CNC S4000DDH

CNC for Linear and Torque Motors

TECHNICAL SPECIFICATIONS
 Supplement to the Technical Specifications of S4000 CNCs

S4000 DIRECT DRIVE

INTRODUCTION
DIRECT DRIVE
This term classifies motors that have a direct coupling with the load to be moved: linear motors for straight
movements and torque motors for rotary movements.

In modern CNC milling machines the search for ever better quality and machining speed clashes with the
limits of conventional drive parts made with ball re-circulation screws, belts, racks and pinions. These
components are afflicted with problems of clearances, friction, inertia, thermal expansion, elastic strain and
they absorb much of the engine’s power.

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The main movements to be obtained in a milling machine are linear movements. Linear motors are electric
drives which feature the direct development of motion in this form without the need for kinematic conversion
mechanisms. Indeed, the reduction or even elimination of the kinematic chain makes it possible to achieve
repeatability and positioning accuracy that were unconceivable with conventional methods, allowing higher
performance while preserving total operating flexibility and, eliminating all wear phenomena, excellent levels
of reliability and constant performance rates can be attained. They also feature the possibility of achieving
laws of motion with high accelerations and speeds, which makes them unique in applications with extreme
dynamics.

Conceptually, linear motors are obtained by unrolling a

synchronous motor with permanent magnets on a plane, thereby
obtaining a cursor with windings that runs along a bed of
magnets. The forces induced by the sinusoidal current applied to
the windings, which formerly developed torque, now generates
the thrust directly along the axis of motion. Position and speed
are detected by a single measuring system with high resolution
optical rule which is also available for reading the absolute
position. In order to allow accurate speed adjustment also in the
presence of slow transfer movements, besides high resolution of
the measuring system, fine signal interpolation is necessary, for
example 16 µm in 1024 parts.
Also the Numerical control and the Drives are heavily enhanced
to exploit the potential of this family of motors. For example, the
calculation times of the control loops must be reduced through
the use of more powerful CPUs, and to reach the high gains
possible, the control software makes heavy use of digital filters.

Torque motors are synchronous motors with permanent

magnets on the rotor supplied with sinusoidal current and are
distinguished from the more common motors for digital axes
by the high number of poles. For this reason, they have a
higher torque and lower speed. Combination with a position
and speed feedback obtained with a high resolution encoder
allows the drive to achieve very regular speed control even at
very low speed rates.

Despite the many advantages, the spreading of direct transmission, linear motors and torque motor is
hindered by precise factors; for example they are still unable to generate the force rates typical of
conventional kinematic mechanisms, they call for the introduction of systems for cooling the heat generated,
and also, in the case of vertical axes, it is objectively complicated to implement brake systems or static
balancing systems. In addition to these purely technical reasons, the main reasons they are not very
widespread remain a lack of knowledge of their true potential and their price, which is still objectively high. In
addition to the costs of the materials used, considering for example permanent magnets and their machining
process, this is attributable to the fact that the still restricted market does not allow scale economies and
effective levels of competition. It should however be noted how the simplicity in design and development of a
system based on linear motors can involve a total cost wholly comparable with that of a conventional system,
calculating the design, assembly and installation costs.

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CHARACTERISTICS

S4000DDH CNC Series

In order to respond to the specific control needs of linear and torque motors, Selca has created a new
S4000DD (Direct Drive) CPU for the S4000 series. This implements a new DCB6 or DCB10 axis and spindle
control board (6 or 10 axis Direct Control Board) designed by the group leader Dr. Johannes Heidenhain.
This board has specially designed electronics for the treatment of digital signals (DSP Digital Signal
Processing) which makes it possible to control the axes 10000 times a second, from 20 to 50 times the
current standards.

The new CNC range is available in four versions, which differ in calculating power and number of axes.

These are:
- S4060DDH6 with 40MHz Motorola 68040 CPU Master up to a maximum of 6 axes/spindle
- S4060DDH10 with 40MHz Motorola 68040 CPU Master up to a maximum of 10 axes/spindle
- S4045PDDH6 with 25MHz Motorola 68040 CPU Master up to a maximum of 6 axes/spindle
- S4045PDDH10 with 25MHz Motorola 68040 CPU Master up to a maximum of 10 axes/spindle

The Motorola 68040 Master CPU designed for this series, besides the optic fiber connection for the RIO
modules, implements on-board drive interface (MCB-INT), PROBE and BERO interfaces and the connection
for communicating with the Video Unit (PCREM) via fiber optics.
Optical line inputs are on the DCB control board, so the MODENC board is seldom a necessary option.

Consequently, the CPU rack is smaller in size than the previous models and contains the following
components:
- 40MHz (S4060DDH) or 25 MHz (S4045PDDH) Motorola 68040 Master board
- I/OMIX-A Board
- I/OD-A Board (S4060DDH version only)
- Power Supply

The DCB6 or DCB10 axis and spindle drive control board (6 or 10 axis Direct Control Board) is arranged on
the left-hand side of the CPU by the side of the HEIDENHAIN modular or compact inverters connected by
means of flat wires.
Linear and torque motors require double calculation speed with respect to traditional motors. The control
boards have some single speed channels and some double speed. The maximum limit is 4 linear motors with
DCB6 and 6 linear motors with DCB10.

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S4000DDH CNC TECHNICAL SPECIFICATIONS CSTDD405010E
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CONTROLLER UNIT (DCB6 and DCB10)

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COMMON CHARACTERISTICS

Max spindle speed 40000 rpm (with two pole pair per motors)

60000 . [ rpm ]
Max feed axes . PassoVite [ mm ]
CoppiePoli Motore

Sampling position 200 µs (100 µs double speed)

Sampling time 200 µs (100 µs double speed)

Current loop control fPWM [Hz] TINT [µs]

3333 150
4000 125
5000 100
6666 150 (75 double speed)
8000 125 (60 double speed)
5000 100 (50 double speed)

Housing environment temperature 0 °C to 45 °C (32 °F to 113 °F)

Storage temperature –35 °C to 65 °C (-31 °F to 149 °F)

MCB6-6 (ASSI MAX) MCB10 (10 ASSI MAX)

Basic version 4 axes 7 axes

Encoder input 6 x 1 VPP or ENDAT® 10 x 1 VPP or ENDAT®

Max N. linear motor or

4 8
torque motor

Options 1° additional axis ASSE-H 1° additional axis ASSE-H

2° additional axis ASSE-H 2° additional axis ASSE-H
3° additional axis ASSE-H

Weight 5 kg about 6 kg about

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Main differences between S4xxDH and S4xxDDH

Function S4xxDDH (DCB..) S4xxDH(MCB..)

Controlled motor types Synchronous Motors, Asynchronous Synchronous and Asynchronous

motors, Linear motors, Torque motors
motors

Position transducers Optical line inputs are on drive Optical line inputs are on CNC
control board

Position loop sampling time Single-speed: 3 ms or 6 ms

200 µs
Double-speed:
200 µs (with position transducer +
motor)
100 µs (with motor transducer)

Speed loop sampling time Single-speed: 600 µs

200 µs

Double-speed:
100 µs

Current loop sampling time (with 100 µs 100 µs

5000 Hz PWM frequency) (with 5000 Hz PWM frequency)

Speed control filters 5, adjustable frequency, band and 2, adjustable frequency and
attenuation attenuation

MCBINT interface boards Integrated in Master CPU Single Eurocard format inserted
in UC rack

Probe Interface Integrated in Master CPU Single Eurocard format inserted

in UC rack

Bero Interface Integrated in Master CPU Single Eurocard format inserted

in UC rack

For the other characteristics not shown explicitly, reference should be made to the technical specifications of
the CNC S4000 series.

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S4000DDH CNC TECHNICAL SPECIFICATIONS CSTDD405010E
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