 0.5 ms are sup-
as extreme temperatures and high vibration and shock
ported.
loads.
All described operating modes and functions are available Thanks to their robust construction, their compact design
independent of the used communication interface. and the connection concept with industrial-grade stand-
ard cables, the new FAULHABER Motion Control Systems
Note are perfectly suited for use in automation applications.
Device manuals for installation and commissioning, Modifications and accessories
communication and function manuals as well as the FAULHABER specialises in the adaptation of its standard
“FAULHABER Motion Manager” software are available products for customer-specific applications. The follow-
on request or on the Internet under www.faulhaber.com. ing standard options and accessory parts are available for
FAULHABER Motion Control Systems:
■ Industrial-grade connection and interface cables with
plugs
■ Configurable shaft lengths
■ Modified shaft dimensions and pinion configurations
such as flats, gears, pulleys and eccenters
■ Modifications for applications with higher speeds and/
or higher loads
■ Adaptation of the protection classification via shaft
seals
■ Connection and configuration adapter
■ Customized special configuration and firmware
79
8000
7000
Motion Control Systems 6000
Speed [min-1]
5000
V3.0, 4-Quadrant PWM UN
with RS232 or CANopen interface 4000

Operation point
3000
2000
Peak torque
MCS 3242 ... BX4 RS/CO 1000
Values at 22°C and nominal voltage MCS 3242G
0
0 25 50 75 100 125 150 175 200
Power supply motor Umot Torque [mNm]
Nominal voltage for motor UN
Example: MCS 3242...BX4
Explanatory Notes for Data Sheets Torque constant km [mNm/A]

Constant that describes the ratio between motor torque
The following data sheet values of the Motion Control Sys- and current input.
an ambient temperature of 22°C. PWM switching frequency ƒPWM [kHz]
Motion Control Systems generally feature separate supply Pulse width modulation describes the change of the elec-
inputs for motor and electronics with the same ground trical voltage between two values. The motors integrated
connection; if necessary, these inputs can also be used as a in the MCS have a low electrical time constant. To keep the
common supply. losses associated with PWM low, a high switching fre-
Power supply for electronics Up [V DC]
Describes the range of the permissible supply voltage for Electronics efficiency η [%]
the integrated control electronics. Ratio between consumed and delivered power of the
Power supply for motor Umot [V DC]
Describes the range of the permissible supply voltage for Standby current for the electronics Iel [A]
the base motor integrated in the complete system. Describes the additional current consumption of the
complete system that can be attributed to the integrated
Nominal voltage UN [V] electronics.
The voltage applied between two winding phases by
means of block commutation. This is the voltage at which Shaft bearings
the data sheet parameters are measured or calculated. The bearings used for the brushless DC motors.
Depending on the required speed, a higher or lower volt- Shaft load, max. permissible [N]
age can be applied within the permissible range of the Max. permissible shaft load of the output shaft with
supply voltage. specified shaft diameter. The values for load and lifetime
No-load speed n0 [min-1] of motors with ball bearings are based on manufacturer
Describes the motor speed when idling and in the steady- specifications. This value is not applicable for a possibly
state condition at nominal voltage and sinus commutation. available rear or second shaft end.
Peak torque Mmax. [mNm] Shaft play [mm]

Specifies the torque that the drive can reach in S2 opera- Play between the shaft and bearing including the
tion (cold start without additional cooling) at nominal additional bearing clearance for ball bearings.
voltage and nominal conditions under constant load for Operating temperature range [°C]
the time specified in the data sheet without exceeding Shows the minimum and maximum operating temperature
the thermal limit. Unless otherwise defined, the value that of the complete system under nominal conditions.
applies for the peak torque is twice the continuous torque.
EN,DE,FR,CN.indd 33 11.02.20 15:37

80
Speed range [min-1] Rated Values for Continuous Operation
Describes the maximum no-load speed for continuous
operation in the steady-state condition at elevated The following values are measured at nominal voltage, an
nominal voltage (30 V). Depending on the required speed, ambient temperature of 22°C and with assembly method
higher or lower voltage can be applied within the given IM B 5.
system limits.
Assembly method IM B 5 defines the flange mounting of
Mounting of the system on a plastic flange according to the drive without mounting feet with two bearing plates,
assembly method IM B 5. free front shaft end and mounting flange close to the
Housing material bearing.
Housing materials and, if necessary, surface treatment. Rated torque MN [mNm]
Protection classification Maximum continuous torque (S1 mode) at nominal volt-
Defines the level of protection of the housing against age at which in the steady-state condition the tempera-
contact, foreign bodies and water. The codes that follow ture does not exceed the maximum permissible winding
designation IP indicate the level of protection a housing temperature and/or the operating temperature range of
offers against contact or foreign bodies (first digit) and the motor. The motor is fastened to a metal flange here,
humidity or water (second digit). which approximates the amount of cooling available
from a typical mounting configuration of the motor. This
Maintenance measures are to be performed in defined
value can be exceeded if the motor is operated intermit-
time intervals due to additional protective measures such
tently, for example, in S2 mode and/or if more cooling is
as shaft seals > see device manual for details.
applied.
Mass [g]
Rated current IN [A]
The typical mass of the standard system may vary within
Typical maximum continuous current in the steady-state
the individual interface variants due to the different
condition which results from the rated torque in continu-
component variants.
ous operation. This value can be exceeded if the drive is
Length dimensions without mechanical tolerance operated intermittently, in start/stop mode, in the starting
specifications: phase and/or if more cooling is used.
Rated speed nN [min-1]
≤ 6 = ± 0.1 mm Typical rated speed in the steady-state condition which is
≤ 30 = ± 0.2 mm determined from the given rated torque.
≤ 120 = ± 0.3 mm This value takes into account the effects that motor losses
The tolerances of non-specified values are available on have on the slope of the n/M characteristic curve.
request.
All mechanical dimensions of the motor shaft are meas- n [min-1] Plastic flange
Watt Metal flange
ured with an axial shaft load in the direction of the motor. 8 000
10 20 30
7 000
n0@ 30V
6 000
n0 @ UN
5 000
4 000 PD
3 000
2 000 MN =MD
1 000
0 M [mNm]
0 10 20 30 40 50 60 70 80 90

continuous operation.
81
Explanations on the Performance Diagram Nominal voltage curve UN [V]

The nominal voltage curve describes the possible conti-
The possible speed ranges are shown in dependence on nuous operating points at UN. In steady state, the starting
the shaft torque. The performance diagram shows the point corresponds to the no-load speed n0 of the drive.
possible operating points of the servo-drives. Operating points above this curve can be attained by an
increase, operating points below by a reduction of the
Operating points in the dark blue area are reached conti-
nominal voltage.
nually in the case of pure flange mounting (IM B5) on a
plastic flange (approx. 100mm x 100mm x 10mm) and at
an ambient temperature of 22 °C. Easy commissioning with the new
Motion Manager 6.
Operating points in the light blue area up to PD are rea-
ched continually in the case of pure flange mounting (IM Depending on the cooling factor, operating point and
B5) on an aluminium flange (approx. 100mm x 100mm x ambient temperature, it may be necessary to adjust the
10mm) and at an ambient temperature of 22 °C. current limitation parameters using the operating soft-
The maximum achievable speed depends on the motor ware. See technical manual for details.
supply voltage. At nominal voltage, the maximum achie-
vable operating points are those on the nominal voltage
line through the no-load point and nominal point.
Speeds above the nominal voltage line are reached at
an increased supply voltage. In this case, the maximum
voltage for the electronics or motor supply must never
be exceeded.
The sector shown dashed describes possible operating
points in which the drive can be engaged in intermittent
operation or with increased cooling.

Describes the max. recommended continuous torque in the
steady-state condition at nominal voltage and mounting
on an aluminium flange. With Motion Control Systems,
the continuous torque simultaneously corresponds to the
rated torque.
Here, the speed is linear to the continuous torque. The
continuous torque is independent of the continuous
output power and can be exceeded if the motor is opera-
ted intermittently, for example, in S2 operation and/or if
more cooling is applied.
Continuous output PD [W]

operation in steady-state condition with mounting on an
aluminium flange. The value is independent of the conti-
nuous torque, responds linearly to the cooling factor and
for example, in S2 operation and/or if more cooling is
applied.
82
Notes
83
Brushless DC-Servomotor with
integrated Motion Controller
The 3564…B Cx series stands out first and foremost due to its Series
extremely constant speed control coupled with very smooth-
running operation. 3564 … B Cx
These features make the servo-drive with compact integrated

Motion Controller ideal for use in vibration-sensitive applica-
tions, e.g. in optics, in welding and balancing machines used Key Features
in special machinery construction as well as in measuring or Motor diameter [] 40 x 54 mm
weighing systems. Integrated current control limits the torque
Motor length 84 mm
of the drive if necessary, reliably protecting the drive against
Nominal voltage 24 V
overload.
The interface (RS232 or CANopen) allows simple connection to
Torque up to 71 mNm
networks. The integration of motor and control electronics in
a single unit minimises both space and wiring requirements,
thereby simplifying installation and commissioning. The con-
trol electronics are already perfectly matched to the motor
when the unit leaves the factory. Programming is simple and
convenient using the Motion Manager.
Product Code

K Shaft type
35 64 K 0 2 4 B CS
B Product family
CS Integrated Motion Controller,
RS232 interface
WE CREATE MOTION
FAULHABER B Cx
Wide speed range from 1 to 14,000 min-1 Simple and convenient programming using the
RS232 or CANopen interface, Motion Manager and programming adapter
adapter for connection to USB interface Minimal wiring requirements
Compact mounting concept with Smooth running operation
integrated current limitation
The highly dynamic positioning systems of generation V2.5 are Series
available in two motor diameters with integrated, diameter-
compliant Motion Controllers or with mounted, highly com- 2232 … BX4 CxD 2250 … BX4 CxD
pact Motion Controllers. The different versions with their 3242 … BX4 Cx 3268 … BX4 Cx
high torque, outstanding volume/performance ratio as well as
highly dynamic control characteristics are suitable for a wide
variety of market sectors, e.g. medical and laboratory techno- Key Features
logy, automation technology, robotics or special machinery
construction. Integrated current control limits the torque of Motor diameter Ø 22; [] 40 x 54 mm
the drive if necessary, reliably protecting the drive against Motor length 50 ... 90 mm
overload. Nominal voltage 12 ... 24 V
The interface (RS232 or CANopen) allows simple connection to Speed up to 11.300 min-1
networks. The integration of motor and control electronics in Torque up to 96 mNm
a single unit minimises both space and wiring requirements, Continuous output up to 48 W
thereby simplifying installation and commissioning. The con-
trol electronics are already perfectly matched to the motor
when the unit leaves the factory. Programming is simple and
convenient using the Motion Manager.
Product Code

S Shaft type
22 32 S 0 2 4 BX4 CS D
BX4 Product family
CS Integrated Motion Controller,
RS232 interface
WE CREATE MOTION D Diameter-compliant
FAULHABER BX4 CxD/Cx
Wide speed range from 1 to 11,300 min-1 Simple and convenient programming using the
RS232 or CANopen interface, Motion Manager and programming adapter
adapter for connection to USB interface Minimal wiring requirements
Compact mounting concept with Smooth running operation
integrated current limitation
The motion control systems of the most recent generation V3.0 Series
are available in three performance classes with a continuous
torque of 76 to 160 mNm. The drives comprise a brushless MCS3242 … BX4 RS/CO MCS3242 … BX4 ET
DC-Servomotor, a high-resolution actual value encoder and a MCS3268 … BX4 RS/CO MCS3268 … BX4 ET
Motion Controller in a complete, compact drive unit. The large
MCS3274 … BP4 RS/CO MCS3274 … BP4 ET
number of different communication interfaces, the highly
dynamic controllability, the robust design with protection class
IP 54 as well as the industry standard connection concept via
Key Features
M12 connectors enable use in industrial environments ranging
from automation technology and industrial special machinery Motor diameter [] 42 x 50 mm
construction to robotics and aerospace. Motor length 75 ... 100 mm
In combination with precision gearheads screw systems, this Nominal voltage 24 V
results in complete system solutions for a wide variety of dif- Speed up to 11.600 min-1
ferent applications. The systems can be used with any of the Torque up to 160 mNm
interface variants, both as stand-alone axes or in slave mode at
various master controls. Furthermore, flexible usage possibilities
are supported by various libraries and application notes that
are available for download on the home page. All features of
the drives are available here without restriction via all of the
standard interfaces.
Product Code
MCS Motion Control System

3242 Motor series
G Shaft type
MCS 32 42 G 024 BX4 ET

BX4 Product family
ET EtherCAT interface
WE CREATE MOTION
FAULHABER MCS
Maximum torque in compact installation space Standardised plug and connection cable concept
Interfaces: RS232, CANopen, EtherCAT, Can be universally used in slave
configuration via USB or stand-alone operation
Optionally available with protection class IP 54 Extensive protective and diagnostic functions,
Simple and convenient programming using the local status LEDs
Motion Manager and programming adapter
Stepper Motors
WE CREATE MOTION
Stepper Motors
Rotor inertia [kgm2]

This value represents the inertia of the complete rotor.
Stepper Motors Step angle (full step) [degree]

Two phase with Disc Magnet, Number of angular degrees the motor moves per full-step.
20 steps per revolution Angular accuracy [% of full step]
The percentage position error per full step, at no load
and nominal current. This error is not cumulative between
Series DM0620 steps.
Values at 20°C DM0620
Nominal current per phase (both phases ON) Angular acceleration, max [rad/s2]
Boosted current per phase (both phases ON)
Nominal voltage per phase (both phases ON) Maximum acceleration the motor can reach in boosted
Phase resistance
Phase inductance (1 kHz)
mode and without any load.
Holding torque (at nominal current in both phases)
Holding torque at boosted current
max.
M boosted
= ––––––––
J
Notes on technical datasheet
Speed up to [min-1]
Nominal current per phase [A]
The maximum recommended motor speed. Exceeding this
The current supplied to the motor phases that will not
speed could affect the motor integrity.
exceed, at an ambient temperature of 20 °C, the thermal
limits of the motor. Resonance frequency (at no load) [Hz]
The step rate at which the motor at no load will demon-
Boosted current per phase [A]
strate resonance. The resonance frequency is load depend-
Maximum current which can be supplied to the motor
ent. For the best results the motor should be driven at a
phases for a short period of time not to exceed the ther-
higher frequency or in half-step or microstepping mode
mal capacity of the motor.
outside of the given frequency.
Nominal voltage per phase [V]
1 M
Voltage necessary to reach the nominal current per f = ––– · ––
2π J
phase.
Phase resistance [⍀]
Thermal resistance [K/W]
Winding resistance per phase. Tolerance +/- 12%, steady
R th1 corresponds to the value between the coil and the
state.
housing. Rth2 corresponds to the value between the
Phase inductance [mH] housing and the ambient air. Rth2 can be reduced by
Winding inductance per phase measured at 1kHz. enabling exchange of heat between the motor and the
Holding torque [mNm] ambient air (for example using a heat sink or forced
The torque generated by the motor at nominal current. air cooling). If only one value is provided, Rth, it is the
equivalent resistance between the coil and the air.
Holding torque at boosted current [mNm]
The torque the motor generates at boosted current. The Thermal time constant [s]
magnetic circuit of the motor will not be affected by this The thermal time constant specifies the time needed for
boosted current, however, to avoid thermal overload the the winding respectively the housing to reach a tempera-
motor should only be boosted intermittently. ture equal to 63% of the final steady state value.
Residual torque, typ [mNm] Operating temperature range [°C]
The typical torque applied to the shaft to rotate it without Temperatures at which the motor can operate.
current to the motor. Residual torque is useful to hold
Winding temperature, max. [°C]
a position without any current to save battery life or to
Maximum temperature supported by the windings and the
reduce motor temperature.
magnets.
Back-EMF amplitude [V/k step/s]
Shaft bearings
Amplitude of the back-EMF measured at 1000 steps/s.
Self lubricating sintered sleeve bearings or preloaded ball
Electrical time constant [ms] bearings are available.
Time needed to establish 63% of the max. possible phase
current under a given operation point.
EN,DE,FR,CN.indd 1 91 20.01.20 14:00

Stepper Motors
Shaft load max. [N] Rotor

The inertiaand
motion [kgm 2]
load profiles of the movement used in this
The output shaft load at a specified shaft diameter for the This valueare
example represents the inertia of the complete rotor.
shown below.
front output shaft. For motors with ball bearings the load Depending on the motor size suitable for the application
Stepper Motors
and lifetime are in accordance with the values given by
Step angle0,25 mNm
(full step) [degree]
it
Number of angular degrees the
is required to recompute the load
motor parameters
moves perwith the
full-step.
Two phase
the bearing with Disc This
manufacturers. Magnet,
value does not apply to motor inertia as well.
20 steps per revolution
second, or rear shaft ends. In case of ball bearings, if the
Angular accuracy [% of full step]
In
The the present case
percentage it is assumed
position error perthat
fullastep,
motorat with an out-
no load
bearing preload is exceeded, reversible shaft displacement
side diameter of maximum 15 mm is suitable and
and nominal current. This error is not cumulative between the data
of ~200µm may occur.
Series DM0620 has
steps.been computed with the inertia of the AM1524.
Shaft play
Values max.
at 20°C [mm] DM0620 0130 0080 0040
Nominal current per phase (both phases ON) Angular 0,13
acceleration,
0,08 max [rad/s2A]
0,04
The play between
Boosted the
current per shaft
phase (both and
phasesbearings.
ON) 0,26 0,16 0,08 A
Nominal voltage per phase (both phases ON) Maximum 2 )
Speed (minacceleration
-1 3 the
6 motorV can reach in boosted
Housing material
Phase resistance
mode and
6000
13,6 30
without 120
any load. Ω
Phase inductance (1 kHz) 2 4,5 18,5 mH
Material of the
Holding torquemotor housing.
(at nominal current in both phases) 0,25 0,25 0,25 mNm
Holding torque at boosted current 5000 0,39 0,39 0,39 mNm
M boosted
= ––––––––
Mass [g]
Residual torque, typ.
Back-EMF amplitude 4000
0,03
0,53
0,03
0,83
max.0,03
1,6
mNm
J V/k step/s
IsNotes on mass
the motor technical datasheet
in grams.
Electrical time constant 0,15 3000 ms
Rotor inertia 0,5·10-9 Speed up to [min-1] kgm²
Magnet
Nominal material
current per phase [A]
Step angle (full step) 18 The 2000
maximum recommended motor ° speed. Exceeding this
The basic
currenttype
Angular of magnet
accuracy
supplied to the used in the
motor standard
phases motor.
±5
that780·10
will3 not %
Angular acceleration, max. speed could
1000 affect the motor integrity.
rad/s²
exceed, at an frequency
Resonance ambient temperature
(at no load) of 20 °C, the
110 thermal Hz
limits of theresistance
Thermal motor. 15 / 96,6
Resonance
0 frequency (at no load)K/W [Hz]
How to select a Stepper Motor
Thermal time constant 3,2 / 120 The step0 rate 500 at which1000
the1500
motor 2000 2500
sat no load3000 3500
will demon-
Boosted current
Operating per phase
temperature range [A] -35 ... +70 T (ms) °C
The selection
Winding of a1) stepper
temperature, max. motor requires the use of +130 strate resonance. The resonance frequency
°C is load depend-
Maximum current
Shaft bearings 2) which can be supplied to the motor
sintered bearing ball bearings, preloaded
published ent. For the best results the motor should be driven at a
phasesShaftfortorque
a short
load max.:
speed
periodcurves based
of time notonto
the load(Bearing
exceed parameters.
code: SB)
the ther- (Bearing code: 2R)
It
malis not possible
capacity
– with to
theverify
ofdiameter
shaft the motor selection mathematically
motor. 1 1
Load (mNm) mm
– radial at 5 000 min-¹ (3 mm from bearing) 0,3 outside of
3 the given frequency. N
without
Nominal the use of the
– axial at 5 000 min ¹ -
voltage per phase [V] curves. 0,5 1.25 0,5 N
– axial at standstill 0,5 5,8 N
To select aplay:
motor the following parameters must per
be 1 M
Voltage necessary
Shaft to reach the nominal current 1
f = ––– · ––
– radial 0,02 0,012 2π J mm
known:
phase.– axial 0 0.75 0 mm
Housing material aluminium, black anodized
Phase
■ Motion
Mass profile[]
resistance 1,1 0.5 g
Magnet material NdFeB Thermal resistance [K/W]
Winding
■ resistance
Load friction andper phase. Tolerance +/- 12%, steady
inertia corresponds to the value between the coil and the
R th10.25
state.
■ Required resolution housing.0 Rth2 corresponds to the value between the
Phase inductance [mH] housing 0 and 500
the ambient
1000 air. R2000
1500 th2 can be reduced
2500 3000 by
3500
■ Available space -0.25
■ Available power supply voltage -0.5
The
1. torque
Defi nitiongenerated
of the load byparameters
the motor at at nominal
the motor current.
shaft air -0.75
cooling). If only one value is provided, Rth, it is the
T (ms)
The target of this step is to determine a motion profi le equivalent resistance between the coil and the air.
HoldingSpecial
torque
1) at boosted
lubricant current
options available [mNm]
on request.
needed 2to move the motion angle in the given
The torque the motor generates at boosted current. The (bearing
preloaded
2)
ball bearings available on request for vacuum / time frame
low temperature code: RC).time constant [s]
Thermal
and to calculate the motor torque over
magnetic circuit of the motor will not be affected by thisthe entire cycle The thermal time constant specifies the time needed for
using thecurrent,
boosted application
Driver load parameters
however,
settings to avoid thermal such as M frictionthe
[mNm]
overload and the winding 1.5x
1x Nominal voltage
respectively the housing to reach a tempera-
Nominal voltage*
load inertia.
Relevant for 2 phases ON only.
motor should only be boosted intermittently. 0,24 ture equal to2.5x 63% of voltage*
Nominal the final steady state value.
On PWM drivers or chopper (current mode),
the current is set to the nominal value and * Current limited to its nominal value
Residual torque, typ [mNm]
the supply voltage is typically 1.5 to 2.5x higher 0,20 Operating temperature range [°C]
The typical
thantorque applied
the nominal voltage. to the shaft to rotate it without Temperatures at which the motor can operate.
0,16
current toCurves
themeasured
motor.with Residual torque
a load inertia of is useful to hold
3·10 kgm , in half-step mode for the
-9 2 0,12 Winding temperature, max. [°C]
a position“1without any current to save battery life or to
x nominal voltage” curve, in 1/4 micro- Maximum temperature supported by the windings and the
reduce motor
steppingtemperature.
mode for the other curves. 0,08
magnets.
Back-EMF amplitude [V/k step/s] 0,04
Shaft bearings
Amplitude of the back-EMF measured at 10000 steps/s. Self lubricating sintered sleeve bearings or preloaded ball
0 3 000 6 000 9 000 12 000 15 000 18 000 21 000 n [min-1]
Electrical time constant [ms] 1 000 2 000 bearings
3 000 are available.
4 000 5 000 6 000 7 000 [steps/s]
Time needed to establish 63% of the max. possible
Possible phase
operation areas
For notes on technical data and lifetime performance © DR. FRITZ FAULHABER GMBH & CO. KG
refer to “Technical Information”. Specifications subject to change without notice.
Edition 2020 – 2021 www.faulhaber.com
EN,DE,FR,CN.indd 1 92 20.01.20 14:00

Stepper Motors
2. Verification of the motor operation. 3. Verification of the resolution

The highest torque/speed point for this application is It is assumed that the application requires a 9° angular
found at the end of the acceleration phase. The top speed resolution.
is then n = 5000 min-1, the torque is M = 1 mNm. The motor selected, the AM1524, has a full step angle of
Using these parameters you can transfer the point into 15° which is not suitable in full step mode. It can be opera-
the torque speed curves of the motor as shown here with ted either in half-step, or in microstepping. With micro-
the AM1524 curves. stepping, the resolution can be increased even higher but
To ensure the proper operation of the motor in the appli- the angular accuracy is reduced because the error angle
cation, it is highly recommended to use a design margin (expressed in % of a full-step) is independant from the
of 30% during the torque calculation. The shown example number of microsteps.
assures that the motor will correctly fulfil the requested For that reason the most common solution for adapting
application conditions. the motor resolution to the application requirements is
The use of a higher supply voltage (typically 2.5 to 5 x the use of a gearhead or a lead-screw where linear motion
higher than the nominal voltage) provides a higher torque is required.
at higher speed (please refer to the torque-speed curves).
4. Operation at low speed
In case no solution is found, it is possible to adapt All stepper motors exhibit a resonance frequency.
the load parameters seen by the motor by the use of a These are typically below 100Hz. When operating at this
reduction gearhead. frequency stepper motors will exhibit uncontrolled per-
turbations in speed, direction of rotation and a reduced
Driver settings
torque. Thus, if the application requires a speed lower or
1x Nominal voltage equal to the resonance frequency, it is recommended to
M [mNm]
2.5x Nominal voltage* drive the motor in microstepping mode where the higher
5 5x Nominal voltage*
the microstepping rate, the better performance can be
* Current limited to its nominal value
4 achieved. This will greatly decrease the effects of the reso-
nant frequency and result in smoother speed control.
3
5. Verification in the application
2
Any layout based on such considerations has to be verified
1 in the final application under real conditions.
Please make sure that all load parameters are taken into
0
0 2 500 5 000 7 500 10 000 12 500 15 000 17 500 n [min-1]
account during this test.
1 000 2 000 3 000 4 000 5 000 6 000 7 000 [steps/s]
Possible operation areas Direction of rotation
All motors will rotate in CCW direction when using the
following commutation sequence : 1.A+B+ 2.A-B+ 3.A-
B- 4.A+B-. Only exception is the AM1524 which runs CW
using here above commutation sequence.
+ A –
CW 1 2
CCW
+
nt f
ace vi
e
3
1 2 3 4 ro
w
F
Phase A + – – + B
CCW Rotor CW
Phase B + + – – 4
–
93
Stepper Motors
Rotor
As inertia above,
explained [kgm2] one electrical cycle or revolution of
General application notes
Thisfivalue
the represents
eld vector (4 fullthe inertia
steps) of the
requires complete
the driver torotor.
provide
In principle each stepper motor can be operated in a number of distinct current values proportional to the
three Stepper Motors 0,25
Step angle (fullmNm
step) [degree]
modes: full step (one or two phases on), half step number of microsteps per full step.
Two phase with Disc Magnet, Number of angular degrees the motor moves per full-step.
or microstep.
20 steps per revolution For example,
Angular 8 microsteps
accuracy [% of fullrequire
step] 8 different values which
Holding torque is the same for each mode as long as dis- in phase A would drop from full current to zero
The percentage position error per full step, at nofollowing
load
sipated power (I2R losses) is the same. The theory is best the
and nominal current. This error is not cumulativeBbetween
cosine function from 0° to 90°, and in phase would
presented on a basic motor model with two phases and rise from zero to full following the sine function.
Series DM0620 steps.
one pair ofatpoles
Values 20°C where mechanical and electrical
DM0620 angle 0130
Nominal current per phase (both phases ON)
These values
Angular are 0080
stored
acceleration,
0,13 0,08 max
0040
and called
[rad/s
0,04
2 up by the program
]
A
are equal.
Boosted current per phase (both phases ON) controlling
Maximum
0,26 the chopperthe
0,16
acceleration driver.
0,08
motorTheA rotor target position is
Nominal voltage per phase (both phases ON) 2 3 6 V can reach in boosted
■ In full
Phasestep mode (1 phase on) the phases are successive-
resistance determined
mode and 13,6 by the
without 30 vector120
any sum of Ωthe torques generated in
load.
Phase inductance (1 kHz) 2 4,5 18,5 mH
ly energised
Holding torquein(atthe following
nominal way:
current in both phases) phase A and
0,25 B: 0,25 0,25 mNm
Holding torque at boosted current 0,39 0,39 0,39 mNm
1. A+ 2. torque,
Residual B+ 3. typ.A– 4. B–. 0,03 0,03
M boosted
= ––––––––
max.0,03 mNm
Back-EMF amplitude 0,53 0,83 1,6 J V/k step/s
■Notes on mode
Half step technical datasheet
is obtained by alternating between MA = k · IA = k · Io · cos ϕ
Electrical time constant 0,15 ms
1-phase-on
Rotor inertiaand 2-phases-on, resulting in 8 half 0,5·10steps
-9 Speed up to [min-1] kgm²
Nominal current per phase [A]
perStep angle (full step)
electrical
Angular accuracy
cycle: 1. A+ 2. A+B+ 3. B+ 18 4. A–B+
±5
The maximum recommended
MB = k · IB =motor
k ·°% speed.
Io · sin ϕ Exceeding this
The current suppliedmax. to the motor phases that780·10 will3 not
5. A– 6. acceleration,
Angular A–B– 7. B– 8. A+B–. speed could affect the motor integrity.
rad/s²
exceed, at an frequency
Resonance ambient temperature
(at no load) of 20 °C, the
110 thermal Hz
■ If every
limits of the
Thermal
half step should generate the same 15
motor.
resistance
holding
/ 96,6
where M is frequency
Resonance the motor (at torque, k isK/W
no load) the
[Hz]torque constant
torque,
Thermal the
timecurrent
constant per phase is multiplied by / 120each
3,2 √2 and step
The Io therate
nominal
at whichphase thecurrent.
motorsat no load will demon-
Boosted current
Operating per phase
temperature range [A] -35 ... +70 °C
time onlytemperature,
Winding 1 phase ismax. energised. +130 strate resonance. The resonance frequency °C is load depend-
Maximum current which can be supplied to the
Shaft bearings 1) 2) motor
sintered bearing For the motor without
ball bearings, load the position error is the same
preloaded
(Bearing code: SB) ent. For the best results
(Bearing code: 2R) the motor should be driven at a
phasesShaft
forload
a short
max.:
period of time not to exceed the ther- in full, half or microstep mode and depends on distortions
mal capacity
The two
– with shaft
major ofdiameter
the -motor. provided by microstep
advantages
1
opera-
1
of the sinusoidal motor torque functionmm
due to detent
– radial at 5 000 min ¹ (3 mm from bearing) 0,3 outside of3 the given frequency. N
Nominal– axial at 5 000 min ¹
tion are voltage
lower per phase
running
-
noise[V] 0,5
and higher resolution, both torque, saturation
0,5 or constructionN details (hence on the
– axial at standstill 0,5 5,8 N
actual rotor position), as M
1 as––
Voltage
depending necessary
Shaft on the number
play: to reachofthe nominal current
microsteps per full per
step f =well
––– · on the accuracy of the
– radial 0,02 0,012 2π J mm
phase.
limited– axial
by the capability of the controller. 0 phase current
0 values. mm
Housing material aluminium, black anodized
Phase Mass
resistance [] 1,1 g
Magnet material NdFeB Thermal resistance [K/W]
Winding resistance per phase. Tolerance +/- 12%, steady
R th1 corresponds to the value between the coil and the
state.
housing. Rth2 corresponds to the value between the
Phase inductance [mH] housing and the ambient air. Rth2 can be reduced by
The torque generated by the motor at nominal current. air cooling). If only one value is provided, Rth, it is the
equivalent resistance between the coil and the air.
HoldingSpecial
torque
1) at boosted
lubricant current
options available [mNm]
on request.
2 preloaded ball bearings available on request for vacuum / low temperature (bearing
2)
code: RC).time constant [s]
Thermal
The torque the motor generates at boosted current. The
magnetic circuit of the motor will not be affected by this The thermal time constant specifies the time needed for
1x Nominal voltage
boosted current, however, to avoid thermal M
Driver settings [mNm]
overload the the winding 1.5x respectively the housing to reach a tempera-
Nominal voltage*
Relevant for 2 phases ON only.
motor should only be boosted intermittently.
On PWM drivers or chopper (current mode), 0,24 ture equal to 63%
2.5x of
Nominal the final steady state value.
voltage*
the current is set to the nominal value and * Current limited to its nominal value
Residual torque, typ [mNm]
the supply voltage is typically 1.5 to 2.5x higher 0,20 Operating temperature range [°C]
The typical
thantorque applied
the nominal voltage. to the shaft to rotate it without Temperatures at which the motor can operate.
0,16
current toCurves
themeasured
motor.with Residual torque
a load inertia of is useful to hold
3·10 kgm , in half-step mode for the
-9 2 0,12 Winding temperature, max. [°C]
a position“1without any current to save battery life or to
x nominal voltage” curve, in 1/4 micro- Maximum temperature supported by the windings and the
reduce motor
steppingtemperature.
mode for the other curves. 0,08
magnets.
Back-EMF amplitude [V/k step/s] 0,04
Shaft bearings
Amplitude of the back-EMF measured at 10000 steps/s. Self lubricating sintered sleeve bearings or preloaded ball
0 3 000 6 000 9 000 12 000 15 000 18 000 21 000 n [min-1]
Electrical time constant [ms] 1 000 2 000 bearings
3 000 are available.
4 000 5 000 6 000 7 000 [steps/s]
Time needed to establish 63% of the max. possible
Possible phase
operation areas
For notes on technical data and lifetime performance © DR. FRITZ FAULHABER GMBH & CO. KG
refer to “Technical Information”. Specifications subject to change without notice.
Edition 2020 – 2021 www.faulhaber.com
EN,DE,FR,CN.indd 1 94 20.01.20 14:00

Stepper Motors
Basic design
2 6
3
7
4
5
8
Two phase
10
1 Retaining ring
2 Washer
3 PCB
4 Ball bearing 11
5 Rear cover / stator
6 Coil, Phase A
9
7 Inner stator
8 Rotor
13
9 Magnets
10 Shaft 4
11 Housing
12 Coil, Phase B
13 Front cover / stator
12
2
3 1
1
4
2
6
Two phase with Disc Magnet
Ø 6 and 12 mm
1 Retaining ring
2 PCB
7
3 Rear cover / stator
4 Coil 8
5 Housing
6 Sleeve
9
7 Disc Magnet
8 Shaft 10
9 Front cover
1
10 Sintered bearing
95
Stepper Motors
Basic design
2
Two phase with Disc Magnet
Ø 40 – 52 mm
4
6
1 Rear flange
2 ½ stator
3 Phase A & B windings
4 Phase A & B cables
7
5 Disc magnet
5
6 Shaft
7 ½ stator
8 Phase A & B cables
9 Front flange
2
3
Ring motor 4
5
1 Ball bearing
2 Flexboard
6
3 Stator
4 Hollow shaft
5 Coil 7
6 Disc Magnet
7 Front flange
8 Housing 8
96
Notes
97
Stepper Motors – 2 phases
permanent magnet Technology
The FAULHABER Stepper Motors are two phase multi-polar Series
motors with permanent magnets. The use of rare-earth
magnets provides an exceptionally high power to volume DM0620 AM2224R3
ratio. Their rotor design with very low inertia makes them AM0820 DM40100R
ideally suited for applications requiring very fast acceleration
AM1020 DM52100S
or change of directions and allows to start from the first step
DM1220 DM52100R
with a given speed, reducing further time needed for the
acceleration ramp. Their short length and light weight allow AM1524 DM52100N
them to be used in highly integrated systems. AM2224 DM66200H
Thanks to a robust design they can be selected for the

harshest environments. Precise, open-loop, speed and
position control can be achieved with the application of Key Features
full step, half step, or microstepping electronics. Outer diameter 6 ... 66 mm
The FAULHABER Stepper Motors can be combined with lead- Motor length 9,5 ... 32,6 mm
screws or gearheads enabling to reach operational points that Number of steps 20 / 24 / 100 / 200
are today unmatched in the market. per revolution
Holding torque 0,25 (0,39)
(boost) ... 307 (581) mNm
Product Code
DM Motor design
20 Steps per revolution
DM 0620 2R 0080 11
_ Version (if applicable)
2R Bearings
0080 Winding
11 Motor execution
WE CREATE MOTION
FAULHABER Stepper Motors
Cost effective positioning Wide operational temperature range

drive without encoder Speed range up to 16 000 min -1
High power density using a current mode chopper driver
Very high acceleration Possibility of full step,
Ultra-fast change of direction capability half step and microstep operation
Long operational lifetimes Extremely low rotor inertia

Linear DC-Servomotors
WE CREATE MOTION
Force constant kF [N/A]

Linear DC-Servomotors the motor force delivered and the motor line current with
sine wave commutation.
with Analog Hall Sensors
Terminal resistance, phase-phase R [ ] ±12%
The resistance measured between two motor phases.
This value is directly influenced by the coil temperature
LM 1247 ... 11 (temperature coefficient: α 22 = 0,0038 K-1).
Values at 22°C LM 1247 ... 11
Continuous force Fe max. 3,6
Terminal inductance, phase-phase L [μH]
Peak force Fp max. 10 The inductance measured between two phases at 1 kHz.
Continuous current Ie max. 0,5
Peak current Ip max. 1,6 Stroke length smax. [mm]
Back-EMF constant kE 5,2
The datasheet parameters are only valid if the rod move-
ment is within the given stroke range, smax.. Aligning the
Notes
N t on ttechnical
h i ld datasheet
t h t
rod and stator axial centres, the allowed movement is
All values at 22 °C. therefore half the overall stroke length.
Continuous force Fe max. [N] Repeatability σ r [μm]

The maximum force delivered by the motor at the thermal The typical measured difference when repeating several
limit in continuous duty operation and with a reduced times the same movement under the same conditions.
thermal resistance Rth2 by 55%. Measurements done with FDS MC (-01, 11 versions) and
3rd party sin/cos motion controller (-02, 12 versions).
Fe max. = kF · Ie max. Accuracy σ a [μm]
The typical positioning error. This value corresponds to the
Peak force Fp max. [N] difference between the set position and the exact meas-
The maximum force delivered by the motor at the ured position of the system. Measurements done with FDS
thermal limit in intermittent duty operation (max. 1 s, MC (-01, 11 versions) and 3rd party sin/cos motion controller
10% duty cycle) and with a reduced thermal resistance (-02, 12 versions).
Rth2 by 55%.
Acceleration ae max. [m/s2]
The maximum theoretical no-load acceleration from stand-
Fp max. = kF · Ip max.
still in continuous duty operation.
Continuous current Ie max. [A] Fe max.
ae max. = –––––
The maximum motor current consumption at the thermal mm
limit in continuous duty operation and with a reduced
thermal resistance Rth2 by 55%. Speed ve max. [m/s]
The maximum theoretical no-load speed from standstill,
T125 – T22 2 considering a triangular speed profile and maximum stroke
Ie max. = ––––––––––––––––––––––––––––––––––––– · –––
R · (1 + 22 · (T125 – T22 )) · (Rth 1 + 0,45·R th 2 ) 3 length.
Peak current Ip max. [A] ve max. = ae max. · s max.

The maximum motor current consumption at the
thermal limit in intermittent duty operation (max. 1 s, Thermal resistance Rth 1; Rth 2 [K/W]
10% duty cycle) and with a reduced thermal resistance Rth1 corresponds to the value between coil and housing.
Rth2 by 55%. Rth2 corresponds to the value between housing and
Back-EMF constant kE [V/m/s] ambient air.
The constant corresponding to the relationship between The listed values refer to a motor totally surrounded by air.
the induced voltage in the motor phases and the linear Rth2 can be reduced with a heat sink and/or forced air cooling.
motion speed.
2 · kF
kE = ——––
6
101
Thermal time constant τw1; τw2 [s] where:
The thermal time constant of the coil (τw1) and housing
(τw2), respectively. Fe : Continuous force delivered by motor [N]
Operating temperature range [°C] Fext : External force [N]

The minimum and maximum permissible operating
Ff : Friction force Ff = m · g · ⋅ cos ( ) [N]
temperature values of the motors.
Fx : Parallel force Fx = m · g · sin ( ) [N]
Rod mass mm [g]
The normal mass of the rod (cylinder with magnets). m: Total mass (incl. rod) [kg]
Total mass mt [g] g: Gravity acceleration [m/s2]
The total mass of the linear DC-Servomotor.
a: Acceleration [m/s2]
Magnetic pitch τ m [mm]
The distance between two equal poles.
Rod bearings Speed profiles
The material and type of bearings.
Shifting any load from point A to point B is subject to the
Housing material laws of kinematics.
The material of the motor housing. Equations of a uniform straight-line movement and
Direction of movement uniformly accelerated movement allow definition of the
The direction of movement is reversible, determined by various speed vs. time profiles.
the control electronics. Prior to calculating the continuous duty force delivered by
the motor, a speed profile representing the various load
Force calculation movements needs to be defined.
To move a mass on a slope, the motor needs to deliver Triangular speed profile
a force to accelerate the load and overcome all forces The triangular speed profile simply consists of an accelera-
opposing the movement. tion and a deceleration time.
Fext Speed (m/s)
t The shaded area equals

the movement length
Fe during time t.
m
Ff
Fg Fy t/2 t/2 Time (s)
Fx
11 11 vv2 2
Displacement: ss ==______· ·vv· t· t==______· ·aa· ·tt2 2==____
____ [m]
[m]
The sum of forces shown in above figure has to be equal to: 22 44 aa
ΣF=m·a [N] Speed: v= 2·

s
___
a·t
= ________ = a·s [m/s]
t 2
Entering the various forces in this equation it follows that:

s s v v 2v 2
v ____
Acceleration: a =a 4= ·4____
· ____
= 2= ·2____
· = = ________ [m/s
[m/s2 2]
]
Fe - Fext - Ff - Fx = m · a [N] t 2t2
t t s s
102
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 2 1 1 v2 v2 Calculation example
Displacement: s =s ___=· ___
v ··tv=· t______ · a ·· ta2·=t 22 =· ____
= ______ 2 · ____ [m][m] Speed and acceleration of part 1
3 3 4,5 4,5 a a
s 20 · 10-3
vmax. = 1,5 · ___ = 1,5 · _________________
= 0,3 m/s
s s a · at · t a · as · s t 100 · 10-3
Speed: = 1,5
v =v1,5 · ___· ___ = =_________
= ________
= ________ _________ [m/s]
[m/s]
t t 3 3 2 2 s 20 · 10-3
a = 4,5 · ___ = 4,5 · ____________________
= 9 m/s2
s s v v v v 2 2 t2 (100 · 10-3) 2
Acceleration: = 4,5
a =a4,5 = 3=· 3___· =___2=· 2____· ____
· ___· ___ [m/s
[m/s 2 2]
]
t2 t2 t t s s Force definition
Assuming a total mass 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 · μ · 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 = 4,5FaN= m · a = 0,5 · 9 = 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
Let’s assume a total mass 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
103
The continuous force is represented by the expression:
Σ (t · Ft2 )
Fe = _______________
= ...
2 · Σt
2 2 2 2
0,033 · 7,15 + 0,033 · 2,65 + 0,033 · (–1,85) + 0,1 · 0,77
2 2 2 2
+ 0,033 · 3,73 + 0,033 · ( –0,77) + 0,033 · (–5,27) + 0,1 · (–0,77)
Fe = ________________________________________________________________________________________
= 2,98 N
2 · (0,033 + 0,033 + 0,033 + 0,1)
With these two values it is now possible to select the

suitable motor for the application.
Linear DC-Servomotor LM 1247–020–11

smax. = 20 mm ; Fe max. = 3,6 N ; Fp max. = 10,7 N
Slope angle:
Rest time:
Load:
Coil winding temperature calculation
To obtain the coil winding temperature, the continuous
motor current needs to be calculated. External force:
For this example, considering a force constant kF equal
to 6,43 N/A, gives the result:
- 0,1 kg
- 0,2 kg
- 0,5 kg
F e 2,98
Ie = = _________ = 0,46 A
_____
kf 6,43
With an electrical resistance of 13,17 , a total thermal

resistance of 23,2 °C / W (Rth1 + Rth2) and a reduced ther-
mal resistance Rth2 by 55% (0,45 · Rth2), the resulting coil
temperature is:
3 ) 2· ( 1 – α22 · T22) + T22

R · (Rth1 + 0,45 · Rth2) · (Ie · _____
Tc (I) = 2 = ...
______________________________________________________________________________
1 – α22 · R · ( Rth1 + 0,45 · Rth2) · (Ie · ) 3

_____ 2
13,17 · (3,2 + 0,45 · 20,0) · (0,46 · _____ 3 ) · ( 1 - 0,0038 · 22) + 22

2
2
Tc (I) = _____________________________________________________________________________________________ = 85,26 °C
1 – 0,0038 · 13,17 ( 3,2 + 0,45 · 20,0) · (0,46 · ) 3
_____ 2
104
Motor characteristic curves The motor characteristic curves are dependent on

movement parameters (speed profile, displacement
Motion profile:
distance, friction coefficient, slope angle and rest time).
Trapezoidal (t1 = t2 = t3), back and forth
Consequently by modifying one or more of these input
Motor characteristic curves of the linear DC-Servomotor data, the motor characteristic curves will change
with the following parameters: accordingly. Comparing the above diagram with the one
Displacement distance: 20 mm reported in the datasheet of the LM 1247-020-11 it can
immediately be seen that with the same linear motor we
Friction coefficient: 0,2 get different curves by only changing the slope angle
(in this example 20° and in the datasheet 0°).
Slope angle: 20°
Rest time: 0,1 s
Load (incl.rod) [kg] External force [N]

(t1 = t2 = t3)
2,00 4,0
20° 1,75 3,5
0,1 s
1,50 3,0
1,25 2,5
1,00 2,0
0,75 1,5
0,50 1,0
0,25 0,5
0 Speed [m/s]
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0
LM 1247–020–11
Load curve
Allows knowing the maximum applicable load (incl. rod)
for a given speed with 0 N external force.
The graph shows that a maximum load (incl. rod) ( ) of
0,72 kg can be applied at a speed of 0,125 m/s.
External force curve

Allows knowing the maximum applicable external force
for a given speed with a load of
- 0,1 kg
- 0,2 kg
- 0,5 kg
Considering the 0,5kg curve, the graph shows that the

max. achievable speed without external forces, but with
a load of 0,5 kg is 0,32 m/s (✖).
The maximum applicable external force (✖) at a speed
of 0,3 m/s is 0,17 N.
The external peak force (✖) is achieved at a speed
of 0,125 m/s, corresponding to a maximum applicable
external force of 1,1 N.
105
7
8
3
Linear DC-Servomotor
4
5
1 Sleeve bearings
6
2 Bearing support
3 Coil
4 Housing
5 PCB
6 Hall sensors
7 Cable 9
8 Cover
9 Forcer rod
Features Benefits
FAULHABER technology combines the speed and ■ High dynamics
robustness of a pneumatic system with the flexibil- ■ Excellent force to volume ratio
ity and reliability features of an electro-mechanical ■ No residual force present
linear motor. The innovative design with a 3-phase ■ Non-magnetic metal housing
self-supporting coil and non-magnetic metal housing ■ Compact and robust construction
offers outstanding performance. ■ No lubrication required
■ 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 Linear DC-Servo-
motor is made possible by the built-in Hall sensors.
Product code
Performance lifetime of the 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 12 4 7 – 0 2 0 – 1 1
12 Motor width [mm]
020 Stroke length [mm]
11 Sensors type: linear
106
Notes
107
Precision Gearheads
WE CREATE MOTION
Precision Gearheads
General information
Precision Gearheads Input speed Page
03A The recommended
Planetary Gearheads maximum input speed for continuous
0,88 mNm 372
Life performance operation serves as a guideline. It is possible
06A Planetary Gearheads 25 mNm to operate 373
The operational lifetime of a reduction gearhead and the gearhead
06/1 Planetary Gearheadsat higher speeds. However,
25 mNmto obtain 374
motor combination is determined by:08/1 optimum
Planetary life performance in applications
Gearheads 60 mNmthat require375con-
■ Input speed 08/2 Spur Gearheads
tinuous 15 mNm
operation and long life, the recommended 376
speed
■ Output torque 08/3 Spur Gearheads,
should zero backlash
be considered. 15 mNm 377
10/1 Planetary Gearheads 0,1 Nm 378
■ Operating conditions 12/3 BallGearheads
Spur bearings 0,03 Nm 379
■ Environment and Integration into12/4 other systems RatingsGearheads
Planetary on load and lifetime, if not stated,
0,3 Nm are according380
12/5
Since a multitude of parameters prevail in any application, to the
Spur information
Gearheads, from the ball bearing
zero backlash 0,03 Nmmanufacturers.
381
13A Planetary Gearheads 0,18 Nm 382
it is nearly impossible to state the actual lifetime that can Operating temperature range
14/1 Planetary Gearheads 0,3 Nm 383
be expected from a specific type of gearhead or motor- Standard range as listed on the data sheets.
gearhead combination. A number of15/5 options to the Special
Spur executions for extended temperature
Gearheads 0,1 Nm range 385
standard reduction gearheads are available
15/5 S to increase available
Spur Gearheadson request. 0,1 Nm 386
life performance: ball bearings, all metal
15/8 gears, reinforced Spur Gearheads, zero backlash 0,1 Nm 387
Reduction ratio
lubrication etc. 15/10 Planetary Gearheads 0,35 Nm 388
The listed ratios are nominal values only, the exact ratio
16A Spur Gearheads 0,03 Nm 389
Bearings – Lubrication 16/5 for Gearheads
Spur each reduction gearhead can be calculated
0,1 Nm by means390of
Gearheads are available with a range16/5 of Sbearings to meet the Gearheads
Spur stage ratio applicable for each type. 0,1 Nm 391
various shaft loading requirements: sintered
16/7 sleeve bear- Planetary Gearheads
Output torque 0,3 Nm 392
ings, ball bearings and ceramic bearings.
16/8 Where indicated, Spur Gearheads, zero backlash
Continuous operation.
0,1 Nm 393
ball bearings are preloaded with spring 17/1washers of limited Planetary Gearheads 0,55 Nm 394
The continuous torque provides the maximum load pos-
20/1R
force to avoid excessive current consumption. Planetary Gearheads 0,8 Nm 395
22E sible applied
Planetary Gearheadsto the output shaft; exceeding
0,6 Nm this value396 will
A higher axial shaft load or shaft pressfi t force than speci-
22EKV reduce the service
Planetary Gearheads life. 1,2 Nm 397
fied in the data sheets will neutralise22F
the preload on the Intermittent
Planetary operation.
Gearheads 1 Nm 398
ball bearings. 22/2 Spur Gearheads 0,1 Nm
The intermittent torque value may be applied for a short 399
The satellite gears in the 38/1-2 Series22/5
Planetary Gearheads Spur Gearheads, zero backlash 0,1 Nm
period. It should be for short intervals only and not exceed 400
are individually supported on sintered 22/7
sleeve bearings. Planetary Gearheads
5% of the continuous duty cycle. 0,7 Nm 401
23/1gears are indivi-
In the 38A and 44/1 Series, the satellite Planetary Gearheads 0,7 Nm 402
26A Direction
Planetary of rotation, reversible
Gearheads 1 Nm 403
dually supported on needle or ball bearings.
26/1 All gearheads
Planetary Gearheadsare designed for clockwise
3,5 Nmand counter-404
All bearings are lubricated for life. Relubrication
26/1R is not Planetary
clockwise Gearheads 3,5 Nm
rotation. The indication refers 405
to the direction
necessary and not recommended. The30/1 use of non-approved Planetary Gearheads
of rotation as seen from the shaft end,4,5 Nm
with the motor406
lubricants on or around the gearheads 30/1orS motors can Planetary
runningGearheads
in a clockwise direction. 4,5 Nm 407
negatively influence the function and life expectancy.
32ALN Backlash
Planetary Gearheads 4,5 Nm 409
The standard lubrication of the reduction gears is such as
32/3 Backlash
Planetary is defined by the amount by7 which
Gearheads Nm the width410
to provide optimum life performance at minimum cur-
32/3R Planetary
of a toothGearheads
space exceeds the width of 7 Nm 411
the engaging tooth
rent consumption at no-load conditions. For extended life
38A Planetary
on the Gearheads
pitch circle. Backlash is not to 20
beNmconfused with412
performance, all metal gears and heavy 38/1 duty lubrication Planetary Gearheads
elasticity or torsional stiffness of the 10 Nm
system. 413
are available. Specially lubricated gearheads
38/1 S are available Planetary Gearheads
The general purpose of backlash is to10prevent Nm 414
gears from
for operation at extended temperature 38/2environments and Planetary Gearheads 10 Nm 415
jamming when making contact on both sides of their teeth
under vacuum. 38/2 S Planetary Gearheads 10 Nm 416
simultaneously. A small amount of backlash is desirable
44/1 Planetary Gearheads 16 Nm 417
Notes on technical datasheet to provide for lubricant space and differential expansion
FAULHABER GPT between gear components. The backlash is measured Page
on
Unspecified tolerances Portfolio description the output shaft, at the last geartrain stage. 418 – 419
Tolerances in accordance with ISO
NEW2768
22GPTmedium. Planetary Gearheads 1,8 Nm 426 – 427
NEW 32GPT Planetary Gearheads 8 Nm 428 – 429
≤ 6 = ± 0,1 mm NEW 42GPT Planetary Gearheads 18 Nm 430 – 431
≤ 30 = ± 0,2 mm
≤ 120 = ± 0,3 mm
109
Precision Gearheads
Zero Backlash Gearheads How to select a Precision 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 [min-1]
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 min-1
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 min-1
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.
110
Calculation of the input speed ninput
ninput = n · i [min-1]
ninput = 30 · 159 = 4 770 min-1
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 min-1
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.
111
Precision Gearheads
Planetary Gearheads 1
Planetary Gearhead 7
1 Motor flange
2 Screws 8
3 Washer
9
4 Satellite gears
10
5 Planet carrier
6 Sun gear
7 Satellite gear shafts
11
8 Output shaft
9 Washer
10 Sintered bearing
11 Housing / ring gear 10
12 Retaining ring 9
12
Features Benefits
Their robust construction make the planetary gearheads, ■ Available in all plastic or metal versions
in combination with FAULHABER DC-Micromotors, ideal ■ Use of high performance plastic and ceramic materials
for high torque, high performance applications. ■ 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 ■ Modified versions for extended temperature and special
environmental conditions are available
speed. All steel input gears as well as a modified lubri-
■ 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
112
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. ■ 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. ■ Zero backlash versions are available
■ Available with a variety of shaft bearings including
Zero Backlash Spur Gearhead sintered, ceramic, and ball bearings
1
1 Motor pinion
Dual-pass geartrain
Product code
2
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
113
Planetary Gearheads
The GPT planetary gearheads exhibit high torque and Series

enhanced input speed in compact dimensions. Their improved
efficiency and numerous reduction ratios uniformly distrib- 22GPT 32GPT
uted help to exploit the maximum motor power. 42GPT
Their geartrain is designed for robustness to sustain inter-
mittent or sudden load changes. Depending on the diam-
eter size, these gearheads can sustain input speed up to Key Features
20.000 min -1 or output torque up to 25 Nm when operating in
Gearhead diameter 22 ... 42 mm
intermittent cycles. The GPT product family is also particularly
suited for accurate positioning applications granted by a low Material stainless steel
backlash characteristic. Continuous torque 0,45 ... 18 Nm
Continuous input up to 15.000 min-1
These gearheads can be combined with an extensive range
speed
of DC or brushless motors and they come with various shaft
Intermittent torque 0,6 ... 25 Nm
configurations to adapt to many applications. They are ideal
for different types of robots – inspection, assembly, rehabili- Intermittent input up to 20.000 min-1
speed
tation or exoskeletons – as well as for production and labora-
tory automation, for packaging machines, measurement and Radial load up to 390 N
testing equipment or for semiconductor handling. Reduction ratio from 3:1 up to 1294:1
Product Code
22 Gearhead diameter
GPT Product family
89:1 Reduction ratio
22 GPT 89:1 KS1

KS1 Standard options
WE CREATE MOTION
FAULHABER GPT
Compact length Reduced backlash

High continuous torque Many reduction ratios
Very robust for intermittent or impulsive cycles Large selection of motor combinations
High intermittent speed up to 20.000 min -1
Many standard options
Precision Gearheads
General information Since a multitude of parameters prevail in any applica-

tion, it is nearly impossible to state the actual lifetime
The FAULHABER GPT metal planetary gearhead series that can be expected from a specific type of gearhead or
are designed to provide high torque in compact dimen- motor-gearhead combination. A number of options to the
sions, they can support large input speeds and are suited standard reduction gearheads are available to increase life
for a wide range of applications like robotics, industrial performance: ball bearings, different lubrication etc.
machines and laboratory equipment. The GPT product
Bearings – Lubrication
family is designed to leverage at best the maximum power
Gearheads are available with different bearings to meet
of FAULHABER DC-Micromotors and Brushless DC-Servo-
various requirements. Where indicated, ball bearings are
motors. Besides high torque performance, GPT series are
preloaded with spring washers of limited force to avoid
also particularly well suited for positioning applications
excessive current consumption.
granted by their low backlash characteristics.
A higher axial shaft load than specified in the data sheets
On top of optimizing performance for continuous opera-
will neutralize the preload on the ball bearings.
tion, GPT series are also designed to sustain strong torque
impulses and large speed variations when used in intermit- All bearings are lubricated for life. Relubrication is not
tent cycles. A large number of reduction ratios uniformly necessary and not recommended. The use of non-
distributed are available to select the most appropriate approved lubricants on or around the gearheads or motors
configuration to fit various torque or speed operating can negatively influence the function and life expectancy.
points required by the application. The standard lubrication of the reduction gears is such as
A large selection of options are available to match differ- to provide optimum life performance at minimum current
ent ambient conditions and make the mechanical inte- consumption at no-load conditions. Special lubricated
gration inside applications faster and smoother through gearheads are available for operation at extended tem-
various shaft configurations. perature environments and under vacuum.
The main advantages of the GPT series are: Operating limits

In order to avoid short service life or early damage,
■ compactness with short length
gearheads
Planetary are Gearheads
intended to be used within the following
■ high torque and high inputs speeds limits:
High Torque
■ very robust with high intermittent or impulsive torque ■ maximum output torque
■ many reduction ratios ■ and maximum input speed
■ minimum backlash ■ and maximum output power
■ high efficiency
Series 22GPT
Values at 22°C
Number of gear stages 1 2 2 3 4
■ different shaft configurations Reduction ratio (rounded)1) 3:1 9:1 11:1 41:1 178:1
3,6:1 14:1 49:1 215:1
■ large selection of motors combinations 4,5:1 16:1 59:1 267:1
6,6:1 20:1 72:1 323:1
24:1 89:1 401:1
Service Life 30:1 108:1 474:1
The operational lifetime of a reduction gearhead and 44:1 131:1 588:1
158:1 862:1
motor combination is determined by: 196:1
■ input speed and output torque, resulting in output Continuous torque, max. Nm 0,45 0,8 0,8 1,3 1,8
Intermittent torque, max. Nm 0,6 1,1 1,1 1,8 2,5
power Peak torque Nm 1 2,5 2,5 3,5 4,5
Continuous input speed, max. min-1 9 000 10 000 12 000 15 000 15 000
■ motor operating temperature Intermittent input speed, max. min-1 11 000 12 000 15 000 20 000 20 000
Continuous output power, max. W 21 12 12 8 7
Intermittent output power, max. W 30 18 18 12 10
■ operation mode (continuous, intermittent or impulsive) Efficiency, max. % 92 84 82 78 65
and duty cycle Input inertia with pinion, max.
Torsional stiffness, typical
gmm2
Nm/°
75 78 50 34 14
Backlash, at no-load, typical °

■ output shaft load (radial or axial load)
An
Shaftimportant
load, max: aspect to consider
– radial (10 mm from mounting face) N
is that gearhead cannot
■ operating conditions like temperature, dust and other operate
– axial simultaneously at maximum
N output torque and
Shaf press fit force, max N
ambient conditions maximum
Shaft play: input speed, such operating condition would
– radial (10 mm from mounting face) mm
■ environment and integration into other systems result
– axial in a power transmission mm generating excessive heat
Length withtout motor (L2) mm
dissipation and would degrade
Mass without motor and flange g
significantly service life. For
such reason, a limitation relative maximum output power
Operating temperature °C -30 ... +120
isDirection
also specifi eddrive
of rotation, in the datasheet.=
to output
Housing material stainless steel
Geartrain material stainless steel
Bearings on output shaft ball bearings, preloaded
116
These speed, torque and power limits are specified to For each specific configuration, the gearhead efficiency
different values depending on the operating mode, either varies with speed and torque. The following graph reports
continuous operation or intermittent operation, for which the typical behavior of gearhead efficiency.
intermittent operation refers to an operating duty cycle of
20% on-time. Efficiency
Those limits are represented in a graphical form to 100%

illustrate the recommended area of operations for con- 1-stage
2-stage
tinuous and intermittent operations. Such graph reports
3-stage
the output speed versus output torque on both logarith-
mic scales.
4-stage
n [min-1] 1 gear stage

output 2 gear stages
10 000 Watt 3 gear stages
70 4 gear stages
Intermittent torque
1 000
Torque
1-stage 2-stage 3-stage 4-stage

100 nominal torque nominal torque nominal torque nominal torque
10
Efficiency
1 M [Nm]
0,1 1 10 output 100%
Recommended areas for continuous operation
The limits also vary depending on the number of reduction low speed
Planetary
stages Gearheads
and is also depending on the reduction ratio as 1,8 Nm
expressed
High Torquein the datasheet through the various columns 15 000 min-1 high speed
-1
reporting performance based on reduction ratios.
These limit values are referring to the only gearhead for Same gearhead configuration,
same reduction ratio with
ambient temperature around 22°C and do not consider different speeds
Series
any 22GPT
external effects relative to the gearhead. Ambient Torque
Values at 22°C
conditions, infl
Number of gear uence of integration1in the system
stages 2 applica-
2 3 4 4
Reduction ratio (rounded) 1)
3:1 9:1 11:1 41:1 178:1 711:1 2-stage
711:1
tion and motor behavior like motor temperature
3,6:1 are14:1
not 49:1 215:1 1042:1 nominal torque
4,5:1 16:1 59:1 267:1 1294:1
1042:1 considered when defining those maximum 6,6:1 operating20:1 72:1 323:1
1294:1
limits. 24:1
30:1
89:1
In
108:1
401:1
order
474:1to achieve a good efficiency the gearhead should
44:1 ideally
131:1 be used at torque level above 30% of nominal
588:1
Efficiency 158:1 862:1
torque. The primary parameter to ensure good efficiency is
196:1
Datasheets report the maximum efficiency of the gear-
Continuous torque, max. Nm 0,45 0,8 0,8 1,3 torque1,8 while 1,4speed affect also efficiency but a minor
head based
Intermittent onmax.
torque, its configuration
Nm as per
0,6 number
1,1 of stage
1,1 1,8 2,5 2,0
Peak torque
and reduction ratio. Such effi Nm
ciency9 000
value refers
1 2,5 only2,5to 3,5 proportion.
4,5 To
4,0 provide good efficiency a gearhead should
Continuous input speed, max. min -1
10 000 12 000 15 000 15 000 15 000
not20
be used20at000low torque and high speed.
continuous operation
Intermittent input speed, max. mode.
min -1
11 000 12 000 15 000 20 000 000
Continuous output power, max. W 21 12 12 8 7 7
7
Intermittent output power, max. W 30 18 18 12 Besides10 motor 10current consumption, the impact of eff-
Efficiency, max. % 92 84 82 78 65 65
Input inertia with pinion, max. gmm2 75 78 50 34
ciency
14
is related
13
to heat dissipation inside the gearhead
Torsional stiffness, typical Nm/° 6 11 11 11 which 11 also depends
11 on the input power transmitted by the
Such maximum
Backlash, efficiency occurs
at no-load, typical ° on 0,8
a specifi0,8
c operating
0,8 0,8 0,8 0,8
Shaft load, max: motor. Such heat dissipation is increasing gearhead
point in mm
– radial (10 termsfrom of speed
mounting and Ntorque and
face) 65 it depends
90 also
90 on 120 150 150
– axial N 60 85 85 110 temperature
140 and contribute to degrade lubricant over
140
the gearhead
Shaf press configurationNand on150
fit force, max the specifi
150
c reduction
150 150 150 150
time, impacting thus service life.
ratio.
Shaft play:
– radial (10 mm from mounting face) mm ≤ 0,05 ≤ 0,05 ≤ 0,05 ≤ 0,05 ≤ 0,05 ≤ 0,05
– axial mm =0 =0 =0 =0 =0 =0
Length withtout motor (L2) mm 18,1 24,5 24,5 30,8 37,2 37,2
Mass without motor and flange g 51 66 66 82 97 97
Operating temperature °C -30 ... +120

Direction of rotation, drive to output =
Housing material stainless steel
Geartrain material stainless steel
Bearings on output shaft ball bearings, preloaded
117
Precision Gearheads
Motor Combinations
GPT gearhead series can be combined with a wide range
of DC motors, 4-pole and 2-pole brushless motors, for
smaller diameter size also combination with stepper
motors are available. This gearhead series are optimized to
leverage at best the torque and speed range of the
different FAULHABER motor families.
Combinations with motors come assembled from the
factory. Motor-gearhead combination cannot be assem-
bled other than on the factory line.
When combining a motor with GPT gearhead series, the
motor should be selected with enough performance
capabilities to avoid bringing the motor at a too high
steady temperature. Such high temperatures would
produce extra heat transfer towards the gearhead and
could degrade prematurely the lubricant, thus impacting
service life of the combination unit.
To achieve long service life, a general guideline is to
ensure that the motor won’t exceed a temperature of 60°C
to 70°C at steady state during operation. Such motor
temperatures will avoid premature degradation of
lubricant inside the gearhead.
Modifications and standard options
GPT gearhead series are available with a big range of
standard options and modifications. Some of these options
are made available to match particular requirements
related to specific applications with special ambient
conditions, others are made to ease the product integra-
tion inside the application system, others to enhance
particular performance parameters for specific needs.
Such product options refers to:
■ output shaft shape and dimensions
■ ambient conditions like particular temperature range or
special environmental conditions as vacuum.
■ different motor cable or terminals orientation when
integrating the combination unit inside the application
■ other requirements related to output load fixed on the
output shaft
Most options are modifying the basic product so that
characteristics will differ from the performance of the
standard version. This latest aspect should be considered
when selecting an option and eventual questions should
be addressed to your local sales representative.
118
Input speed
Continuous operation: The recommended maximum input
speed for continuous operation serves as a guideline. It is
Planetary Gearheads possible to operate the gearhead at higher speeds.
High Torque However, to obtain optimum life performance in applica-
tions that require continuous operation and long life, the
recommended speed should be considered.
Intermittent operation: The intermittent input speed value
Series 32GPT
Values at 22°C may be applied for a short period. It should be for short
Number of gear stages 1 1
Reduction ratio (rounded)1) 3:1 3,6:1
intervals only and not exceed 20% of the continuous duty
4,5:1 cycle. Operating gearhead at speeds higher than intermit-
6,6:1
tent maximum value is not recommend as it will reduce
significantly service life, and in some cases it could gener-
ate early damage with abrupt stop.
Notes on technical datasheet
Output Power
Unspecified tolerances Continuous operation: The recommended maximum
Tolerances in accordance with ISO 2768 medium. output power for continuous operation serves as a guide-
line. It is possible to operate the gearhead momentarily
≤ 6 = ± 0,1 mm with higher output power for brief period. However, to
≤ 30 = ± 0,2 mm obtain optimum life performance in applications that
≤ 120 = ± 0,3 mm
require continuous operation and long life, the recom-
mended continuous output power should be considered.
Reduction ratio Intermittent operation: The intermittent output power
The listed ratios are nominal values only, the exact ratio value may be applied for a short period. It should be for
for each reduction gearhead can be calculated by means short intervals only and not exceed 20% of the continu-
of the stage ratio applicable for each type. ous duty cycle. Operating gearhead at higher power than
Output torque intermittent maximum value is not recommend as it will
Continuous operation: The continuous torque provides the reduce drastically service life.
maximum possible load applied to the output shaft; Efficiency
exceeding this value will reduce the service life. The maximum efficiency refers to the continuous opera-
Intermittent operation: The intermittent torque value may tion mode. Such value varies depending on the number of
be applied for a short period. It should be for short stages and could also depend on the reduction ratio. The
intervals only and not exceed 20% of the continuous duty gearhead efficiency varies depending on the speed-torque
cycle. operating point. For low torque value below 30% of
Peak torque: This torque limit represents the absolute nominal torque, efficiency could be significantly reduced.
maximum torque supported by the gearhead for unex- Efficiency varies in minor proportion with speed, at high-
pected events generated randomly on the output shaft est speed efficiency is slightly reduced.
load. Such peak torque cannot occur in cyclic mode or in a Input inertia
timely repetitive manner. This parameter is not intended Maximum input inertia can be used to determine the
to be used as a dimensioning constraints to drive any necessary torque required to ensure a particular accelera-
loads. Gearhead output is able to support such torque tion of the geartrain typically for positioning applications
value with a non-repetitive scheme few hundreds to few with high dynamics. Such inertia value is referred to the
thousand times during its operation without impacting gearhead input at the motor output shaft and including
service life. the motor pinion. Such value is depending on the geart-
rain configuration (e.g.: number of satellite gears), the
number of stage and thus on the reduction ratio also. The
reported value is the maximum one considering the vari-
ous possible configuration of the geartrain.
32GPT_FMM_def.indd 1 15.11.19 08:30
119
Precision Gearheads
Torsional stiffness Shaft load

Torsional stiffness represents the angular rigidity of the Radial load: The maximum output shaft load represents
whole geartrain including the output shaft. This param- the maximum dynamic load (when output shaft is rotat-
eter is reporting the output torque necessary to twist the ing) that can be applied radially at a particular distance
output shaft by one degree when the gearhead input is from the output flange and that the gearhead ball bear-
fixed. This is a typical measured on several samples. ing system can support without impacting the service
life. In case the radial load would be applied at another
Backlash
distance this value should be extrapolated appropriately.
Backlash: Backlash is defined by the amount by which the
width of a tooth space exceeds the width of the engaging Axial load: The maximum axial load is the maximum
tooth on the pitch circle. Backlash is not to be confused dynamic load (when output shaft is rotating) when press-
with elasticity or torsional stiffness of the system. ing the shaft towards the inner side of the gearhead
without damaging prematurely the bearing system and
The general purpose of backlash is to prevent gears from
without impacting service life.
jamming when making contact on both sides of their teeth
simultaneously. A small amount of backlash is desirable Shaft press fit force
to provide for lubricant space and differential expansion The press fit force is the maximum static force that can be
between gear components. The backlash is measured on axially applied to gearhead output shaft in order to mount
the output shaft, at the last geartrain stage. a coupling element, for example a pulley or a pinion. This
Backlash represent the angular play of the whole geartrain is a static force while the geartrain is stand-still and not
when rotating the gearhead output shaft with no load rotating. Please note that this force does not refer to any
while the gearhead input is fixed. Such angular play con- operating conditions of the gearhead when used inside
sider the angle between both clockwise and counterclock- the application.
wise end positions of the output shaft, without applying Shaft play
torque. This reported value is typical measured on several Radial Play: The radial play is the maximum clearance that
samples. the output shaft can move radially when measured at a
Backlash under load: The backlash under load between specific distance from the front flange. Such radial play
2 angular positions is depending on the torque load in measure depends on the position of measurement along
the CW and CCW directions for those respective positions. the shaft and on the force used for measurement. The
Such backlash is the sum of the backlash at no-load and radial play value assumes that maximum force reported in
the contribution of the torsional stiffness depending the the datasheet will not exceed the maximum radial load.
torque values in these 2 load positions as illustrated the Axial Play: The axial play on the gearhead output shaft is
graph below: the maximum distance that the output shaft move in the
axial direction when pushing the shaft towards the inner
2
side of the gearhead. Such axial play value depends on the
ball bearing system and the relative preload design. The
1,5
axial play assumes that maximum axial load force reported
1
in the datasheet is not exceeded. When pulling the shaft
0,5
in the direction out from the gearhead, a minimum play
Torsional Backlash at no load
is required to avoid ball bearings to jam, such play in pull
Torque [Mm]
Stiffness
0
direction depends on the bearing preload design.
-0,5
-1
-1,5
-2
7,00
7,04
7,08
7,12
7,16
7,20
7,24
7,28
7,32
7,36
7,40
7,44
7,48
7,52
7,56
7,60
7,64
7,68
7,72
7,76
7,80
7,84
7,88
7,92
7,96
Angle [°]
120
Operating temperature range Ball bearings
Standard range as listed on the data sheets. Service Ratings on load and lifetime, if not stated, are according
lifetime is also influenced by the operating temperature, to the information from the ball bearing manufacturers.
especially for high temperature above 70°C.
Length
Special executions for extended temperature range avail- The length L2 without motor reported in the datasheet
able on request. is the length of the stand-alone gearhead excluding any
Direction of rotation, reversible adaptation flange. The length L1 with motor is reporting
All gearheads are designed for clockwise and counter- the total length of the combination including the motor,
clockwise rotation. The indication refers to the direction the coupling flange and the gearhead.
of rotation as seen from the shaft end, with the motor
running in a clockwise direction.
6
Planetary Gearhead
1 Motor flange
2 Washer 7
3 Satellite gears
4 Planet carrier
5 Sun gear 8
6 Output shaft
7 Housing / ring gear
8 Bearing flange 9
9 Retaining ring
121
Linear Components
WE CREATE MOTION
Lead Screws and Options
Lead screws parameters

Resolution (travel/step) Lead Screw
A lead screw combined with a stepper motor can achieve Linear actuation for positioning tasks
a positioning with a resolution of 10μm.
The resolution of the position depends on the pitch and
number of steps per revolution: Series M1,2 x 0,25 x L1
Ordering information L1 (mm) =
Ph Order code (no bearing tip)
Order code (with bearing tip)
P=
n Nominal diameter 1,2
Pitch 0,25
Material Stainless steel
With Ph the pitch of the screw and n the number of steps
per revolution of the motor.
Driving the motor with half-stepping or microstepping Backdriving
will improve the resolution up to a certain extent. Backdriving the motors while applying an axial load on
The resolution must be balanced with another parameter: the lead screws is impossible. The pitch vs. diameter ratio
the precision. does not allow it.
Precision Force vs speed curves

The motor step angle accuracy is one parameter, together The force that a linear system can provide depends on the
with the axial play between the nut and the lead screw, type of screw and stepper motor selected. Torque vs speed
influencing the precision of the linear displacement. It curves for each solution are provided in this catalogue.
varies between ±3 and ±10% of a full step angle depend- Those curves do already consider a 40% safety factor on
ing on the motor model (see line 9 on motor datasheet) the motor torque as well as a conservative lead screw
and remains the same with microstepping. It is however efficiency in the calculation.
not cumulative. Tip for bearings
Axial play Ideally, the application should handle radial loads and the
An axial play up to 30μm is measured with optional nuts lead screw only axial loads. If it is not the case, it is possible
offered in this catalogue. However, it is possible to negate to get lead screws with a tip suitable for bearing at its
the axial play by implementing a preloading system in front end in order to handle radial loads. With this con-
the design of the application (for instance with a spring figuration, a special care to the alignment of the motor
mechanism). and bearing must be paid to not deteriorate the thrust
The “zero” axial play between the lead screw and motor force achievable. Optional mating ball bearings are avail-
housing is ensured thanks to a preload of the motor ball able in the dedicated datasheet for options.
bearings (in standard configuration: spring washer on rear Nut
ball bearing). An axial play up to 0.2 mm will occur if the Optional nuts offered in this catalogue are shaped with a
axial load on the lead screw exceeds the ball bearing pre- flat in order to prevent its rotations in the application.
load. Alternatively, tapped holes on the application are a
This does not cause any damage to the motor and is convenient solution since metric taps are readily available.
reversible. This occurs only while pulling on the shaft.
On request, customization can overcome this limitation.
To avoid irreversibly damaging the motor, the maximum
axial load should always remain under the maximal push
force the motor can generated with a mounted lead screw.
LSM1,2_PCS_NEW.indd 1
123
Lead Screws and Options
Lead Screws
1 Stepper motor
2 Lead screw
3
Nut
Features Benefits
Stepper motors can be used for more than just a rotation. ■ Cost effective positioning drive without encoder
When combined with lead screws, they provide a high ■ High accuracy
accuracy linear positioning system that provides the
■ Wide range of lead screws available
benefits of a stepper (open loop control, long life, high
■ Short lead time for standard length
torque density, etc.).
■ Flexibility offered by optional nuts and ball bearings
The lead screws available on stepper motors are all based
■ Custom length on request
on metric dimensions (M1.2 up to M3) and specifically
designed to be assembled with stepper motors. The
technique used to produce the thread ensures a very high
precision and consistency of quality. A large choice of
standard lengths is available from stock and customiza- Product code
tion is possible on request.
Such a combination is ideal for any application such as

requiring accurate linear movement or lens adjustment
(zoom, focus), microscope stages or medical syringes.
A M 1 5 2 4 2R 0 0 7 5 5 5 M3 x 15
AM1524 Motor series M3 Screw type

2R Bearing type 15 Length (mm)
0075 Winding type
55 Motor execution
124
Notes
125
Encoders
WE CREATE MOTION
Encoders
under “Controller combinations”. If this option is selected,

General
Encodersinformation
– 2 Channel Page
no encoder is needed. The space and cost advantages
PA2-50 optical 458 – 460
FAULHABER Motors are available with a variety of sensors make analog Hall sensors the preferred solution for most
PA2-100 optical 461 – 463
and encoders for providing solutionsIE2-16
to a wide range of positioning applications with Brushless DC-Motors. When
magnetic 464 – 466
drive applications – from speed control to high-precision
IE2-400
selecting this option, it is recommended that the 468
magnetic
sensors
– 469
positioning. IE2-1024 be operated
magnetic with FAULHABER Controllers, which are– 472
470
IEH2-4096 perfectly designed for the analog Hall signals. 473 – 475
magnetic
Sensors and encoders PE22-120 optical 476 – 477
FAULHABER Motors are offered in combination
HEDS 5500 with sen- Functionality
optical 478 – 479
sors and encoders. An encoder is a sensor for angle meas-
Encoders
urement that –
is 3 Channel
usually used for speed or position control. Measurement principle Page
HXM3-64Hall sensor
The term sensor refers to digital or analog The FAULHABER Sensors and Encoders are based 480
magnetic on – 482
HEM3-256-W are usually
which, in the FAULHABER Brushless DC-Motors, magnetic or optical measurement principles.
magnetic 483 – 485
mounted directly on the motor circuit IEM3-1024
board. Digital Hall magnetic 486 – 488
Magnetic encoders are especially insensitive to dust,
IE3-1024 magnetic 489 – 493
sensors are used primarily for the commutation of the humidity and thermal and mechanical shock. In magnetic
IE3-1024L magnetic, Line Driver 494 – 497
Brushless DC-Motors and for simple speed control. Almost encoders, sensors are used that determine the changes of
NEW IEF3-4096 magnetic 498 – 500
all FAULHABER Brushless DC-Motors are equipped stand-
NEW IEF3-4096L
the magnetic
magnetic, field. The magnetic field is changed501
Line Driver by–the
503
ard with three integrated digital HallIEH3-4096
sensors. movement
magnetic of a magnetic object. This can be the magnet
504 – 506
NEW IEH3-4096L of the motor
magnetic, or an additional sensor magnet with507
Line Driver a – 509
0° 120° 240° IERS3-500
360° defi ned
optical measuring element that is secured to the510 – 512of
shaft
1
IERS3-500L the motor.
optical, With encoders, an additional sensor magnet
Line Driver 513 – 515is
HA IER3-10000 optical
usually necessary. 516 – 519
0
IER3-10000L optical, Line Driver 520 – 523
In the case of integrated digital or analog Hall sensors, the
HEDL 5540 optical, Line Driver 524 – 525
HB
1 movement of the rotor magnet of the motor can be meas-
Encoders – Absolute
0 ured directly. With the integrated Hall sensors, an addi-
Page
tional sensor magnet is therefore normally not necessary.
1
AESM-4096 magnetic 526 – 528
HC AES-4096 Digital Hall Optical encoders are characterised by a very high 529
magnetic position
– 531
0
NEW AES-4096L sensor accuracy
magnetic, and
Line repeatability and a very high signal 532
Driver quality
– 534
output signal
2-pole motor
due to the precise measuring element. Furthermore, they
S1 S2 S3 S4 S5 S6 S1
are insensitive to magnetic interference. In optical encod-
ers, a code disc with a measuring element is used that is
In addition, analog Hall sensors are generally available as attached to the shaft of the motor. A distinction is made
an option. between reflective and transmissive optical encoders. With
Hall signals HallA – HallC
reflective encoders, the light from an LED is reflected back
5 HallA to the code disc by a reflective surface and collected by
4.5 HallB photodetectors. Reflective optical encoders are especially
4
HallC
compact since the LED, the photodetectors and the elec-
3.5 tronics can be mounted on the same circuit board or even
3 on the same chip. FAULHABER therefore primarily uses
UA … UC
2.5
reflective optical encoders. With transmissive encoders,
2
the light from the LED passes through slits in the code disc
1.5
and is collected by photodetectors on the other side of the
1
Analog code disc.
0.5
Hall sensor
0 output signal
0° 60° 120° 180° 240° 300° 360° 2-pole motor
Absolute mechanical rotational angle
Due to the higher resolution, the analog Hall sensors can

also be used for precise speed or position control, making
them an especially economical, lightweight and compact
alternative to encoders. The option for analog Hall sensors
can be found directly in the data sheets of the motors
127
Encoders
Moving Element Signal processing and interpolation

Depending on the measurement principle and dimen- In addition to the sensors for signal acquisition, the
sional constraints different moving elements are applied FAULHABER Encoders also include electronic components
in different types of FAULHABER Encoders. The moving for signal processing. These process the signals from the
element has a significant impact on the accuracy and reso- sensors and generate the standardised output signals of
lution of the encoder. In general, the higher the physical the encoders. In many cases, the signals are also interpo-
(native) resolution of the moving element, the higher the lated, i.e., multiple signal periods are generated by inter-
resolution and accuracy of the encoder as a whole. polating a single physically measured signal period. The
In magnetic encoders, simple, two-pole sensor magnets physical resolution of the measuring element can thereby
and magnetic rings are used. The magnetic rings have be increased many times over.
several signal periods per revolution through the use of
a special tooth structure or targeted magnetisation. The Characteristic encoder features
number of signal periods corresponds to the physical reso-
The quality of an encoder is largely determined by the
lution of the magnetic rings.
resolution and the accuracy.
Resolution
The resolution is the number of edges or steps that an
N
S S N encoder produces within a revolution. The resolution is
N S S S N
determined from the physical resolution of the moving
N S N
S element and the interpolation of the physical signal via
the electronics. Due to the large amount of information
Two-pole sensor Multi-pole Magnetic ring with that is made available per motor revolution, a high resolu-
magnet with one magnetic ring tooth structure tion offers various advantages for a drive system:
signal period with multiple with multiple
signal periods signal periods ■ Smoother speed control and lower audible noise
■ Operation at lower speed
In optical encoders, moving elements in the form of code
A high resolution in excess of 4 000 edges or steps is rele-
discs are used. With reflective encoders, these consist of a
vant if the motor is used as a direct drive for positioning or
series of surfaces that alternately reflect or absorb light.
if the motor is operated at very low speeds.
With transmissive encoders, the code discs consist of a
series of bars and slits. The number of reflective surfaces
or slits corresponds to the physical resolution. In general,
0° 360°
optical encoders can have a significantly higher native Low resolution
resolution than magnetic encoders.
0° 360°
Higher resolution
Distribution of encoder edges during rotation of the motor shaft
Accuracy
Independent of the resolution, the accuracy also plays an
important role. The accuracy is determined by the physical
Code disc for reflective Code disc for transmissive resolution of the moving element and the precision with
encoders with high number encoders with high number
of signal periods of signal periods which not only the moving element and the encoder are
manufactured, but the entire drive system as well. If an
encoder has a high accuracy, it always transmits the signals
at the same spacing for each and every motor revolution
and thus has a high signal quality.
128
For encoders with at least two channels, the state of
channel A or channel B changes every 90 °e due to the
0° 360° phase offset. The edges, i.e., the state change of the
Low signal quality
encoder channels, are evaluated for determining the
position. Because four edges occur per pulse, the resolu-
0° 360° tion of the FAULHABER Incremental Encoders is four times
High signal quality
their pulse number. Thus, an encoder with 10 000 pulses
Distribution of encoder edges during rotation of the motor shaft per revolution, for example, has 40 000 edges per revolu-
tion, which corresponds to a very high angular resolution
The most important parameter for the signal quality of the
of 360°/40 000 = 0,009°.
FAULHABER Encoders is the phase shift tolerance (∆� ). If
the phase shift tolerance is low, the encoder transmits uni-
Amplitude
C
form signals. While FAULHABER magnetic encoders have a
high signal quality with a phase shift tolerance of approxi-
mately 45 °e, FAULHABER optical encoders demonstrate an A
especially high signal quality with a phase shift tolerance
of approximately 20 °e . Optical encoders are generally
more accurate than magnetic encoders.
Detailed information for the calculation of the phase shift B
tolerance can be found in the chapter “Notes on technical
data sheet” under the heading “phase shift”. Angle
A high accuracy or a high signal quality has multiple

advantages for a drive system: An incremental encoder does not measure absolute posi-
tions, but rather relative positions. Incremental encoders
■ Exact determination of the position and, thus, accurate determine a position relative to another reference posi-
positioning tion. For this purpose, the signal edges must be counted
■ Smoother speed control and lower audible noise forward or backward by the motor control using a square
counter according to their edge sequence. This position
A high accuracy is relevant above all if the motor is used as
value is lost if the power supply is interrupted. A position-
a direct drive and exact positioning is necessary.
ing system must therefore move to a defined reference
To position a drive system precisely, a highly accurate position during commissioning or after a power interrup-
encoder is not enough. Tolerances in the entire drive tion to initialise the position counter (homing). For the
system must be taken into account, such as the concen- determination of the reference position, an external addi-
tricity tolerance of the motor shaft. The accuracy and the tional sensor, such as a reference switch or limit switch, is
phase shift tolerance of the FAULHABER Encoders is there- usually used.
fore determined in combination with the FAULHABER
To determine the reference position with an especially
Motors. The specified position accuracy and repeatability
high level of accuracy, the FAULHABER 3 Channel Encoders
is the system accuracy that a FAULHABER Motor-Encoder
have an additional channel – the index. Here, a single
combination actually achieves in an application.
index pulse is generated once per revolution. External
reference switches or limit switches can have a comparably
Output signal
high position error due to environmental influences and
Incremental encoder can sometimes trigger a little earlier, sometimes a little
Incremental encoders transmit a specific number of uni- later. To nevertheless accurately determine the reference
formly distributed pulses per revolution. All FAULHABER position, the drive system can move back after the limit
Incremental Encoders have at least two channels: A and switch until the first signal edge of the index pulse occurs.
B. Both channels supply a square wave signal, shifted by This point can then be used as an exact reference position.
90 °e with respect to one another, i.e., one quarter cycle C. The index pulse has a width of 90 °e and always occurs
Through the shift of the pulses, the direction of rotation at defined states of channels A and B. For longer travel
of the motor can be determined. distances and multiple revolutions of the encoder, the
The highest angular resolution of incremental encoders index pulse can also be used to verify the counted number
is not determined by the number of pulses per revolution of edges.
but rather the total number of signal edges.
129
Encoders
reference motion is, therefore, not necessary if positioning

Amplitude
within one or one half revolution of the motor shaft.
A
The resolution of an absolute encoder is defined via the
number of steps per revolution and is specified in bits.
Absolute encoders generate a serial code from multiple
bits. The FAULHABER Absolute Encoders support the SSI
B Interface with BISS-C Protocol. BISS-C supports communica-
tion with clock speeds of up to 2 MHz. Here, the absolute
position value (DATA) is transferred in synch with a cycle
(CLK) specified by the controller.
I
CLK
Angle
Timeout
DATA Ack Start CDS D11 D10 D0 Res. Res. CRC5 CRC4 CRC0 Stop
Absolute encoder Data Range
Unlike the incremental encoder, an absolute encoder Interface protocol (BISS-C) of an absolute encoder
determines absolute positions, not relative positions. After
switching on the absolute encoder, an absolute return
value is available for each position of the motor shaft. A Line Driver
distinction is made between single turn and multi turn Some of the FAULHABER Encoders are equipped with a
encoders. The FAULHABER Absolute Encoders are single Line Driver. The Line Driver generates an additional diffe-
turn encoders. rential signal for all channels. With an incremental enco-
– – –
der with three channels, A, B, I and A, B and I are thus
With the single turn encoders, each position of the
available. With an absolute encoder, the inverted signals
motor shaft corresponds to a specific return value. After
CLK and DATA are available in addition to CLK and DATA.
a complete revolution of the motor shaft, the signals
Electromagnetic interference can thereby be eliminated
repeat. Thus, the single turn encoder supplies no absolute
during signal transmission. Especially if the encoder signals
information about the number of completed revolutions.
must be transmitted over long distances of 5 m and more
Positioning over more than one revolution is, however, still
and for position control, the use of a Line Driver is there-
possible with the single turn encoder. Like with the incre-
fore recommended.
mental encoder, this is performed by counting the number
of revolutions forward or backward using a counter on the On the control side, these differential signals must be
motor control. For travel distances greater than one motor combined again with a receiver module. The actually
revolution, referencing is therefore necessary after a achievable line length is dependent on the ambient condi-
power interruption. No referencing is necessary for travel tions and the type of analysis. Ideally, the differential sig-
distances of less than one motor revolution. nals are twisted pairs as well as shielded against the motor
phases to allow the coupled interference at the end of the
Unlike single turn encoders, multi turn encoders also cap-
line to be decoded as error-free as possible. For longer line
ture the number of travelled revolutions by means of an
lengths, one may wish to consider buffering the encoder
additional sensor and an electronic memory element or via
voltage supply at the end of the line on the encoder side
a gearhead. Thus, multi turn encoders supply an absolute
to ensure a stable voltage supply. Furthermore, a line ter-
return value over multiple revolutions of the motor shaft
minator with characteristic impedance (100 ... 120 Ω) may
within a defined maximum amount of revolutions that
be useful with longer line lengths.
can be captured by the electronic memory element or the
gearhead. Referencing is generally not necessary if the
maximum amount of revolutions is not exceeded.
The analog Hall sensors, which are mounted directly in
the FAULHABER Brushless DC-Motors as an option, supply
absolute return values within one revolution of the motor
shaft in combination with the motors with 2-pole tech-
nology and absolute return values within half of a revolu-
tion of the motor shaft in combination with motors with
4-pole technology. When using the analog Hall sensors, a
130
This must be tested in the given application. The Line Driv-
ers from FAULHABER are TIA-422 compatible. TIA-422, also
known as EIA-422 or RS-422, is an interface standard for Encoders
cable-based differential, serial data transfer. magnetic Encoder, digital outputs,
2 channels, 16 - 4096 lines per revolution
Amplitude
Series IEH2-4096
__ IEH2 -16 -32
A Lines per revolution N 16 32
Frequency range, up to1) f 5 10
Signal output, square wave 2
B
__ Supply voltage UDD 4,5 ... 5,5
Current consumption, typical2) IDD typ. 15, max.
B Output current, max.3) IOUT 2,5
Phase shift channel A to B4) ) 90 ± 45
I
__ Notes on technical data sheet
I
Lines per revolution (N)

Angle Specifies how many pulses are generated at the incre-
mental encoder outputs per channel on each motor shaft
CMOS and TTL revolution. Through the phase offset of encoder channels
The FAULHABER Encoders are normally compatible with A and B, four edges are available per line. Thus, the resolu-
the CMOS and TTL standard. This means that the “low” tion of the incremental encoder is four times the number
logic state is typically at 0V and the “high” logic state at of pulses. If, for example, an encoder has 1 024 lines per
5V. It is important to note that the tolerances indicated in revolution, the resolution is 4 096 edges per revolution.
the controller specification must be observed.
Steps per revolution
Integrated solutions The value for “steps per revolution” specifies the number
of position values per motor shaft revolution. The value
Many FAULHABER Encoders are highly integrated into is generally used with absolute encoders and corresponds
the existing geometry of the motor. By integrating the to the resolution or number of edges for incremental
solutions in the motor, they are especially lightweight, encoders.
compact and economical.
Resolution
For the Brushless DC-Motors, these include the integrated
Number of binary bits of the output signal. The steps per
digital and analog Hall sensors and encoders IEM3-1024
revolution of an absolute or incremental encoder corre-
and AESM-4096. The outer dimensions of the motors are
spond to the resolution of 2number of bits.
not affected by these solutions.
For the DC-Micromotors of the FAULHABER SR series, Frequency range, up to (f)
the following integrated encoders are available, which Indicates the maximum encoder frequency. This is the
lengthen the motors by just 1,4 – 1,7 mm: IE2-16, IE2-400, maximum frequency at which the encoder electronics can
IE2-1024, IEH2-4096 and IEH3-4096. switch back and forth between the low and high signal
In combination with the Flat DC-Micromotors, the FAUL- level. The maximum achievable operating speed (n) for
HABER SR-Flat series includes integrated encoders that the encoder can be derived from this value and the pulse
lengthen the motors by just 2,3 mm: IE2-8 and IE2-16. number (N). If this frequency range and the resulting
speed are exceeded, the result may be the transmission of
incorrect data or the premature failure of the encoder. For
very high-speed applications, it may be necessary to select
a correspondingly low pulse number.
60 . f
n=
N
EN,DE,FR,CN.indd 15
131
A
Φ
B
Po
Encoders I
Drehrichtung
P
Amplitude
A
Φ
Signal output Permissible deviation ∆P0:
With incremental encoders, square wave signals are B
output. 2 channel encoders have two channels: AΔand Φ P
Φ = B.
90° – 180° ≤ 45° Δ P0 = 90° – 0 * 180° ≤ 45°
3 channel encoders have an additional index channel. P * P
Po
I
C Phase shift, channel A to B (� )
Amplitude
P
The phase shift (in °e) in between output signals A and B is
Drehrichtung
referred to as phase shift and is ideally 90 °e.
S S S S The phase shift tolerance (∆� ) is the deviation of two
A
successive edges at outputs A and B from the ideal value
Φ of 90 °e.
Permissible deviation ∆� :
B
Φ P0
Po ΔΦ = 90° – 180° ≤ 45° Δ P0 = 90° – 180°
P * P *
I
Logic state width (S)
Distance of two adjacent edges (in °e) between the two
Angle
channels A and B. There are four logic state widths (S) per
cycle. Ideally, a logic state width is 90 °e.
With absolute encoders, a digital word is output.
FAULHABER Encoders use a SSI Interface with BISS-C Cycle (C)
Protocol. SSI is an interface for absolute encoders with The duration of a total period (in °e) on channel A or B.
which absolute position information is made available Normally, a cycle is 360 °e.
via serial data transfer.
Signal rise/fall time, max. (tr/tf)
Supply voltage (UDD) Maximum time for changing from the lower to the higher
Defines the range of supply voltage necessary for the signal level or vice versa. This describes the edge steepness
encoder to function properly. To avoid damaging the of the encoder signals. CLOAD specifies the maximum per-
encoder, this range must always be adhered to. missible load of the signal line at which the edge steepness
is still reached.
Current consumption (IDD)
Indicates the current consumption of the encoder at the Clock frequency, max. (CLK)
given operating voltage. Normally, typical and partial Maximal permissible clock frequency for reading the BISS-C
maximum values are specified. Protocol.
Output current, max. (IOUT) Input - low / high level (CLK)

Indicates the maximum allowable output current at the The level of the CLK input signal must lie in the specified
signal outputs. If necessary, this value should be aligned value range in order to ensure reliable signal detection.
with the controller that is used.
Setup time after power on, max.
Pulse width (P) Maximum time to availability of the output signals, as of
Width of the output pulse (in °e) of encoder channels A when supply voltage is applied.
and B. It is ideally 180 °e.
Timeout
Index pulse width (P0) Refers to the time after which communication is termi-
The index pulse width specifies the width of the index nated by the encoder, when the master is no longer trans-
pulse (in °e) and is ideally 90 °e. mitting a clock rate.
The index pulse width error (∆P0) is the deviation from the
ideal value of 90 °e.
132
Inertia of sensor magnet / code disc (J)
Indicates the amount by which the rotor inertia of the
motor is increased by the sensor magnet or the code disc.
Operating temperature range

Indicates the minimum and maximum permissible operat-
ing temperature for encoder operation.
Accuracy
Indicates the average position error of the encoder in
mechanical degrees (°m). This describes the extent to
which the current position of the encoder can deviate
from the target position.
Repeatability
Indicates the average repeatability error of the encoder in
mechanical degrees (°m). This describes the average devia-
tion of multiple position values for the encoder when posi-
tioning at the same position multiple times. Repeatability
shows how precisely a certain position can be reached
when repeatedly moving to the same position.
Hysteresis
Indicates the dead angle during a change in direction in
which no information related to the position is output.
Edge spacing, min.

The minimum spacing between two successive edges of
channels A and B. For a reliable evaluation of the square
wave signal, a controller that is able to detect this mini-
mum edge spacing is required. If no information on the
minimum edge spacing is available, this can also be deter-
mined as an approximate value.
1 ΔΦ
Tmin = · 1–
f·4 90°
Mass
The typical mass of the encoder, including housing and
adapter flange with standard cable without connector.
Battery voltage
Specifies the voltage range in which the counter state of
a multiturn encoder is reliably detected and incremented
by means of an external backup battery. If the battery
voltage is too low, an error bit is set.
133
Encoders
How to select an appropriate sensor DC-Motors

This chapter describes how a suitable sensor is selected for Commutation
FAULHABER Motors. Which sensors can be used depends The commutation of DC-Motors with precious metal or
primarily on the selected motor technology. A distinction is graphite brushes is mechanical and therefore requires
to be made between: neither a sensor nor a motor control.
■ DC-Motors Speed and position control
■ Brushless DC-Motors For some applications, the DC-Motors are operated with-
■ Stepper Motors out a sensor and without a controller. In these cases, a
■ Linear DC-Servomotors
specific voltage is applied to the motors at which a specific
speed is produced when operated at a constant load.
Depending on the motor technology, the sensor is neces-
sary not only for speed or position control, but also for the A controller is necessary in order to regulate the speed.
commutation of the motors. Simple speed control is possible by measuring the back
electromotive force (EMF). For precise speed control, an
encoder is necessary. For position control, an encoder is
Commutation Speed control Position control absolutely required.
For DC-Motors, a large selection of incremental encoders is
DC-Motors
available.
Sensors ■ encoders ■ encoders
Without mechanical back-EMF
sensors
■ ■
Brushless DC-Motors
Brushless DC-Motors
Commutation
Sensors Block commuta- ■ integrated ■ integrated The Brushless DC-Motors are electronically commutated.
tion: digital Hall analog Hall
■ integrated sensors sensor For their operation, a controller is therefore always neces-
digital Hall ■ integrated ■ encoders sary.
sensors analog Hall
sensors Most of the FAULHABER Brushless DC-Motors are
Sinus commuta-
tion: ■ encoders equipped with three digital, integrated Hall sensors that
■ integrated determine the position of the motor shaft and supply a
analog Hall commutation signal.
sensors
■ encoders The exception here are motors for simple speed applica-
tions, which can be commutated with the help of the back
Without Block commuta- ■ back-EMF
sensors tion: electromotive force (EMF). Here, the controller evaluates
■ back-EMF the zero crossing of the back-EMF and then commutates
Stepper Motors the motor after a speed-dependent delay. The zero cross-
Sensors ■ encoders ■ encoders ing of the back-EMF cannot be evaluated while the motor
Without ■ stepper mode ■ stepper mode ■ stepper mode is at a standstill and, thus, the position of the rotor cannot
sensors be detected. When starting, it is therefore possible that
the motor first moves in the wrong direction.
If digital Hall sensors are selected or in sensorless oper-
Sensors ■ integrated ■ integrated
analog Hall analog Hall ation with back-EMF, the Brushless DC-Motors are block
sensors sensors commutated. With block commutation, the voltage
characteristics of the three 120° offset windings are block
shaped. The windings are abruptly switched every 60°. The
FAULHABER Speed Controllers use this commutation form.
134
For position control, encoders or integrated Hall sensors
+ are needed. Almost all FAULHABER Brushless DC-Motors
UA 0 Angle are offered with integrated analog Hall sensors as an
– option. For most applications, operation with the analog
0° 60° 120° 180° 240° 300° 360°
Hall sensors is recommended. Encoders are needed if the
+ application requires a higher resolution or accuracy or if
UB 0 Angle the motor is operated at very low speeds.
– For the Brushless DC-Motors, a large selection of incremen-
0° 60° 120° 180° 240° 300° 360°
tal and absolute encoders is available.
+
UC 0 Angle Stepper Motors

–
0° 60° 120° 180° 240° 300° 360° The control of stepper motors in full step, half step and
micro step operation enables exact speed and position
A better running smoothness with a lower torque ripple is control in an open control loop. As a result, sensors are
achieved through sinus commutation. not generally needed in the application – a decisive cost
With sinus commutation, the phase voltages have advantage of stepper motors. A closed control loop is,
a sinusoidal characteristic. The FAULHABER Motion however, often required during development for verifying
Controllers use this commutation form as standard. For the function or for minimizing power consumption and
sinus commutation, analog Hall sensors or encoders are motor heating. The FAULHABER product range includes
required. magnetic (IE3) and optical encoders (PE22) compatible
with the stepper motor series. Other combinations of step-
per motors with encoders are possible on request.
+
UA 0 Angle
–
0° 60° 120° 180° 240° 300° 360°
The linear DC-Servomotors are equipped with analog Hall
+ sensors. By integrating sensors in the motor, this solution is
UB 0 Angle very compact, lightweight and economical. As a result, an
– additional encoder is not necessary.
0° 60° 120° 180° 240° 300° 360°
UC 0 Angle
–
0° 60° 120° 180° 240° 300° 360°
Speed and position control

For speed control, digital Hall sensors are generally used.
The back electromotive force is only suitable for simple
speed control at higher speeds. Analog Hall sensors or an
encoder are necessary if the drive system is operated at
low speeds or a very high running smoothness is required.
135
Encoders
Optical Encoders
1 3
Optical Encoder 6
1 Cover
2 Encoder circuit board
with LED and photo sensor
7
3 Adapter flange
4 Housing
5 Code disc
6 Hub
7 Motor
Function Features and benefits

Encoders of the IER3-10000 (L) series consist of a high- ■ Very high resolution of up to 40 000 edges per revolution
(corresponds to a 0,009° angle resolution)
resolution code disc that is attached to the motor shaft,
■ Very high position accuracy, repeatability and high signal
a light source and a photo sensor with interpolator and
quality
driver stages. The light from the light source is reflected or
■ Various resolutions available as standard feature
absorbed by the code disc. The reflected light is collected
■ Insensitive to magnetic interference
by the photo sensor and the signal processed into a
high-resolution encoder signal. With this, two square wave
signals that are phase-shifted by 90 °e, as well as an index
signal to display output shaft rotation, are available at the
outputs. A Line Driver is also available as an option.
The high-precision optical encoders are ideally suited for

position control. Product code
IER encoder series

I E R 3 – 6800 L
3 3 channel
6800 lines per revolution
L with integrated Line Driver
136
Encoders
Magnetic Encoders
1
Magnetic Encoder 7
1 Screws
2 Cover
3 Encoder circuit board with chip
8
4 Adapter flange
5 Screws for intermediate flange
6 Intermediate flange
7 Sensor magnet
8 Motor

Encoders of the IE3-1024 (L) series consist of a diametric- ■ Compact modular system
and robust housing
ally magnetized, two-pole sensor magnet which is
■ Various resolutions available as standard feature
fastened to the motor shaft. A special angle sensor for
■ Index channel for referencing a rotation
detecting the motor shaft position is positioned in an
of the drive shaft
axial direction in relation to the sensor magnet. The
■ Also available as Line Driver version
angle sensor comprises all necessary functions, such as
■ Standardized electronic encoder interface
Hall sensors, an interpolator and driver stages. Analog
■ Flexible customer-specific modifications including custom
signals of the sensor magnets are detected by the Hall resolution, direction of rotation, index pulse width and
sensors and, after suitable amplification, passed along to index position are possible
the interpolator. By means of a special processing algo-
rithm, the interpolator generates the high-resolution
encoder signal. Product code
With this, two square wave signals that are phase-shifted
by 90 °e, as well as an index signal to display output shaft
rotation are available at the outputs.
IE encoder series
IE3 – 1024 L
3 3 channel
L with integrated Line Driver
137
Encoders
Integrated Magnetic Encoders
4
3
Integrated Magnetic
Encoder 1
1 Motor
2 Magnet wheel
3 Brushes
4 Brush cover
5 Sensor electronics
6 Flat cable
7 Cover

The encoders of the IEH2-4096 and IEH3-4096 series consist ■ Extremely compact
of a multi-part magnetic ring, which is attached to the ■ High resolution of up to 16 384 edges per revolution
(corresponds to a 0,022° angle resolution)
rotor, and an angle sensor. The angle sensor comprises all
■ No pull-up resistors are necessary at the outputs because
necessary functions, such as Hall sensors, an interpolator
there are no open collector outputs
and driver stages. Analog signals of the sensor magnets
■ Symmetric switching edges, CMOS and TTL-compatible
are detected by the Hall sensors and, after suitable ampli-
■ Different resolutions, according to encoder type,
fication, passed along to the interpolator. from 16 to 4 096 lines, are available for standard delivery
By means of a special processing algorithm, the interpo- ■ High signal quality
lator generates the high-resolution encoder signal. With
this, two square wave signals that are phase-shifted by
90 °e, with up to 4 096 lines per revolution, as well as one
additional index signal are available at the outputs. Product code
The encoder is integrated in the motors of the SR series
and lengthens these by just 1,4 mm.
IEH encoder series

I E H 2 – 4096
2 2 channel
138
Encoders
Absolute Encoders 1
8
Absolute Encoder
1 Cover with encoder PCB

2 Sensor magnet
3 Encoder flange
4 Flat cable 10
5 Ball bearing
6 Magnet
7 Shaft 4
8 Winding
9 Ball bearing
10 Housing with stator laminations

Encoders of the AESM-4096 series consist of a diametrically ■ Minimal wiring requirement
magnetized, two-pole sensor magnet which is fastened to ■ Absolute angle information directly after power-on
the motor shaft. A special angle sensor for detecting the ■ No referencing necessary
motor shaft position is positioned in an axial direction in ■ Enhanced control characteristics even at low rotational
speeds
relation to the sensor magnet. The angle sensor comprises
all necessary functions, such as Hall sensors, an inter- ■ Flexible customisation of resolution and direction of
rotation is possible
polator and driver stages. The analog signal of the sensor
magnet detected by the Hall sensors is processed, after
appropriate amplification, by a special algorithm to pro-
duce a high-resolution encoder signal. At the output there
is absolute angle information available with a resolution
of 4 096 steps per revolution. This data can be queried by Product code
a SSI Interface with BISS-C Protocol. The absolute encoder
is ideal for commutation, speed control and position con-
trol.
AESM encoder series

A E S M – 4096
4096 steps per revolution
139
Drive Electronics
WE CREATE MOTION
Speed Controller
Connection variants
Speed Controller Page
DC-Micromotor with encoder and
SC 1801 P for DC and Brushless Motors
programming adapter1 (optional)
A 544 – 545
SC 1801 F for DC and Brushless Motors 1A 546 – 547
SC 1801 S for DC and Brushless Motors 1A 548 – 549
SC 2402 P for DC and Brushless Motors 2A 550 – 551
To customer
SC 2804 S
application for DC and Brushless Motors 4A 552 – 553
SC 5004 P for DC and Brushless Motors 4A 554 – 555
Speed Brushless DC-Servomotor with digital
SC 5008 S forController
DC and Brushless Motors 8A 556 – 557
or analog Hall sensors
Motion Controller Page

MCDC 3002 P for DC-Micromotors 2A 564 – 565
MCDC 3002 S for DC-Micromotors 2A 566 – 567
MCDC 3003 P for DC-Micromotors 3 A without Hall
Brushless DC-Servomotor 568 – 569
sensors
MCDC 3006 S for DC-Micromotors (sensorless operation)6 A 570 – 571
MCBLUSB
3002 P for Brushless DC-Motors 2A 572 – 573
interface
MCBL 3002 F for Brushless DC-Motors 2A 574 – 575
MCBL 3002 S for Brushless DC-Motors 2A 576 – 577
MCBL 3003 P for Brushless DC-Motors 3A 578 – 579
MCBL 3006 S for Brushless DC-Motors Brushless DC-Servomotor 6 A with 580 – 581
absolute encoder (AES)
MCBL 3002 P AES for Brushless DC-Motors with AES 2A 582 – 583
MCBL 3002 F AES for Brushless DC-Motors with AES 2A 584 – 585
MCBL 3002 S AES for Brushless DC-Motors with AES 2A 586 – 587
MCBL 3003 P AES for Brushless DC-Motors with AES 3A 588 – 589
MCBL 3006 S AES for Brushless DC-Motors with AES 6A 590 – 591
MCLM 3002 P for Linear DC-Servomotors 2A 592 – 593
MCLM 3002 F for Linear DC-Servomotors 2A 594 – 595
General Information MCLM 3002 S The
for different
Linear sizes as well as the flexible
DC-Servomotors 2 A connection596possi-
– 597
MCLM 3003 P bilities
for Linear open a wide range of applications
DC-Servomotors 3 A in areas 598
such as
– 599
MCLM dynamic
FAULHABER Speed Controllers are highly 3006 S speed laboratory
for technology and equipment6 Amanufacturing,
Linear DC-Servomotors auto-
600 – 601
controllers for controlling: MC 5004 P mation
for technology,
DC, Brushless and Linearpick-and-place
Motors machines
4A and machine
608 – 609
MC 5004 P STO for Brushless
tools, and Linear Motors
or pumps. 4A 610 – 611
■ DC-Motors with and without incremental
MC 5005 Sencoder for DC, Brushless and Linear Motors 5A 612 – 613
MC sensors
■ BL motors with analog or digital Hall 5010 S for DC, Brushless and Linear Motors 10 A 614 – 615
MCST 3601 for Stepper Motors 1A 620 – 621
■ BL motors with AES absolute encoder
■ BL motors with digital Hall sensors and
incremental encoders
Depending on the size and delivery state, different motor Product code
and sensor combinations can be operated on the Speed
Controller.
DC sensorless
DC + encoder
BL sensorless
BL + D-Hall
BL + A-Hall
Controller
BL + AES
SC 1801 • • • • (2) (2)

SC 2402/2804 • • • • (1) (2) (2)
SC 5004/5008 - • - • (1) (2) (2) SC Speed Controller SC 28 04 S 3530
28 Max. supply voltage (28V)
04 Max. continuous output current (4A)
1) Optionally also available with additional incremental encoder input S Housing with screw terminal
2) Optionally available 3530 Operating mode (brushless motor with
digital Hall sensors)
141
Speed Controller
Connection
General variants
Information
programming adapter (optional)
FAULHABER Speed Controllers can be adapted to the
application via the FAULHABER Motion Manager software.
The type and scaling of the setpoint input, the operating
To customer
mode and the control parameters can be adjusted.
application
The
USB programming adapter for Speed Controllers is used for
Speed Controller Brushless DC-Servomotor with digital
configuration.
or analog Hall sensors
Speed Controllers are available with or without housing.
The variants with housing are connected via screw termi-
nals; the unhoused circuit-board variants can be directly
plugged into a master board. Brushless DC-Servomotor without Hall sensors
(sensorless operation)
USB
Interfaces – discrete I/O interface
■ Analog input as set value input for setting the speed via
PWM or analog voltage value
■ Digital input as switching input for defining the direc-
tion of rotation of the motor
■ Digital output, can be programmed either as frequency
output or as error output
Note
Device manuals for installation and start-up, as well as the The different sizes as well as the flexible connection possi-
General Information
FAULHABER Motion Manager software, are available on bilities open a wide range of applications in areas such as
request or on the Internet under www.faulhaber.com. Not laboratory technology and equipment manufacturing, auto-
FAULHABER Speed Controllers are highly dynamic speed
all Speed Controllers are suitable for all operating modes. mation technology, pick-and-place machines and machine
controllers for controlling:
Detailed information on the individual operating modes tools, or pumps.
■ DC-Motors
can be found with
in theand withoutdata
respective incremental
sheets asencoder
well as in the
technical manual.
■ BL motors with analog or digital Hall sensors
■ BL motors with AES absolute encoder
Benefits
■ BL motors with digital Hall sensors and
Compact design
■ incremental encoders
■ Scalable in current and voltage
Depending on the size and delivery state, different motor Product code
■ Simple
and sensorwiring
combinations can be operated on the Speed
■ Adapted versions for connecting different motors
Controller.
■ Integrated current limiting (motor protection)
DC sensorless
■ Controller setting can be configured in combination

DC + encoder
BL sensorless
BL + D-Hall
BL + A-Hall
with Motion Manager via programming adapters

Controller
BL + AES
■ Extensive range of supported DC-micromotors and

brushless DC-servomotors
SC 1801 • • • • (2) (2)

SC 2402/2804 • • • • (1) (2) (2)
SC 5004/5008 - • - • (1) (2) (2) SC Speed Controller SC 28 04 S 3530
1) Optionally also available with additional incremental encoder input S Housing with screw terminal
2) Optionally available 3530 Operating mode (brushless motor with
digital Hall sensors)
142
Speed Controller
Description & Operating Modes
Operating modes DC-Motors without encoder

In the "sensorless DC motors" configuration, the motors
The speed is controlled via a PI controller with variable are operated with speed control whereby, depending on
parameters. the load condition, either the back electromotive force
(EMF) or IxR compensation is used for speed actual value
Depending on the version, the speed is determined via the
acquisition.
connected sensor system or sensorless from the motor
Matching to the respective motor type is required for this
current. operating mode.
Setpoint specification can be performed using an analog A number of other parameters can also be changed using
value or a PWM signal. The direction of rotation is changed the "FAULHABER Motion Manager" software:
via a separate switching input; the speed signal can be read
out via the frequency output. ■ Controller parameters
■ Output current limiting
The motors can optionally be operated as a voltage control-
ler or in fixed speed mode. ■ Fixed speed
BL motors with digital or analog Hall sensors ■ Encoder resolution

In the "BL motors with Hall sensors" configuration, the ■ Speed setpoint specification via analog or PWM signal
motors are operated with speed control, whereby the
■ Maximum speed or maximum speed range
signals from the Hall sensors are used for commutation and
determination of the actual speed.
BL motors without Hall sensors (sensorless mode)
No Hall sensors are used in this configuration; instead, the Protective functions
back-EMF of the motor is used for commutation and speed
FAULHABER Speed Controllers determine the temperature
control.
of the motor winding from the motor load characteristic.
BL motors with absolute encoder Dynamically, a peak current which is typically 2 times
This mode can only be selected in combination with the larger than the continuous current is available as a result;
appropriate hardware. with a continuously higher load, the current is limited to
In this configuration, the encoder outputs an absolute the set continuous current.
position. This is used for commutation as well as for speed
control. Owing to the high resolution of the encoder, it is In the case of frequent reversing operation with large
possible to achieve low speeds in this mode. connected masses, it is recommended to use a Motion Con-
troller.
BL motors with digital Hall sensors and
brake/enable input
In this configuration, the motors are operated with speed Special functions
control. The additional brake and enable inputs enable
For special applications, special functions such as ramps,
easier connection of the control to e.g. PLCs or safety
switchable fixed speeds or more complex processes can be
circuits.
implemented ex works depending on the additional
BL motors with digital Hall sensors and encoder inputs. This allows FAULHABER Speed Controllers to be
In this configuration, the Hall sensors output the informa- optimally adapted to the requirements of the specific
tion for commutation. The speed is controlled according to application.
the signal from the incremental encoder.
For this reason, it is also possible to achieve extremely low
speeds with a high-resolution encoder.
DC-Motors with encoder
In the "DC motors with encoder" configuration, the
motors are operated with speed control. An incremental
encoder is required as a speed actual value encoder.
143
Speed Controller
Description & Operating Modes
Max. peak output current Imax. [A]

Describes the current that the controller can reach in S2
operation (cold start without additional cooling) at nomi-
Speed Controllers nal conditions under constant load for the time specified
2-Quadrant PWM configurable via PC in the data sheet without exceeding the thermal limit.
Unless otherwise defined, the value that applies for the
peak current is equal to two times the continuous current.
SC 1801 P Standby current for the electronics Iel [A]

Values at 22°C
SC 1801 P
4 ... 18
Describes the additional current consumption of the con-
Power supply motor Umot 1,8 ... 18 trol electronics.
PWM switching frequency 1) fPWM 96
Efficiency electronic K 95
Shows the minimum and maximum operating temperature
Notes on technical data sheet under nominal conditions.
The following data sheet values of the Speed Controllers Housing material
are measured or calculated at an ambient temperature of Housing materials and, if necessary, surface treatment.
22°C.
Mass [g]
Speed Controllers generally feature separate supply inputs The typical mass of the standard controller may vary due
for motor and electronics with the same ground con- to the different components.
nection; if necessary, these inputs can also be used as a
common supply. Note
Power supply for electronics Up [V DC] Speed range
Describes the range of the permissible supply voltage for The speed that can be reached in combination with a
the control electronics. motor depends on the available voltage, the respective
motor type and the maximum processing speed of the
Power supply for motor Umot [V DC]
selected speed controller.
Describes the range of the permissible supply voltage of
the connected motor. The maximum speed range refers to motors with one pole
pair. On motors with a larger number of pole pairs, the
PWM switching frequency ƒPWM [kHz] speed range decreases accordingly.
Pulse width modulation describes the change of the elec-
trical voltage between two values. The motors connected Maximum speed with number of pole pairs 1
to the SCs have a low electrical time constant. To keep the Maximum
=
losses associated with PWM low, a high switching fre- speed Number of pole pairs of
quency is necessary. the connected motor
Electronics efficiency η [%]

Ratio between consumed and delivered power of the
Max. continuous output current Icont [A]

Describes the current that the controller can continuously
deliver to the connected motor at 22°C ambient tempera-
ture without additional cooling.
20190716_EPIM-Vorlage_Steuerungen_dff.indd 1 24.01.20 15:11

144
Motion Controllers
Feature Comparison
■ Numerous configuration options

General Information
■ Successfully used in medical and laboratory technology,
FAULHABER Motion Controllers are highly dynamic equipment manufacturing, automation, medical tech-
positioning systems, available in housed and unhoused nology and aerospace
variants and control DC, LM or BL motors. The Motion ■ Also available in very small sizes
Controllers are configured here via the FAULHABER
Motion Manager. Generation V3.0
The drives can be operated in the network via the A new generation of controllers for applications that go
CANopen or EtherCAT fieldbus interface (only MC V3.0). beyond the features and performance offered by the V2.5
In smaller setups, networking can also be performed via controller series.
the RS232 interface. The Motion Controllers operate in the ■ More power, faster control, new operating modes
network in principle as a slave; master functionality for ■ One controller for all motor types and encoder systems
actuating other axes is not provided. ■ Flexible use of the I/Os for setpoints and actual values
After basic commissioning via Motion Manager, the ■ Additional I/Os and interfaces
controllers can alternatively also be operated without
■ Sequential programs can be programmed in BASIC for
communication interface.
simple, local automation in all interface technologies
Generation V2.5 ■ Expanded diagnostic functions
■ Proven technology for BL, DC and LM motors
■ Simple start-up via Motion Manager beginning with
■ Very simple configuration and start-up version 6.0
Generation V2.5 Generation V3.0

MCxx 3002 MCxx 3003/06 MC 5004 MC 5005/10
Voltage ranges ■ Motor: max. 30V ■ Motor: max. 50V
■ Electronics: max. 30V, optionally separated ■ Electronics: max. 50V, separated standard
Continuous current 2A 3 / 6A 4A 5 / 10A

Peak current 3A 10A 12A 15 / 30A
Motor types ■ MCDC: DC + Encoder ■ DC motors with pos. / speed sensor
■ MCBL: BL + A-Hall ■ BL motors with pos. / speed sensor
■ MCLM: LM + A-Hall
■ MCBL AES: BL + AES Encoder ■ LM motors with pos. / speed sensor
Speed and see motor types ■ DC motors: incremental1), AES Encoder1), SSI encoder1),
position sensors analog value (potentiometer/tachometer)
■ BL/LM motors: D-Hall, D-Hall + Encoder1), A-Hall, AES
encoder1), SSI encoder1), analog value (potentiometer/
tachometer)
Inputs/outputs MCDC: MCBL/MCLM: DigIn: 8 DigIn: 3
DigIn: max. 5 DigIn: max. 3 DigOut: 3 DigOut: 2
DigOut: max. 1 DigOut: max. 1 AnIn ±10V: 2 AnIn ±10V: 2
AnIn ±10V: 1 AnIn ±10V: 1
Optional connection of a second reference encoder Optional connection of a second reference encoder
(Gearing mode). Not all I/Os available depending on (Gearing mode).
wiring.
Communication RS232 or CANopen USB, RS232 and/or CANopen, EtherCAT
Controller Position, speed, current limiting Position, speed, current / torque
with and without Line driver
Operating ■ Depending on the interface variant, position, ■ Profile Position mode (PP) and Profile Velocity
modes speed and current control with setpoint input mode (PV), taking into account profile settings
via the interface or analog (RS) ■ Cyclic Synchronous Position, speed
or torque (CSP, CSV or CST)
■ Analog input for position, speed, torque or
voltage (APC, AVC, ATC, volt)
Profile operation Linear trapezoidal profiles in all operating modes Linear or sin² speed in PP and PV modes
Autonomous processes Available in the versions with RS232 interface Up to eight sequential programs in all versions,
with optional password protection
1)
145
Motion Controllers
Connection variants
programming adapter (optional)
Brushless DC-Servomotor
with analog Hall sensors
Motion Controller
Linear DC-Servomotor
CANopen with analog Hall sensors
USB
RS232

Features Benefits
FAULHABER Motion Controllers of generation V2.5 are ■ Compact design
highly dynamic positioning systems for controlling
■ Can be controlled either via RS232
different motors and sensor systems:
or CAN interface
■ MCDC 300x: DC-Motors with incremental encoder ■ Minimal wiring requirements
■ MCBL 300x: BL-motors with analog Hall signals ■ Configurable using the “FAULHABER Motion
■ MCLM 300x: LM-motors with analog Hall signals
Manager” software and USB interface
■ Extensive range of accessories
■ MCBL 300x AES: BL-motors with absolute encoder
■ Simple start-up
In addition to use as a servo drive with controlled posi-
tion, the speed can also be controlled. Via the integrated
Product code
current control, the torque is limited and the electronics or
the connected motor protected against overload.
Motion Controllers of generation V2.5 are available in var-

ious sizes and performance classes as well as with RS232 or
with CAN interface and, as a result, can also be integrated
in networks. In addition to operation on a PC, the systems
can also be operated on all common industrial controls.
The Motion Controllers are available with or without hous-

ing. The variants with housing are connected via screw ter-
MC Motion Controller MC BL 30 06 S CO
minals; the unhoused circuit-board variants can be directly BL For Brushless DC-Motors
plugged into a master board. 30 Max. supply voltage (30 V)
06 Max. continuous output current (6 A)
S Housing with screw terminal
CO CAN interface
146
Motion Controllers

Positioning operation Separate supply of power to the motor and electronic
The drive moves to the preset target position and, in doing actuator is optional (important for safety-critical applica-
so, maintains the specified limits for speed and position. tions).
The dynamics of the control can be adapted to a wide Third input is not available with this option. Depending on
range of loads. Limit switches can be evaluated directly. the controller, additional programming adapters and
The position can be initialised via limit switches or a refer- connection aids are available. The modes and parameters
ence switch. can be specially pre-configured on request.
Speed control
Interfaces – discrete I/O
The drive controls the preset target speed via a PI speed
controller without lasting deviation. Setpoint input
Current control Depending on the operating mode, setpoints can be input
Protects the drive by limiting the motor current to the set via the command interface, via an analog voltage value, a
peak current. By means of integrated thermal models, the PWM signal or a quadrature signal.
current is limited to the continuous current if necessary. Error output (Open Collector)
Motion profiles Configured as error output (factory setting). Also usable
Acceleration and brake ramp as well as the maximum as digital input, free switch output, for speed control or
speed can be preset in speed and positioning operation. signaling an achieved position.
Autonomous operation Additional digital inputs

In version RS, freely programmable processes can be stored For evaluating reference switches.
without RS232 interface.
Interfaces – position encoder
Depending on the model, one of the listed interfaces
Protective features
for the position and speed sensor is supported.
■ Protection against ESD
■ Overload protection for electronics and motor Analog Hall signals
Three analog Hall signals, offset by 120°, in Brushless
■ Self-protection from overheating
DC-Motors and Linear DC-Servomotors.
■ Overvoltage protection in generator mode
Incremental encoder
Operating modes (RS version) In DC-Micromotors and as additional sensors for Brushless
■ Position control DC-Motors.
– with analog setpoint Absolute encoder
– gearing mode Serial SSI port, matching Brushless DC-Servomotors with
– stepper motor operation AES encoders.
■ Speed control
■ Torque control
Operating modes (CO version)

■ Homing mode
147
Motion Controllers
The CO version provides the CiA 402 standard operating

Networking
modes. All the parameters are directly stored in the object
FAULHABER Motion Controllers of generation V2.5 are
Positioning operation Separate
directory.supply of powercan
Configuration to therefore
the motorbe and electronicwith
performed
available
The drive in all two
moves networking
to the versions.
preset target position and, in doing actuator is optional
the help of (important
the FAULHABER for safety-critical
Motion Manager or by applica-
apply-
so, maintains the specified limits for speed and position. tions).
ing available standardized configuratons tools common to
RS – systems with RS232 interface
The dynamics of the control can be adapted to a wide Third input is notmarket.
the automation available with this option. Depending on
Ideal for equipment manufacturing and for all applications
range of loads. Limit switches can be evaluated directly. the controller, additional programming
The CO version is particularly suitable foradapters
users whoand
in which the controller is also to be used without a higher
The position can be initialised via limit switches or a refer- connection aids are available. The modes and
already use various CANopen devices or operate the parameters
level controller. Using Net mode, it is also possible to oper-
ence switch. can be specially
Motion pre-confi
Controllers gured
on a PLC. on dynamic
With request. PDO mapping
ate multiple RS controllers on an RS232 interface.
Speed control it is possible to achieve highly efficient networking on the
CO – CANopen acc. to CiA 402 Interfaces – discrete I/O
CAN.
The drive controls the preset target speed via a PI speed
The ideal variant for the operation of a FAULHABER
controller without lasting deviation. Setpoint input
Motion Controller on a PLC – directly via the CANopen
interface or via a gateway on, e.g., Profibus/ProfiNET or
Current control Depending on the operating mode, setpoints can be input
on EtherCAT.
Protects the drive by limiting the motor current to the set via the command interface, via an analog voltage value, a
peak current. By means of integrated thermal models, the PWM signal or a quadrature signal.
Interfaces
current – Bus
is limited Connection
to the continuous current if necessary. Error output (Open Collector)
Motion profi Configured as error output (factory setting). Also usable
Version with les
RS232
Acceleration and as digital input, free switch output, for speed control or
For coupling to a brake
PC withramp as wellrate
a transfer as the maximum
of up to signaling an achieved position.
speed can be preset in speed and positioning
115 kbaud. Multiple drives can be connected to operation.
a single
controller using the
Autonomous operation RS232 interface. As regards the control Additional digital inputs
computer, no special arrangements are necessary.
In version RS, freely programmable processes can be Thestored For evaluating reference switches.
interface also offers the possibility of retrieving online
operational
without RS232data and values.
interface.
Interfaces – position encoder
A comprehensive ASCII command set is available for Depending on the model, one of the listed interfaces
Protective features
programming and operation. This can be preset from the for the position and speed sensor is supported.
■ Protection
PC against ESD Motion Manager“ software or
using the “FAULHABER
■ Overload
from anotherprotection for electronics and motor
control computer. Analog Hall signals
Three analog Hall signals, offset by 120°, in Brushless
■ Self-protection
Additionally, therefrom
is theoverheating
possibility of creating complex
DC-Motors and Linear DC-Servomotors.
processes from these
■ Overvoltage commands
protection and storing
in generator modethem on the
drive. Once programmed as a speed or positioning Incremental encoder
Operating modes
controller via (RS version)
the analog input, as step motor or electronic In DC-Micromotors and as additional sensors for Brushless
Position control
gear unit, the drive can operate independently
■ DC-Motors.
of –the
with setpoint
RS232 input via the interface
interface.
– with analog setpoint Absolute encoder
Version withmode
– gearing CANopen CO Serial SSI port, matching Brushless DC-Servomotors with
A controller variantoperation
– stepper motor with CANopen interface is available to AES encoders.
allow optimal integration in a wide variety of different
■ Speed control
applications. CANopen is ideal for networking microdrives
because the interface can also be integrated in small
electronics modules. Its size and the efficient communica-
■ Torque
tion control
procedures mean that it is ideally suited for use in
industrial automation.
Operating modes (CO version)

■ Homing mode
148
Motion Controllers
Features CO
CO
NMT with node guarding •
Baud rate 1 Mbit max., LSS
EMCY object •
SYNCH object •
Server SDO 1x
PDOs 4 x Rx
4 x Tx
each with dynamic
mapping
PDO ID adjustable
Configuration Motion Manager from V5
Trace Any PDO
Standard operating •
modes
- Profile Position Mode
- Profile Velocity Mode
- Homing
The model supports the CANopen communication profile

acc. to CiA 301 V4.02. Transfer rate and node number are
set via the network in accordance with the LSS protocol as
defined in CiA 305 V1.11.
For this purpose, we recommend using the latest version
of the FAULHABER Motion Manager.
Note
communication and function manuals as well as the
“FAULHABER Motion Manager” software are available on
request or on the Internet under www.faulhaber.com.
149
Motion Controllers
Configuration, networking, interfaces

Motion Controllers nal conditions under constant load for the time specified
V2.5, 4-Quadrant PWM in the data sheet without exceeding the thermal limit.
with RS232 or CAN interface Depending on the size and version, the value is up to three
times higher for the ratio of peak current to continuous
current.
MCDC 3002 P
Values at 22°C
Power supply electronic
MCDC 3002 P
UB/UEL 8 ... 30
Standby current for the electronics Iel [A]
Power supply motor 1) --/UB 0 ... 30 Describes the additional current consumption of the con-
PWM switching frequency fPWM 78,12
Efficiency electronic K 95 trol electronics.

Notes on technical data sheet Shows the minimum and maximum operating temperature
under nominal conditions.
The following data sheet values of the Motion Controllers
of generation V2.5 are measured or calculated at an ambi- Housing material
ent temperature of 22°C. In their standard version, the Housing materials and, if necessary, surface treatment.
Motion Controllers do not have separate supply inputs
Mass [g]
for motor and electronics, but can optionally be equipped
The typical mass of the standard controller may vary
with these inputs (via 3rd input).
within the individual interface variants due to the differ-
Power supply for electronics UB /UEL [V DC] ent components.
Describes the range of the permissible supply voltage for
the control electronics. Note
Power supply for motor -- /UB [V DC] Speed range
Describes the range of the permissible supply voltage of The speed that can be reached in combination with a
the connected motor. motor depends on the available voltage, the respective
PWM switching frequency ƒPWM [kHz] selected motion controller.
Pulse width modulation describes the change of the
The maximum speed range refers to motors with one pole
electrical voltage between two values. The motors con-
pair. On motors with a larger number of pole pairs, the
nected to the MCs have a low electrical time constant. To
speed range decreases accordingly.
keep the losses associated with PWM low, a high switching
frequency is necessary.
Maximum speed with number of pole pairs 1
Maximum
Electronics efficiency η [%] =
speed Number of pole pairs of
Ratio between consumed and delivered power of the
the connected motor


150
Motion Controller

available in three sizes and three power classes:
■ MC 5004 – with a continuous current of up to 4 A, can be
plugged directly into a motherboard and offers most I/Os
■ MC 5005 – with a continuous current of up to 5 A, is the
ideal partner for most motors from the FAULHABER product
portfolio
■ MC 5010 – with a continuous current of up to 10 A, is also
suitable for applications with higher power requirements.
Especially well suited for use in combination with the highly
dynamic BL motors.
The possible applications are diverse: from laboratory auto-

mation to industrial equipment manufacturing, automation
technology and robotics to aerospace.
The connection to the motors is established via pre-

configured plugs or extension cables, which are available
for all supported motors as options or as accessories.
Features Benefits
■ One controller for all motor types and encoder types
highly dynamic, optimally tuned positioning controllers for ■ Very dynamic control
use in combination with DC-micromotors as well as BL and ■ Ideally matched to FAULHABER DC, BL and LM motors
LM DC-servomotors from FAULHABER’s line of motors. The ■ Various setpoint and actual value interfaces
motor type can be configured during commissioning using ■ Stand-alone operation possible in all variants
the FAULHABER Motion Manager from version 6.0.
■ Connection via simple plug concept
In addition to use as a servo drive with controlled position, ■ Fast feedback with status LEDs
the speed or current can also be controlled. The actual ■ Commissioning with the free FAULHABER Motion Manager
values for speed and position can be ascertained here using from version 6.0
a number of supported sensor systems. Limit switches and ■ Extensive mounting accessories available
reference switches can be directly connected.
The control setpoints can be preset via the communication Product code
interface, via the analogue input or a PWM input or can
come from internally stored sequential programs.
Supported as communication interfaces are – depending

on the device – USB and RS232, CANopen and, optionally,
EtherCAT. All functions of the drive are available here with-
out limitation via all interfaces.
MC Motion Controller MC 50 05 S RS
50 Max. supply voltage (50 V)
05 Max. continuous output current (5 A)
S Housing with plug-in connections
RS RS232 interface
151
Motion Controller
Networking Cyclic Synchronous

The drives Position in
can be operated (CSP)
the/network
Cyclic Synchronous
via the CAN-
Error handling Diagnosis Velocity
open or (CSV) / Cyclic
EtherCAT Synchronous
fieldbus Torque
interface. (CST)setups,
In smaller
RS – systems with RS232 interface For applications
networking can in which
also a higher-level
be performed controller
via the RS232 per-
inter-
Ideal for device construction and for all applications in forms
face. the path planning, even synchronised for multiple
Device control Motor control
which the Motion Controller is to be operated on an axes. The setpoints for position,
operatesspeed
in theand current
in are
Object dictionary
The Motion Controller network prin-

embedded controller. Using Net mode, it is also possible constantly updated. Typical update rates are in the
ciple as a slave; master functionality for actuating other range
to operate multiple RS controllers
+ on an RS232 interface. of a few
axes milliseconds.
is not provided. Cyclic modes are, thus, primarily
The transmission rate can lie between 9600 baud and suited for combination with EtherCAT. CANopen can also
– After basic commissioning via the Motion Manager, the
115 kbaud. be used.
CO – CANopen acc. to CiA 402 communication
Analogue interface.
Position Control (APC) / Analogue Velocity
The ideal variant for the operation of a FAULHABER Control (AVC) / Analogue
The controllers of the MCTorque Control
5004 series can(ATC)
be plugged into
Motion Controller on a PLC – directly
Hardware via the CANopen
driver For applications via
a motherboard in which the setpoints
the 50-pin connector of strip.
the control
For this
interface or via a gateway on, e.g., Profibus/ProfiNET or on are specifiFAULHABER
purpose, ed as an analogue
offers avalue or, e.g., viafor
motherboard a directly
connect-
EtherCAT. Dynamic PDO mapping as well as node guarding connected reference
ing up to four encoder. These operating modes are
controllers.
orOperating
heartbeat are supported. Refresh rates for setpoint and therefore particularly
modes The controllers of thewell suitedand
MC 5005 for MC
stand-alone opera-
5010 series are
actual values are typically from 10 ms here. tion without higher-level master.
secured to a flat base plate via the mounting holes. With
Motor control
ET – EtherCAT optionalmode
Voltage accessories,
(VOLT) mounting is also possible on a DIN
Current, speed and position of the drive can be controlled
Motion Controllercascade.
with direct EtherCAT interface. The rail.
In the voltage mode, only a current limiting controller is
via the controller By means of the optional pilot
controllers are addressed via CoE via the CiA 402 servo used.
paths, even the fastest movements can be reliably con- ModifiAll control
cations and loops are closed by a higher-level system.
accessories
drive profi
in ale. Ideal in combination with a high-perfor- The
trolled reproducible manner. Adjustable filters enable FAULHABER specialises via
setpoint can be set theadaptation
in the communication
of itssystem or
standard
mance industrial controller that
adaptation to a wide range of encoders also performs path
and loads. via an analogue input.
products for customer-specific applications. The follow-
planning and interpolation of the movement for multiple
ing standard
Interfaces optionsI/O
– discrete and accessory parts are available for
Motion profiles
axes. Refresh rates for setpoint and actual values from
FAULHABER
Three Motion
to eight digitalController
inputs for MC V3.0: limit and
connecting
Acceleration and brake ramp as well as the maximum
0.5 ms are supported.
speed can be preset in speed and positioning operation in reference switches
■ Connection or for connecting
cables a reference
the supply and encoder.
motor side
the Profile Position
Interfaces – BusMode (PP) and Profile Velocity Mode
Connection The logic levels are switchable.
■ Adapter sets for encoders
(PV) operating modes. Two analoguesets
■ Connector inputs (±10V) are available that can be
Configuration freely used as setpoint or actual value.
Autonomous operationof generation V3.0 are equipped
All Motion Controllers ■ Motherboard MC 5004
Up toaeight sequentialThis
programs written in BASIC Two to three digital outputs are available that can be
with USB interface. is intended primarily ascan
a be ■ Programming adapter
stored and executed directly freely used as error output, for direct actuation of a
configuration interface. Via aonUSBtheto
controller.
RS232 orOne USB of
to ■ Starter kits or as flexible diagnosis output.
these can be confi gured from holding brake
CAN converter, the drives can the autostart application.
alternatively likewise be
Access protection canrestriction.
be activated. ■ Customized special configuration
configured without Interfaces – position encoder
and firmware
All described
Protection andoperating
diagnostic modes and functions are avail-
functions FAULHABER Motion Controllers of generation V3.0
able independent of the used communication interface. support all sensor systems typically used on micro motors
FAULHABER Motion Controllers of generation V3.0 protect Functional safety
The interfaces
motors can also against
and electronics be usedoverload
in parallel, thereby
by means ofallow- for position and speed as well as analogue or digital Hall
ing a drive
thermal to beThe
models. integrated in an industrial
supply voltage interface
is monitored via
and can STO – Safe
signals, Torque Off
incremental encoders with and without Line Driver
the CANopen
also be used inor EtherCAT interface,
regenerative operation.while diagnostics
External devicesare The products
or protocol-basedof the MCor5004
AES P STO series have a function
SSI encoders.
evaluated
are therebywith the trace
protected function
against via the USB
overvoltage interface.
during dynamic which safely shuts down the torque via a certified inte-
operation. Options
grated safety circuit.
General Information Disconnection
All through
controllers can two redundant
optionally be equippedoptocoupler inputs
with an Ether-
Profile Position Mode (PP) / Profile Velocity Mode (PV) ensures operation up to safety integrity level SIL3 as
System
For description
applications in which only the target of the movement CAT interface.
defined by IEC 61800-5-2 and performance level PL e as
The
is products
specifi ed forofthe
the MC 5004,The
controller. MCacceleration
5005 and MC 5010
and brake For highly dynamic applications, the use of a braking
defined by EN ISO 13849-1. Signalling and visualisation is
series as
ramp arewell
variants of the FAULHABER
as a possible maximum speedMotion
are Controllers
taken into chopper can help to dissipate recovered energy.
via local LEDs as well as two separate outputs for status
with andvia
account without housing profi
the integrated and control eitherProfi
le generator. DC, le-based
LM or and error reporting.
BL motors. The
movements are,Motion Controllers
thus, suited are configured
for a combination withhere
stand-
The corresponding EC type examination is available for
via the
ard FAULHABER
networks, such asMotion
RS232 Manager.
or CANopen.
download at www.faulhaber.com.
152
Motion Controller
Networking The drives can be operated in the network via the CAN-
open or EtherCAT fieldbus interface. In smaller setups,
RS – systems with RS232 interface networking can also be performed via the RS232 inter-
Ideal for device construction and for all applications in face.
which the Motion Controller is to be operated on an The Motion Controller operates in the network in prin-
embedded controller. Using Net mode, it is also possible ciple as a slave; master functionality for actuating other
to operate multiple RS controllers on an RS232 interface. axes is not provided.
The transmission rate can lie between 9600 baud and
After basic commissioning via the Motion Manager, the
115 kbaud.
CO – CANopen acc. to CiA 402 communication interface.
The ideal variant for the operation of a FAULHABER The controllers of the MC 5004 series can be plugged into
Motion Controller on a PLC – directly via the CANopen a motherboard via the 50-pin connector strip. For this
interface or via a gateway on, e.g., Profibus/ProfiNET or on purpose, FAULHABER offers a motherboard for connect-
EtherCAT. Dynamic PDO mapping as well as node guarding ing up to four controllers.
or heartbeat are supported. Refresh rates for setpoint and
The controllers of the MC 5005 and MC 5010 series are
actual values are typically from 10 ms here.
secured to a flat base plate via the mounting holes. With
ET – EtherCAT optional accessories, mounting is also possible on a DIN
Motion Controller with direct EtherCAT interface. The rail.
controllers are addressed via CoE via the CiA 402 servo
Modifications and accessories
drive profile. Ideal in combination with a high-perfor-
FAULHABER specialises in the adaptation of its standard
mance industrial controller that also performs path
products for customer-specific applications. The follow-
planning and interpolation of the movement for multiple
ing standard options and accessory parts are available for
axes. Refresh rates for setpoint and actual values from
FAULHABER Motion Controller MC V3.0:
0.5 ms are supported.
■ Connection cables for the supply and motor side
Interfaces – Bus Connection ■ Adapter sets for encoders
■ Connector sets
Configuration
All Motion Controllers of generation V3.0 are equipped ■ Motherboard MC 5004
with a USB interface. This is intended primarily as a ■ Programming adapter
configuration interface. Via a USB to RS232 or USB to ■ Starter kits
CAN converter, the drives can alternatively likewise be
■ Customized special configuration
configured without restriction.
and firmware
All described operating modes and functions are avail-
able independent of the used communication interface. Functional safety
The interfaces can also be used in parallel, thereby allow-
ing a drive to be integrated in an industrial interface via STO – Safe Torque Off
the CANopen or EtherCAT interface, while diagnostics are The products of the MC 5004 P STO series have a function
evaluated with the trace function via the USB interface. which safely shuts down the torque via a certified inte-
grated safety circuit.
General Information Disconnection through two redundant optocoupler inputs
ensures operation up to safety integrity level SIL3 as
System description defined by IEC 61800-5-2 and performance level PL e as
The products of the MC 5004, MC 5005 and MC 5010 defined by EN ISO 13849-1. Signalling and visualisation is
series are variants of the FAULHABER Motion Controllers via local LEDs as well as two separate outputs for status
with and without housing and control either DC, LM or and error reporting.
BL motors. The Motion Controllers are configured here
The corresponding EC type examination is available for
via the FAULHABER Motion Manager.
download at www.faulhaber.com.
153
Motion Controller

Motion Controllers nal conditions under constant load for the time specified
V3.0, 4-Quadrant PWM in the data sheet without exceeding the thermal limit.
with RS232, CANopen or EtherCAT interface
Unless otherwise defined, the value that applies for the
peak current is equal to three times the continuous cur-
rent.
MC 5004 P
Values at 22°C MC 5004 P
Power supply electronic UP 12 ... 50 Standby current for the electronics Iel [A]
Power supply motor Umot 0 ... 50
PWM switching frequency fPWM 100
Describes the additional current consumption of the con-
Efficiency electronic K 95 trol electronics.
M ti t t t I 4

Explanatory Notes for Data Sheets Shows the minimum and maximum operating temperature
under nominal conditions.
The following data sheet values of the Motion Controllers
are measured or calculated at an ambient temperature of Mass [g]
22°C. The typical mass of the standard controller may vary
within the individual interface variants due to the differ-
Motion Controllers of generation V3.0 generally feature –
ent components.
with the same ground connection – separate supply inputs
for motor and electronics; if necessary, these inputs can
also be used as a common supply. Note
Speed range
Power supply for electronics Up [V DC]
The speed that can be reached in combination with a
Describes the range of the permissible supply voltage for
motor depends on the available voltage, the respective
the control electronics.
Power supply for motor Umot [V DC] selected motion controller.
Describes the range of the permissible supply voltage for The maximum speed range refers to motors with one pole
the motors connected to the MCs. pair. On motors with a larger number of pole pairs, the
PWM switching frequency ƒPWM [kHz] speed range decreases accordingly.
Pulse width modulation describes the change of the
electrical voltage between two values. Bell-type arma- Maximum speed with number of pole pairs 1
Maximum
ture motors have a low electrical time constant. To keep =
speed Number of pole pairs of
the losses associated with PWM low, a high switching the connected motor
frequency is necessary. In generation V3.0, this value
is fixed at 100 kHz. Through the type of pulse pattern
generation (centre aligned), the switching frequency Manuals/Software
effective at the motor is twice as high.
Electronics efficiency η [%] communication and function manuals as well as the
Ratio between consumed and delivered power of the “FAULHABER Motion Manager” software are available
control electronics. on request or on the Internet under www.faulhaber.com.


154
Motion Controller
Software
FAULHABER Motion Manager The software is characterised by the following features:

■ Start-up support wizards
The powerful 'FAULHABER Motion Manager' software is
available for commissioning and configuring drive systems ■ Access to connected devices via Node-Explorer
with motion and speed controllers. ■ Configuration of drive functions and controller
Motion Manager generally supports interfaces RS232, USB parameters using convenient, coordinated dialogues
and CANopen. Depending on the connected device, it may, for the respective device family
however, be necessary to use an interface adapter, e.g., ■ Context-sensitive online help
during the configuration of a Motion Control System via ■ Only for Motion Controllers:
USB.
– Graphical analysis tools for drive behaviours and
The graphical user interface makes uniform and intuitive controller setting
procedures possible independent of the device family and
– Macro function for execution of program sequences
interface used.
– Development environment for sequential pro-
grammes and Visual Basic Script programmes
Supported Motion Controllers Speed Controller
Interfaces Motion Control Speed Control New features in Motion Manager 6:
Systems Systems ■ Completely revised user interface with window docking
function
RS232 • •
■ Node-Explorer with integrated project management
USB • •
■ Support for the MC V3.0 family Motion Controller
CANopen •
– Controller configuration with route identification
– Expanded graphical analysis options
– Further tools for operation and controller tuning
155
Motion Controller
Software
“FAULHABER Motion Manager” for Microsoft Windows

can be downloaded from www.faulhaber.com free of
charge.
Commissioning and Configuration

FAULHABER Motion Manager can be used to easily access
settings and parameters of the connected controller.
Wizards assist during the commissioning of a controller.
Drive units detected on the selected interfaces are dis-
played in the device explorer.
The current interface and display settings can be saved in
project files.
Sequential programs for saving and execution can be cre-
ated, edited, transferred and executed on the devices. Pos-
sibilities for error detection and monitoring the program
flow are also available.
The operation of a controller and the execution of motion
tasks are performed via:
■ Graphical operating elements
■ Command entries
■ Macro functions
■ Programming of sequences via
Visual Basic Script (VBScript)
FAULHABER Motion Manager The software is characterised by the following features:
Control parameters such as setpoints and actual values can ■ Start-up support wizards
The powerful 'FAULHABER Motion Manager' software is
be recorded in Logger or Recorder mode via a graphical ■ Access to connected devices via Node-Explorer
available for commissioning and configuring drive systems
analysis function. Additional tools are available for the
with motion and speed controllers. ■ Configuration of drive functions and controller
creation and optimisation of control parameters.
Motion Manager generally supports interfaces RS232, USB parameters using convenient, coordinated dialogues
and CANopen. Depending on the connected device, it may, for the respective device family
however, be necessary to use an interface adapter, e.g., ■ Context-sensitive online help
during the configuration of a Motion Control System via ■ Only for Motion Controllers:
USB.
– Graphical analysis tools for drive behaviours and
The graphical user interface makes uniform and intuitive controller setting
procedures possible independent of the device family and
– Macro function for execution of program sequences
interface used.
– Development environment for sequential pro-
grammes and Visual Basic Script programmes
Supported Motion Controllers Speed Controller
Interfaces Motion Control Speed Control New features in Motion Manager 6:
Systems Systems ■ Completely revised user interface with window docking
function
RS232 • •
■ Node-Explorer with integrated project management
USB • •
■ Support for the MC V3.0 family Motion Controller
CANopen •
– Controller configuration with route identification
– Expanded graphical analysis options
– Further tools for operation and controller tuning
156
Stepper motors Motion Controller
Connection variants
Standard cable with

Molex connector
Flex PCB adapter
Motion Controller Wires plugged to the

connecting terminal
USB
Features Benefits
FAULHABER stepper motor motion controllers are highly ■ Fully programmable via software
dynamic positioning systems tailored specifically to the (Graphic User Interface)
requirements of micro stepper motor operations. ■ USB interface

■ 9V…36VDC / 50mA to 1.1A
In addition to be able to control the whole FAULHABER
■ Microstepping up to 1/256
stepper motor range, the controllers are capable of
■ 4 GPI and 7 GPO
managing three axes positioning (requires 2 additional
■ Can be used as step/direction driver only
boards). Reference search and encoder management
■ Reference input (for homing functions)
functions are part of the numerous features offered by the
■ Compatible with LabView
controllers.
■ Board size: 68mm x 47.5mm
A complete IDE is included, allowing the user to benefit
from the full range of functionalities, through a very com-
Product Code
prehensive and user friendly interface.
The integrated systems require less space, as well as

making installation much simpler thanks to their reduced
wiring.
MC Motion Controller
MC ST 36 01
ST Stepper Motor
157
Main characteristics Special functions

Motion controller Speed profiles
■ Motion profile calculation in real-time Motors movements are realized using user definable speed
■ On the fly alteration of motor parameters profiles. The latter can be setup using a complete param-
(e.g. position, velocity, acceleration) eter calculator interface, helping the user to find the most
suited speed values.
■ High performance microcontroller for overall system
control and serial communication protocol handling StallGuard™
Stall detection feature allows the controller to react in
Bipolar stepper motor driver
case of step losses, and can also be used to detect any
■ Up to 256 microsteps per full step
motor hard stop reach.
■ High-efficient operation, low power dissipation
■ Dynamic current control
CoolStep™
Current flowing to the motor is automatically adapted in
■ Integrated protection
case of load variation. This feature allows a reduced power
Software consumption of the whole system.
■ TMCL™: standalone operation or remote controlled
Homing
operation
Reference search process can be done automatically by
■ PC-based application development software TMCL™ – the controller on startup. The user can setup the way to
IDE available for free. perform the operation (direction, switches number, origin
location, etc.).
Operating modes
Interfaces
Standalone
A program is stored in the controller board memory, and ■ USB device interface (on-board mini-USB connector)
starts when the system is powered ON. The software is
■ 6x open drain outputs (24V compatible)
able to react with external stimulus, such as digital I/Os,
encoders, sensors, etc. Standard processor instructions list ■ REF_L / REF_R / HOME switch inputs (24V compatible
as well as complete list of motor positioning control func- with programmable pull-ups)
tions are available for the programmer. ■ 1x S/D input for the on-board driver (on-board motion
controller can be deactivated)
Direct mode
■ 2x step / direction output for two separate external
Using IDE “direct mode” functions, the user is able to send
drivers (in addition to the on-board)
instructions to the board one by one, through USB link.
Status information and position/speed values can be read ■ 1x encoder input for incremental a/b/n encoder
in real time by the user, thanks to dedicated GUI. ■ 3x general purpose digital inputs (24V compatible)
Remote software ■ 1x analog input (0 .. 10V)

The controller can be remotely controlled through USB Please note: Not all functions are available at the same
link, by any user developed software. Labview and C++ time as connector pins are shared.
libraries are available to be used with the controller.
Notes
Device manuals for installation and start up, communi-
cation and function manuals, and the “TMCL™ – IDE”
software are available on request and on the Internet at
www.faulhaber.com.
158
Software
TMCL™ – IDE Startup and configuration

The high-performance software solution “TMCL™ – IDE”
Drivers and libraries are automatically installed together
enables users to control and configure the stepper motors
with the TMCL™-IDE software. Connected controller
controller, through USB interface.
device is immediately detected and recognized by the soft-
“TMCL™ – IDE” software and lots of program ware. The graphical user interface can be used to read out,
examples can be downloaded free of charge from change and reload configurations. Individual commands or
www.faulhaber.com. complete parameter sets and program sequences can be
entered and transferred to controller.
Operation of drives is also supported by several wizards,
helping user to easily setup all the parameters.
Quickstart, hardware and firmware complete user manuals
are also available for the user and can be downloaded free
of charge from www.faulhaber.com. Please refer to the
Quickstart manual before first use.
159
More information
faulhaber.com
faulhaber.com/facebook
faulhaber.com/youtubeEN
faulhaber.com/linkedin
faulhaber.com/instagram
DFF_TI_06-2020_EN

En Technical Information PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

En Technical Information PDF

Uploaded by

Copyright:

Available Formats

Technical Information

All rights reserved, including translation rights. No part

This document has been prepared with care.

The respective current version of this document is avail-

Brushless DC-Motors Brushless DC-Servomotors 26 – 51

Motors with integrated Brushless DC-Motors with integrated Speed Controller 52 – 87

Stepper Motors Stepper Motors 90 – 99

Linear DC-Servomotors Linear DC-Servomotors 100 – 107

Precision Gearheads Precision Gearheads 108 – 121

Linear Components Lead Screws and Options 122 – 125

Encoders Encoders – 2 Channel 126 – 139

Drive Electronics Speed Controller 140 – 159

No-load speed no [min-1] ±12%

No-load current (typical) Io [A]

nominal voltage with ankMambient temperature of 22 °C. temperature

8 16 24 32 Operating point at nominal value

The bearings used for the DC-Micromotors.

Explanations on the performance diagram How to select a DC-Micromotor

P2 = 3 mNm · 5 500 min-1 · 2π = 1,73 W

Second, compare the physical dimensions (diameter and

Back-EMF constant kE [mV/min-1]

Describes the relation torque

torque M H, a gearhead or a larger frame size motor has to

1 operating temperature, as well as the maximum allowable

Calculation of the main parameters Calculation of the operating point at 20 V

inserting the values 3 mNm + 0,2 mNm

Estimating the lubrication,

resistance between the housing and the ambient air.

Speed constant kn [min /V] -1

1 End cap with encoder PCB

22 Motor diameter [mm]

Advantages of this series at a glance

Motor diameter 8 ... 22 mm

15 Motor diameter [mm]

Advantages of this series at a glance

Powerful rare-earth magnets Low torque ripple and high efficiency

26 Motor diameter [mm]

Advantages of this series at a glance

Highly dynamic performance Wide operating temperature range:

32 Motor diameter [mm]

Advantages of this series at a glance

Best dynamic performance due Extremely wide operating temperature range

15 Motor diameter [mm]

Advantages of this series at a glance

Extremely ﬂat design. Integrated spur gearheads of minimal length

For highly dynamic servo applications requiring very high

As an option, most FAULHABER Brushless DC-Servomotors Modiﬁ

possibilities for customer application of DC-Motors where

ratio and peak

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

Current constant kI [A/mNm] For highly dynamic

long operational lifetimes. Hall sensors

operation. They are available in high speed (BHS) and high

Unspeciﬁed mechanical tolerances: Autoclavable

Air removal Heating Holding time Exhaust Drying

The above mentioned sterilization cycle does not include

For highly dynamic servo applications requiring very high

Continuous operation (R -50%)

progressive, self-supporting, skew-wound rotor winding is suited

example, in S2 operation and/or if more cooling is applied.

Nominal voltage curve UN [V]

n [min-1] Plastic flange

Example: Performance diagram for rated values with