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24 VDC Motor Braking

08/23/2011 5:40 AM

Hi, I have 2 x 24VDC Motors that I want to introduce soft stopping at present we are using Baldor KBBC-44M DC Controllers.

These units have a braking function built in, which shorts the motor armature but this action is to severe for my operation.

As the motor is decelerating I want to dissipate the energy generated on a gradual curve, so I was thinking that maybe we could use a high power resistor via a reversed biased diode to control the braking action. The motors are 500 watts each and the mass of the machine is up to 380kG, we need to have a controlled slow down on this, may be 2-3 seconds until stop.

But this wont work because we also have to reverse the motors and when this happens we will pass current through the braking resistors.

Would Zener Diodes solve the problem, possibly coupled via std diodes, Your input is appreciated.

Best Regards

Joe

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#1

Re: 24 VDC Motor Braking

08/23/2011 6:15 AM

When the motor is reversed is the field or armature current reversed?

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#8
In reply to #1

Re: 24 VDC Motor Braking

08/24/2011 2:58 AM

That is correct Tony

Best Regards

Joe

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#2

Re: 24 VDC Motor Braking

08/23/2011 6:26 AM

The controller datasheet indicates that there's an output to drive an electromagnetic brake - this could be used to drive a contactor to switch in a braking resistor.

The datasheet also states that the acceleration and deceleration rates can be controlled - can't you use that?

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#6
In reply to #2

Re: 24 VDC Motor Braking

08/24/2011 2:50 AM

Hay John, I found the manual not a lot more info but enough. Glad to help.

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#7
In reply to #2

Re: 24 VDC Motor Braking

08/24/2011 2:57 AM

That is a good idea John, but I will be posting shortly just what I have done, watch this space.

Thanks Mate

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Joe

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#3

Re: 24 VDC Motor Braking

08/23/2011 7:04 AM

As JohnDG says (GA), this seems a regenerative controller with J5 selecting decel or fixed ramp (0.1s) at stopping.

Is J5 set to decel and the decel ramp pot adjusted?

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#4

Re: 24 VDC Motor Braking

08/23/2011 9:03 AM

With zeners etc you are trying to dissipate the kinetic load energy as heat.For this you will need massive components and possibly go into other problems. Not really familiar with the controller model but since it is reversible, chanses are it uses a power H-bridge at output so it's inherently capable of regenerating. Try this. Adjust maximum current pot at the minimum level it suites your load's max required acceleration, and test systems behavior. At brake command then it must also restrict braking current and possibly give you the braking time you want. (You will also possibly have to control overvoltage at braking on your power supply by adding bigger caps.) S.M.

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#5

Re: 24 VDC Motor Braking

08/23/2011 10:03 AM

The controller is already designed to allow a controlled deceleration. I think that your problem is that you misunderstand the purpose of the electromechanical braking function. I believe this separate brake works to hold your load in a static, fixed position. This will reduce the thermal load on your motor when holding a position. The brake is not the regenerative braking function. The regenerative braking happens during deceleration not when the electromechanical brake gets engaged.

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#9
In reply to #5

Re: 24 VDC Motor Braking

08/24/2011 3:10 AM

Hi Redfred, you can put a deceleration ramp into the drive but this does not work as to how I want it to work, the problem is if you set a decelleration ramp of lets say 2 seconds that means from full speed to stop is 2 sec, it also means if you are running at half speed the time taken to stop is still 2 sec.

Redfred thanks for your input mate, I will also post a statement on what I have done shortly to overcome the problem.

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Joe

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#10

Re: 24 VDC Motor Braking

08/24/2011 3:52 AM

Thanks to all contributors.

The motors that I have been using are 500 watt and the problem is that we need to operate the motors in various ways from 0- full speed CW and also from 0-full speed CCW there is 2 motors and they don't necessary do the same operations at the same time. When we set a deceleration curve time of say 2 seconds this means that whatever speed we are doing that the deceleration ramp is always 2 seconds, and this did not fit the deceleration ramp profile that I required, so for instance if the motor was operating at half speed we may require a deceleration ramp of 1.2 seconds

I decided today to use a wheel chair controller and installed this today in the prototype machine, with a few programme changes this it has so far has exceeded all expectations.

I would like to tell you all more but I cant "confidentially and all that stuff", I may post something in about 2 months, a video clip of the operation, but i can't do that now due to the customers patient pending.

But I would like to thank all contributors for the informative information that has been contributed.

I take a Bow!

Best Regards

Joe

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#11
In reply to #10

Re: 24 VDC Motor Braking

08/24/2011 10:09 AM

Next Generation Segway Turbo?

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#12

Re: 24 VDC Motor Braking

08/24/2011 12:46 PM

Use a suitably made/sized resistor in the circuit.....you only need to reduce current....

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#13
In reply to #12

Re: 24 VDC Motor Braking

08/24/2011 4:45 PM

Yes, but where in the circuit is the issue here.

Anyway, Joe seems to have sorted himself out by using a different drive.

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#14
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Re: 24 VDC Motor Braking

08/25/2011 4:24 AM

If you short the motor, it stops very abruptly. Adding resistance in place of the short, will slow it down "slower"!!

Its a very common method of slowing down a motor......

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#15
In reply to #14

Re: 24 VDC Motor Braking

08/25/2011 5:32 PM

"If you short the motor ..." - what, short the stator to the frame? short the field winding to ground? short the armature winding to the field winding?

No need to try to be clever, or to state the obvious (again) Andy - if you read through the thread so far, you'll see it's already been said.

(And don't (again, try to) teach your grandmother to suck eggs).

I was going to post this, but I can't be ar$ed.

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#16
In reply to #15

Re: 24 VDC Motor Braking

08/25/2011 8:23 PM

Wow! Bad hair day?

You remove the supply and place a short across the supply terminals to the motor. Or you place a resistor across those terminals...

Remember - Remove supply first!!!

Its often done with a relay or a switch......like this for example:-

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Andy Germany (3); Joe Sparky (4); JohnDG (3); MalcolmK (1); metalSmiths (1); redfred (1); SimpleMind (1); TonyS (1)

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